Pliable laminate weatherline system

Abstract

The present invention relates to a pliable house wrap laminate with at least two thin plastic layers, one or more nonwoven layers and a fibreglass reinforcing layer. Known pliable building wrap may be easily torn, allow ingress of water, and degrade over time. Known fixed air barriers are expensive and difficult to install. The invention overcomes these disadvantages by adding in various layers into a pliable laminate - effectively giving a pliable house wrap laminate fixed air barrier benefits.

Description

PLIABLE LAMINATE WEATHERLINE SYSTEMThe present invention relates to a pliable laminate weatherline system. More particularly but not exclusively it relates to house wrap laminate with at least two thin plastic layers, one or more nonwoven layers and a fibreglass reinforcing layer.BACKGROUNDLiquid water and water vapour typically want to travel from a high pressure environment (outside a building) to a low pressure environment (inside a building). To prevent this a weather line is created about a building structure. This is typically formed using a wall assembly that includes a building wrap or water and air resistant barrier with cladding overlaid upon the structure.The structure is typically wrapped in a flexible building wrap once the structure is erected. The flexible building wrap reduces the liquid water able to enter the structure and regulates the amount the water vapour and air movement that may enter or leave the structure. The flexible building wraps also act to reduce the amount of airflow and water that may enter the building during construction prior to installation of cladding.Cladding is typically then laid over the building wrap to act as the final weather layer. Prior to cladding there is a period of time where the building is only protected by the building wrap. Some building wrap is made from asphalt -impregnated paper, whilst new building wraps are made of laminates of woven or non-woven polypropylene and plastic films.The problem with current building wraps is they may lack durability. I.E. they may be thin, flimsy and prone to tearing and ripping during construction. Building wraps also vary in their ability to resist the inflow of water and their ability to block the movement of air and the rate at which they degrade with UV exposure. If there is any tear or damage in the building wrap prior to cladding, water and air can enter the building. In the same way some building wraps only offer resistance to water ingress consistent with performance behind installed cladding and may allow water to enter the building when subjected to rain and wind pressure. This means the building fit out is limited to when the cladding is overlaid, and the interior is sufficiently dry.If there is a tear in the building wrap after cladding any leak in the cladding may allow water to be drawn in though the tear or other opening in the building wrap into the dry envelope of the building. If there is no tear then water will simply drain the bottom of the wall assembly and drain away.For various reasons delays can mean building wraps are exposed to UV longer than ideal leading lessening of their physical properties and increasing the chances of rips and tears.For the purposes of this specification, the term "plastic" shall be construed to mean a general term for a wide range of synthetic or semisynthetic polymerization products, and generally consisting of a hydrocarbon-based polymer.For the purposes of this specification, "nonwoven" shall be construed to mean a general term for a wide range of fabric like materials compose from staple fiber (short) and long fibres (continuous long), bonded together by chemical, mechanical, heat or solvent treatment.It is an object of the present invention to provide a flexible air barrier which overcomes or at least partially ameliorates some of the abovementioned disadvantages or which at least provides the public with a useful choice.STATEMENTS OF INVENTIONIn a first aspect the present invention may be said to broadly consist in a flexible laminate wrap for covering the at least part of an exterior of a building structure, the laminate comprising at least four layers of materials:a. two layers of nonwoven material,b.  at least one layer of plastic film; andc.  a reinforcing layer.In one embodiment, the plastic film is relatively thin compared to the other layers.In one embodiment, one of the layers is an internal layer in operation adjacent said building and another one of the layers is external layer opposite the internal layer.In one embodiment, the reinforcing layer is intermediate the internal layer and the external plastic film layer.In one embodiment, the reinforcing layer comprises a reinforcing mesh, mat or grid.In one embodiment, the reinforcing layer comprises or is composed of a fibreglass reinforcing mesh, mat or grid.In one embodiment, the internal layer is one of said nonwoven