Structural building elements having pressure-sensitive adhesive

Abstract

A building element having pressure-sensitive adhesive coating layer having a low initial bond strength, to permit a substrate to be repositioned without destroying the integrity of the adhesive, and a long term bond strength, which occurs after the building element is mechanically fastened to another building element. This allows wood deck components, flooring planks, roofing tiles, and other building material components to be fastened together conveniently while securing a waterproofing and/or sound-deadening effect.

1 . A building element having a pressure-sensitive adhesive, comprising: 
 a building element having a three-dimensional body with at least four major faces, at least one of said at least four major faces having, attached thereupon,    a pre-formed, pressure-sensitive adhesive layer comprising a polyolefin resin or a rubber adhesive having a minimum of 50% filler by total weight thereof;    said pressure-sensitive adhesive layer having an average thickness no less than 5 mils and no greater than 100 mils; and    said pressure-sensitive adhesive layer having, at an ambient temperature of 72° C., the following properties:    (A) an initial bond strength of 0.0 to 1.0 pound per lineal inch, as determined by a 180 degree angle peel test on an Instron machine whereby a two-inch strip of polyethylene film is attached to a 20 mil thick layer of the adhesive that has been coated onto a 1.5 inch wide wood sample, fifteen minutes after being compressed four times repeatedly using a 30 pound roller; and    (B) a long term bond strength of no less than 25 pounds per square inch and no greater than 500 pounds per square inch as determined by measuring shear-strength of an adhesive joint comprising plywood, the adhesive layer in a layer thickness of 20 mils, and spruce wood at a time 28 days after mechanically fastening together the adhesive coated spruce to the plywood (with fastener removed to permit shear-strength testing).    
   
   
       2 . The building element of  claim 1  wherein said pressure-sensitive adhesive layer has a penetration of at least 15 dmm.  
   
   
       3 . The building element of  claim 1  wherein said element is a wall stud, floor joist, rafter, beam, floor decking, wall sheathing, or gypsum board.  
   
   
       4 . The building element of  claim 1  wherein said element has a beam shape.  
   
   
       5 . The building element of  claim 1  having an I-beam shape.  
   
   
       6 . The building element of  claim 1  wherein said pressure-sensitive adhesive is a hot melt adhesive applied by extrusion onto said at least one of said at least four major faces of said building element.  
   
   
       7 . The building element of  claim 1  wherein said pressure-sensitive adhesive layer is a polyolefin resin selected from the group consisting of an amorphous propylene homopolymer, amorphous propylene ethylene copolymer, amorphous polypropylene/propylene-ethylene copolymer mixtures, polyethylene wax, polypropylene wax, polyvinyl acetate, copolymer of ethylene and vinyl acetate, and copolymer of ethylene and ethyl acrylate.  
   
   
       8 . The building element of  claim 7  wherein said pressure-sensitive adhesive also comprises one or more materials selected from a list including, plasticizer, tackifier, wax, and particulare filler  
   
   
       9 . The building element of  claim 8  wherein said pressure-sensitive adhesive layer is an ethylene wax, propylene wax, or mixture thereof.  
   
   
       10 . The building element of  claim 9  wherein said ethylene wax, propylene wax, or mixture thereof is modified with maleic anhydride.  
   
   
       11 . The building element of  claim 1  wherein said pressure-sensitive adhesive comprises a rubber adhesive.  
   
   
       12 . The building element of  claim 1  wherein said rubber adhesive is made from a rubber selected from the group consisting of styrene-isoprene-styrene, styrene-butadiene-styrene, styrene-ethylene-butadiene-styrene, natural rubber, butadiene rubber, butyl rubber, an acrylic, neoprene, silicone, and isoprene.  
   
   
       13 . The building element of  claim 12  wherein said rubber adhesive comprises block copolymer comprising styrene-isoprene-styrene, styrene-butadiene-styrene, styrene-ethylene-butadiene-styrene, or mixture thereof.  
   
   
       14 . The building element of  claim 11  wherein said rubber adhesive further comprises a plasticizer, tackifier, wax, particulate filler material, or mixture thereof.  
   
   
       15 . The building element of  claim 14  wherein said plasticizer is naphthenic oil,  
   
   
       16 . The building element of  claim 14  wherein said filler is a particulate material comprising calcium carbonate, sand, silicate sand, cement, talc, titanium dioxide, carbon black, slate dust, granite dust, clay, diatomaceous earth, limestone, clay, shale, fly ash, silica fume, blast furnace slag, alkali or alkaline earth metal nitrite or nitrate, halide, sulfate, carboxylate, aluminum oxide trihydrate, or mixture thereof.  
   
   
       17 . The building element of  claim 1  wherein said pressure-sensitive adhesive layer is protected by a removable release sheet liner.  
   
   
       18 . The building element of  claim 1  wherein said first and second building elements are pre-made building materials selected from the group consisting of wood, plywood, oriented strand board, gypsum, concrete, mortar, brick, or tile.  
   
   
       19 . The building element of  claim 1  wherein said pressure-sensitive adhesive layer has a Brookfiled Thermosel Viscosity of no less than 200 megapascals and no greater than 25,000 megaPascals (determined in accordance with ASTM D3236 @ 190° C.  
   
   
       20 . The building element of  claim 1  wherein said pressure-sensitive adhesive layer comprising ethylene-acrylic copolymers has a Melt Index no less than 10 g/10 minutes and no greater than 1000 g/10 minutes (determined in accordance with ASTM D 1238 @ 190° C./2.16 kg., g/10 min.).  
   
   
       21 . A building structure comprising the building element of  claim 1 .  
   
   
       22 . The building structure of  claim 21  wherein said building element is a component of a roof, deck, or wall.  
   
   
       23 . Method for fastening two or more building elements together, comprising: 
 providing a first building element having a three-dimensional body with at least four major faces, at least one of said at least four major faces having attached thereon a pre-formed, a pre-formed, pressure-sensitive adhesive layer comprising a polyolefin resin or a rubber adhesive having a minimum of 50% filler by total weight thereof; said pressure-sensitive adhesive layer having an average thickness no less than 5 mils and no greater than 100 mils; and said pressure-sensitive adhesive layer having, at an ambient temperature of 72° C., the following properties: (A) an initial bond strength of no less than 0.0025 pound per lineal inch and no greater than 1.0 pound per lineal inch, as determined by a 180 degree angle peel test on an Instron machine whereby a two-inch strip of polyethylene film is attached to a 20 mil thick layer of the adhesive that has been coated onto a 1.5 inch wide wood sample, fifteen minutes after being compressed four times repeatedly using a 30 pound roller; and (B) a long term bond strength of no less than 25 pounds per square inch and no greater than 500 pounds per square inch as determined by measuring shear-strength of an adhesive joint comprising plywood, the adhesive layer in a layer thickness of 20 mils, and spruce wood at a time 28 days after mechanically fastening together the adhesive coated spruce to the plywood (with fastener removed to permit shear-strength testing); and    positioning a second building element against said pressure-sensitive adhesive layer; and    mechanically fastening together said first and second building elements by driving a fastener through said pressure-sensitive adhesive layer.