Laminated building materials

Abstract

The present invention relates to a method of manufacturing an laminated article which includes a building material adhered to a water vapor retarder film having a water vapor permeance dependent on the ambient humidity adhered to the insulation, laminated articles, and uses thereof.

1 . A method of manufacturing a laminated article, comprising providing an adhesive to a water vapor retarder film having a water vapor permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B, wherein the adhesive is provided in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width; and 
 contacting the film to at least one surface of a building material.    
   
   
       2 . The method of  claim 1 , wherein the building material is at least one member selected from the group consisting of fiber reinforced cellulose materials, membranes made from synthetic fiber spun fabrics, membranes made from perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board, fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts, fiber insulation slabs, foam insulation slabs, wall paper, carpet, woven fabrics, and non-woven fabrics.  
   
   
       3 . The method of  claim 1 , wherein the film comprises a polyamide film.  
   
   
       4 . The method of  claim 3 , wherein the polyamide film is a polyamide 6 film, a polyamide 4 film, or a polyamide 3 film.  
   
   
       5 . The method of  claim 1 , wherein the adhesive comprises a polyolefin.  
   
   
       6 . The method of  claim 5 , wherein the polyolefin is a polypropylene, a polyethylene or mixtures thereof.  
   
   
       7 . The method of  claim 1 , wherein the film has a thickness of from 10 μm to 2 mm.  
   
   
       8 . The method of  claim 7 , wherein the film has a thickness of from 20 μm to 100 μm.  
   
   
       9 . The method of  claim 8 , wherein the film has a thickness of from 30 μm to 90 μm.  
   
   
       10 . The method of  claim 9 , wherein the film has a thickness of from 40 μm to 60 μm.  
   
   
       11 . A method of manufacturing a laminated article, comprising providing an adhesive to a water vapor retarder film having a water vapor permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B, wherein the adhesive is provided in an amount sufficient to retain at least about 50% of the permeance relative to the film prior to providing the adhesive; and 
 contacting the film to at least one surface of a building material.    
   
   
       12 . The method of  claim 11 , wherein the building material is at least one member selected from the group consisting of fiber reinforced cellulose materials, membranes made from synthetic fiber spun fabrics, membranes made from perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board, fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts, fiber insulation slabs, foam insulation slabs, wall paper, carpet, woven fabrics, and non-woven fabrics.  
   
   
       13 . The method of  claim 11 , wherein the film comprises a polyamide film.  
   
   
       14 . The method of  claim 13 , wherein the polyamide film is a polyamide 6 film, a polyamide 4 film, or a polyamide 3 film.  
   
   
       15 . The method of  claim 11 , wherein the adhesive comprises a polyolefin.  
   
   
       16 . The method of  claim 15 , wherein the polyolefin is a polypropylene, a polyethylene or mixtures thereof.  
   
   
       17 . The method of  claim 11 , wherein the film has a thickness of from 10 μm to 2 mm.  
   
   
       18 . The method of  claim 17 , wherein the film has a thickness of from 20 μm to 100 μm.  
   
   
       19 . The method of  claim 18 , wherein the film has a thickness of from 30 μm to 90 μm.  
   
   
       20 . The method of  claim 19 , wherein the film has a thickness of from 40 μm to 60 μm.  
   
   
       21 . A laminated article comprising at least one film component having a water vapor permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B; at least one building material component; and an adhesive which adheres the at least one film component and the at least one building material wherein the adhesive is present in an amount of about 0.4 to about 1.0 g per lineal foot of the film based on a 15 inch application width.  
   
   
       22 . The laminated article of  claim 21 , wherein the building material is at least one member selected from the group consisting of fiber reinforced cellulose materials, membranes made from synthetic fiber spun fabrics, membranes made from perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board, fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts, fiber insulation slabs, foam insulation slabs, wall paper, carpet, woven fabrics, and non-woven fabrics.  
   