material layers.In one embodiment, the external layer is a plastic film layer or a nonwovenlayer.In one embodiment, the layers intermediate the plastic film layer or nonwoven layer, and nonwoven layer, is a reinforcing layer and one selected from a plastic film layer and a nonwoven layer.In one embodiment, the laminate has five layers.In one embodiment, the external layer is a plastic film layer.In one embodiment, the laminate comprises two plastic film layers, a first plastic film layer and a second plastic film layer.In one embodiment, the second plastic film layer is intermediate the internal layer and the external plastic film layer.In one embodiment, the reinforcing layer is intermediate the two plastic film layers.In one embodiment, the laminate has six layers.In one embodiment, the laminate comprises three plastic film layers, a first plastic film layer, a second plastic film layer and a third plastic film layer.In one embodiment, the nonwoven layers have an areal density of 30 g / m2 -120 g / m2.In one embodiment, the total grammage of the nonwoven layers combined is 60 g / m2 - 240 g / m2.In one embodiment, the plastic film layers have an areal density of 8 g / m2 - 40 g / m2.In one embodiment, the reinforcing layer has an areal density of 8 g / m2 - 40 g / m2.In one embodiment, the reinforcing layer has an areal density of 15 g / m2.In one embodiment, the laminate has an areal density of between 84 g / m2 and 360 g / m2.In one embodiment, the nonwoven layers are composed from one or more selected from polypropylene, polyethylene and polyester.In one embodiment, the plastic film layers are composed from one or more selected from polyethylene, ethylene, breathable polymers, ethylene, polypropylene with calcium carbonate stretched.In one embodiment, the plastic film layers are water resistant.In one embodiment, the nonwoven layers have a thickness of 0.2mm - 0.5mm.In one embodiment, one or more of the plastic film layers have a thickness between 0.01mm - 0.08mmIn one embodiment, one or more of the plastic film layers have a thickness between 0.04mm and 0.05mm.In one embodiment, the plastic film is applied as a liquid to the laminate during manufacture.In one embodiment, the reinforcing layer has a thickness between 0.005mm -0.30mm.In one embodiment, the reinforcing layer has a thickness of 0.15mm.In one embodiment, the five layers are bonded together.In one embodiment, the five layers are bonded to each other by a squeezing process.In one embodiment, the squeezing process includes adding moisture.In one embodiment, the laminate has a breathability value between 0 perms and 250 perms.In one embodiment, the laminate has a breathability value to comply with ASTM E96.In one embodiment, the laminate has a water penetration resistance value of / between 20mm to 500mm.In one embodiment, the laminate has a water penetration resistance value to comply with AS / NZS4201.4.In one embodiment, the laminate has a moisture vapour transmission between 0 perms and 250 perms.In one embodiment, the laminate has a moisture vapour transmission value to comply with NZS2295 and ASTM E96.In one embodiment, the laminate has a tensile strength (machine direction measured from NZS 2295, Tappi T470 and ASTM D882) between 3 kN / m and 20 kN / m.In one embodiment, the laminate has a tensile strength (cross direction measured from NZS 2295, Tappi T470 and ASTM D882) between 1.5 kN / m and 15 kN / m.In one embodiment, the laminate has edge tear resistance (machine direction measured from NZS 2295, Tappi T470 and ASTM D882) between 35 N and 750 N.In one embodiment, the laminate has edge tear resistance (cross direction measured from NZS 2295, Tappi T470 and ASTM D882) between 35 N and 600 N.In one embodiment, the laminate is mechanically affixed to the building structure in operation.In one embodiment, the laminate can be stapled to the building structure in operation.In one embodiment, the laminate is affixed to the walls of a building structure.In one embodiment, cladding is overlaid the laminate in operation.In one embodiment, the laminate is intermediate the building structure and cladding in operation.In one embodiment, the laminate forms an air cavity intermediate the laminate and cladding in operation.In one embodiment, the laminate is pliable.In one embodiment, the laminate is configured to be stored in a roll.Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.As used herein the term "and / or" means "and" or "or", or both.As used herein "(s)" following a noun means the plural and / or singular forms of the noun.The term "comprising" as used in this specification and claims means "consisting at least in part of". When interpreting statements in this specification and claims which include that term, the features, prefaced by that term in each statement, all need to be present but other features can also be present. Related terms such as "comprise" and "comprised" are to be interpreted in the same manner.The entire disclosures of all applications, patents and publications, cited above and below, if any, are hereby incorporated by reference.This invention may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, and any or all combinations of any two or more of said parts, elements or features, and where specific integers are mentioned herein which have known equivalents in the art to which this invention relates, such known equivalents are deemed to be incorporated herein as if individually set forth.)The invention will now be described by way of example only and with reference to the drawings in which:Figure 1:     shows a cross section schematic view through a building structure, withinternal lining attached, a five layer laminate of the present invention affixed, and a cladding overlaid.Figure 2-4: shows a schematic cross section of other embodiments of a five layer laminate.Figure 5-7:   shows a schematic cross section of embodiments of a four layer laminate.Figure 8:     shows a schematic cross section of an embodiment of a six layerlaminate.DETAILED DESCRIPTIONWith reference to the above drawings, in which similar features are generally indicated by similar numerals, a house wrap according to a first aspect of the invention is generally indicated by the numeral 10.In one embodiment now described, there is provided a flexible air barrier laminate. The barrier also acts as a house wrap, prior to cladding. This house wrap is more durable, and resistant to tearing than typical house wrap. This means it can act as a weather resistant layer / weatherline, prior to cladding, so the fit out of a house can proceed regardless of whether there is cladding on the structure or not. This reduces build time and costs.Figure 1 further shows an internal cladding 20, such as gypsum board, affixed to the building structure 21, such as a wooden framing. The laminate 10 is then affixed to the building structure 21 by typically mechanical affixation means such as stapling or nailing. The present invention laminate 10 is able to withstand this mechanical affection and still provide its desired characteristics due to the number of layers, type of layers, and characteristics of those layers. Preferably the laminate 10 is affixed solely to walls of a structure, but it may be used elsewhere.The laminate 10 is a laminate formed from preferably five layers of material, however four and six layer laminates are also envisaged and described herein. Two layers of film 2 & 5 that provide water resistance; two nonwoven layers 1 & 4 that provide the strength, body and durability; and a final reinforcing layer 3 that provides rip resistance and strength.The preferred order for the layers within the laminate are: a film layer 5 externally facing away from the building, and a nonwoven layer 1 facing the building structure 21. Intermediate the external film layer 5 and the internal nonwoven layer 1, are located the other film layer 2, the reinforcing layer 3 and the other nonwoven layer4.The position and ordering of the intermediate layers 2, 3 and 4 may ordered in a number of ways as shown in figures 2, 3 and 4. Figures 1, 2 and 3 are the most preferred embodiments.The characteristics of each layer of the laminate 10 will now be described, from the inside (adjacent and facing the building structure 21) to the outside (facing the cladding 22) of a preferred embodiment as shown in figure 1.Operationally adjacent to the building structure 21 is a nonwoven material 1 forming the first layer of the laminate 10. The nonwoven material 1 may be different or identical but fall within the same characteristics as the nonwoven material layer 4. The nonwoven material is designed to give strength, body and structure to the laminate 10. This nonwoven material is preferably formed from one or more of the following compositions: polypropylene, polyethylene or polyester. The areal density of the nonwoven material desire is preferably between 20 g / m2 and 180 g / m2.The film 2, and in this embodiment located adjacent the nonwoven material layer 1, is configured to be a waterproofing film layer 2. Is preferably formed from a plastics material. Where the material is composed of a thin (relative to the other layers) plastic being one or more of polyethylene, ethylene, breathable polymers, ethylene, and polypropylene with calcium carbonate stretched. The film 2, adjacent the nonwoven material layer 1, is a backup layer for providing water resistance. The preferred areal density of the film 2 is between 8 g / m2 and 40 g / m2. Preferably the plastic film is applied as a liquid to the laminate during manufacture. In other embodiments it may be applied as a solid layer, and affixed or laid onto the laminate.The reinforcing layer 3, and in this embodiment located adjacent the film 2, is preferably composed of a scrim or mesh like material. The spacing of the mesh is not critical, a more open mesh allows more flexibility and / or