   
       23 . The laminated article of  claim 21 , wherein the film comprises a polyamide film.  
   
   
       24 . The laminated article of  claim 23 , wherein the polyamide film is a polyamide 6 film, a polyamide 4 film, or a polyamide 3 film.  
   
   
       25 . The laminated article of  claim 21 , wherein the adhesive comprises a polyolefin.  
   
   
       26 . The laminated article of  claim 25 , wherein the polyolefin is a polypropylene, a polyethylene or mixtures thereof.  
   
   
       27 . The laminated article of  claim 21 , wherein the film has a thickness of from 10 μm to 2 mm.  
   
   
       28 . The laminated article of  claim 27 , wherein the film has a thickness of from 20 μm to 100 μm.  
   
   
       29 . The laminated article of  claim 28 , wherein the film has a thickness of from 30 μm to 90 μm.  
   
   
       30 . The laminated article of  claim 29 , wherein the film has a thickness of from 40 μm to 60 μm.  
   
   
       31 . A method of constructing a building, comprising installing the laminated article of  claim 21  to said building.  
   
   
       32 . A method of renovating a building, comprising installing the laminated article of  claim 21  to said building.  
   
   
       33 . A building structure, comprising the laminated article of  claim 21 .  
   
   
       34 . The building structure of  claim 33 , which is selected from the group consisting of a roof structure, a wall structure, and a floor structure.  
   
   
       35 . A method of providing a vapor retarder to a building, comprising installing the laminated article of  claim 21  to at least one structure of said building.  
   
   
       36 . A laminated article comprising at least one film component having a water vapor permeance of up to about 1.73 perms as determined according to the dessicant method of ASTM E 96 Method A and a permeance of not less than about 3.45 perms as determined by the water method of ASTM E 96 Method B; at least one building material component; and an adhesive which adheres the at least one film component and the at least one building material wherein the adhesive is present in an amount sufficient to retain at least about 50% of the permeance relative to the film prior to providing the adhesive.  
   
   
       37 . The laminated article of  claim 36 , wherein the building material is at least one member selected from the group consisting of fiber reinforced cellulose materials, membranes made from synthetic fiber spun fabrics, membranes made from perforated polyethylene films, particle board, chip board, oriented strand board, plywood paneling, gypsum board, fiber board, cement board, cementitious wood wool board, calcium silica board, fiber insulation batts, fiber insulation slabs, foam insulation slabs, wall paper, carpet, woven fabrics, and non-woven fabrics.  
   
   
       38 . The laminated article of  claim 36 , wherein the film comprises a polyamide film.  
   
   
       39 . The laminated article of  claim 38 , wherein the polyamide film is a polyamide 6 film, a polyamide 4 film, or a polyamide 3 film.  
   
   
       40 . The laminated article of  claim 36 , wherein the adhesive comprises a polyolefin.  
   
   
       41 . The laminated article of  claim 40 , wherein the polyolefin is a polypropylene, a polyethylene or mixtures thereof.  
   
   
       42 . The laminated article of  claim 36 , wherein the film has a thickness of from 10 μm to 2 mm.  
   
   
       43 . The laminated article of  claim 42 , wherein the film has a thickness of from 20 μm to 100 μm.  
   
   
       44 . The laminated article of  claim 43 , wherein the film has a thickness of from 30 μm to 90 μm.  
   
   
       45 . The laminated article of  claim 44 , wherein the film has a thickness of from 40 μm to 60 μm.  
   
   
       46 . A method of constructing a building, comprising installing the laminated article of  claim 21  to said building.  
   
   
       47 . A method of renovating a building, comprising installing the laminated article of  claim 36  to said building.  
   
   
       48 . A building structure, comprising the laminated article of  claim 36 .  
   
   
       49 . The building structure of  claim 48 , which is selected from the group consisting of a roof structure, a wall structure, and a floor structure.  
   
   
       50 . A method of providing a vapor retarder to a building, comprising installing the laminated article of  claim 36  to at least one structure of said building.