breathability of the laminate 10, and a more closed mesh means that the mesh will have a higher strength. Preferably the scrim or mesh like material is composed of fibreglass, however other sufficiently strong materials may also be used. The reinforcing layer provides rip resistance as well as adding overall strength to the laminate 10. The preferred areal density of the reinforced layer 3 is between 8 g / m2 and 40 g / m2. Having a reinforced layer 3 as part of a breathable pliable weatherline system is new in the industry.A second nonwoven material layer 4 is provided in this embodiment adjacent to the reinforcing layer 3. It has many of the same or similar characteristics as the nonwoven material layer 2.The final external facing layer, as provided in this embodiment, is a second film layer 5. It has many of the same or similar characteristics as the film layer 2. This final external facing film layer 2 acts as a first layer of water resistance.As described above, the intermediate layers intermediate the internal layer 1, and the external layer 5 may be rearranged and still have the same final laminate 10 characteristics, and still be within the scope of the invention.In other embodiments, the laminate is a four layer laminate, as seen in figures 5 to 7. The reference numerals in these figures are consistent with the five layer laminate, where the laminate is composed of an internal layer being a nonwoven layer 1, an external layer being a plastic film layer 2 or a nonwoven layer 4. Intermediate the internal layer and external is a reinforcing layer 4 and one selected from a plastic film layer 2 and a nonwoven layer 4 depending on the external layers. The material characteristics, compositions and functionality are the same as described above in the five layer embodiment.In other embodiments, the laminate is a six layer laminate, an example shown in Figure 8. The extra layer in the six layer laminate is a plastic film layer acting as the internal layer. The extra layer acts as a final external back up layer to moisture ingress. The remaining layers can be arranged in a similar arrangement to any of the five layer laminates (as shown in figures 1 to 4).The total desired thickness of the laminate 10 is between 84 g / m2 and 360 g / m2. The laminate has a preferred thickness between 0.4 and 0.95mm.The laminate 10 will adhere to and have characteristics sufficient to achieve the standards set out in NZS 2295 (Pliable, permeable building underlays) and AS / NZS4200 (Pliable building membranes and underlays).The laminate preferably has a water penetration resistance value of / between 20mm to 500mm to AS / NZS4201, and a moisture vapour transmission rate of / between 0 perms and 250 perms to ASTM E96.The tensile strength is the maximum stress to break a strip of laminate. The tensile strength is different depending on fiber direction. Since the fiber orientation is dissimilar between machine direction (MD) and cross direction CD), hence the tensile strength is measured in both directions. Machine direction is the direction of paper web which is running on the machine whereas cross direction means the direction, which is perpendicular to the laminate that is running on the machine during manufacture. It is calculated with the force per unit width and express as N / m. The following are the preferred tensile strength of the laminate. These values comply with measurement standards set out in NZS 2295, Tappi T470 and ASTM D882.Tensile (machine direction) 3 kN / m and 20 kN / m.Tensile (cross direction) 1.5 kN / m and 15 kN / m.Edge Tear (machine direction) 35 N and 750 N.Edge Tear (cross direction) 35 N and 600 N.The layers forming the laminate 10 may be bonded together via numerous industry standards. In one preferred embodiment, the layers are bonded together a squeezing process, where layers are squeezed / compressed together via rollers.Preferably this process includes adding moisture to the layers, during compression between layers.It is desirable therefore that a flexible building wrap acts as an effective drainage plane by being highly resistant to water, and preferably the movement of air, whilst allowing water vapour to exit the building. Other benefits are preferable, such as difficult to tear, pierce or other wise be susceptible to damage. And preferably, to have sufficient properties so as to reliably protect the structure effectively for a sufficient period of time during construction against the egress of water and air until cladding can be over laid.Where in the foregoing description reference has been made to elements or integers having known equivalents, then such equivalents are included as if they were individually set forth.Although the invention has been described by way of example and with reference to particular embodiments, it is to be understood that modifications and / or improvements may be made without departing from the scope or spirit of the invention.

Claims

Claims1.     A flexible laminate wrap for covering the at least part of an exterior of a building structure, the laminate comprising at least four layers of materials:a.   two layers of nonwoven material,b.    at least one layer of plastic film; andc.    a reinforcing layer.

2. A wrap as claimed in claim 1, wherein the plastic film is relatively thin compared to the other layers.

3. A wrap as claimed in claims 1 or 2, wherein one of the layers is an internal layer in operation adjacent said building and another one of the layers is external layer opposite the internal layer.

4. A wrap as claimed in claim 3, wherein the reinforcing layer is intermediate the internal layer and the external plastic film layer.

5. A wrap as claimed in any one of claims 1 to 4, wherein the reinforcing layer comprises a reinforcing mesh, mat or grid.

6. A wrap as claimed in claim 5, wherein the reinforcing layer comprises or is composed of a fibreglass reinforcing mesh, mat or grid.

7. A wrap as claimed in any one of claims 3 to 6, wherein the internal layer is one of said nonwoven material layers.

8. A wrap as claimed in any one of claims 3 to 7, wherein the external layer is a plastic film layer or a nonwoven layer.

9. A wrap as claimed in any one of claims 1 to 8, wherein the layers intermediate the plastic film layer or nonwoven layer, and nonwoven layer, is a reinforcing layer and one selected from a plastic film layer and a nonwoven layer.

10. A wrap as claimed in any one of claims 1 to 9, wherein the laminate has five layers.

11. A wrap as claimed in claim 10, wherein the external layer is a plastic film layer.

12. A wrap as claimed in any one of claims 10 to 11, wherein the laminate comprises two plastic film layers, a first plastic film layer and a second plastic film layer.

13. A wrap as claimed in claim 12, wherein the second plastic film layer is intermediate the internal layer and the external plastic film layer.

14. A wrap as claimed in any one of claims 12 to 13, wherein the reinforcing layer is intermediate the two plastic film layers.

15. A wrap as claimed in any one of claims 1 to 14, wherein the laminate has six layers.

16. A wrap as claimed in claim 15, wherein the laminate comprises three plastic film layers; a first plastic film layer, a second plastic film layer and a third plastic film layer.

17. A wrap as claimed in any one of claims 1 to 17, wherein the nonwoven layers have an areal density of 30 g / m2 - 120 g / m2.

18. A wrap as claimed in any one of claims 1 to 18, wherein the total grammage of the nonwoven layers combined is 60 g / m2 - 240 g / m2.

19. A wrap as claimed in any one of claims 1 to 18, wherein the plastic film layers have an areal density of 8 g / m2 - 40 g / m2.

20. A wrap as claimed in any one of claims 1 to 20, wherein the reinforcing layer has an areal density of 8 g / m2 - 40 g / m2.

21. A wrap as claimed in claim 20, wherein the reinforcing layer has an areal density of 15 g / m2.

22. A wrap as claimed in any one of claims 1 to 21, wherein the laminate has an areal density of between 84 g / m2 and 360 g / m2.

23. A wrap as claimed in any one of claims 1 to 22, wherein the nonwoven layers are composed from one or more selected from polypropylene, polyethylene and polyester.

24. A wrap as claimed in any one of claims 1 to 23, wherein the plastic film layers are composed from one or more selected from polyethylene, ethylene, breathable polymers, ethylene, polypropylene with calcium carbonate stretched.

25. A wrap as claimed in any one of claims 1 to 24, wherein the plastic film layers are water resistant.

26. A wrap as claimed in any one of claims 1 to 25, wherein the nonwoven layers have a thickness of 0.2mm - 0.5mm.T7. A wrap as claimed in any one of claims 1 to 26, wherein one or more of the plastic film layers have a thickness between 0.01mm - 0.08mm28.   A wrap as claimed in claim 27, wherein one or more of the plastic film layers have a thickness between 0.04mm and 0.05mm.

29. A wrap as claimed in any one of claims 1 to 28, wherein the plastic film is applied as a liquid to the laminate during manufacture.

30. A wrap as claimed in any one of claims 1 to 29, wherein the reinforcing layer has a thickness between 0.005mm - 0.30mm.

31. A wrap as claimed in claim 30, wherein the reinforcing layer has a thickness of 0.15mm.

32. A wrap as claimed in any one of claims 10 to 31, wherein the five layers are bonded together.

33. A wrap as claimed in claim 32, wherein the five layers are bonded to each other by a squeezing process.

34. A wrap as claimed in claim 33, wherein the squeezing process includes adding moisture.

35. A wrap as claimed in any one of claims 1 to 34, wherein the laminate has a breathability value between 0 perms and 250 perms.

36. A wrap as claimed in any one of claims 1 to 35, wherein the laminate has a breathability value to comply with ASTM E96.

37. A wrap as claimed in any one of claims 1 to 36, wherein the laminate has a water penetration resistance value of / between 20mm to 500mm.

38. A wrap as claimed in any one of claims 1 to 37, wherein the laminate has a water penetration resistance value to comply with AS / NZS4201.4.

39. A wrap as claimed in any one of claims 1 to 38, wherein the laminate has a moisture vapour transmission between 0 perms and 250 perms.

40. A wrap as claimed in any one of claims 1 to 39, wherein the laminate has a moisture vapour transmission value to comply with NZS2295 and ASTM E96.

41. A wrap as claimed in any one of claims 1 to 40, wherein the laminate has a tensile strength (machine direction measured from NZS 2295, Tappi T470 and ASTM D882) between 3 kN / m and 20 kN / m.

42. A wrap as claimed in any one of claims 1 to 41, wherein the laminate has a tensile strength (cross direction measured from NZS 2295, Tappi T470 and ASTM D882) between 1.5 kN / m and 15 kN / m.

43. A wrap as claimed in any one of claims 1 to 42, wherein the laminate has edge tear resistance (machine direction measured from NZS 2295, Tappi T470 and ASTM D882) between 35 N and 750 N.

44. A wrap as claimed in any one of claims 1 to 43, wherein the laminate has edge tear resistance (cross direction measured from NZS 2295, Tappi T470 and ASTM D882) between 35 N and 600 N.

45. A wrap as claimed in any one of claims 1 to 44, wherein the laminate is mechanically affixed to the building structure in operation.

46. A wrap as claimed in claim 45, wherein the laminate can be stapled to the building structure in operation.

47. A wrap as claimed in any one of claims 1 to 46, wherein the laminate is affixed to the walls of a building structure.

48. A wrap as claimed in claim 47, wherein cladding is overlaid the laminate in operation.

49. A wrap as claimed in claim 48, wherein the laminate is intermediate the building structure and cladding in operation.

50. A wrap as claimed in any one of claims 48 to 49, wherein the laminate forms an air cavity intermediate the laminate and cladding in operation.

51. A wrap as claimed in any one of claims 1 to 50, wherein the laminate is pliable.

52. A wrap as claimed in any one of claims 1 to 51, wherein the laminate is configured to be stored in a roll.6 1     3   2 4 5

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