Vapor permeable, water resistive, and fire resistive articles

Abstract

Embodiments of the present disclosure generally relate to vapor permeable, water resistive, and fire resistive articles for residential and commercial structures and installations. Methods of making such articles are also described herein. In an embodiment, a vapor permeable laminate is provided. The vapor permeable laminate includes a substrate having a first surface and a second surface opposite the first surface, the second surface for facing an interior of a structure. The vapor permeable laminate further includes an intumescent coating disposed over at least a portion of the first surface of the substrate, the intumescent coating having raised features disposed thereon, recessed features formed therein, or combinations thereof, the features for providing a water drainage path. Embodiments described herein also include wrap for a structure or an installation.

What is claimed is: 
     
         1 . A vapor permeable laminate, comprising:
 a substrate having a first surface and a second surface opposite the first surface, the second surface for facing an interior of a structure; and   an intumescent coating disposed over at least a portion of the first surface of the substrate, the intumescent coating having raised features disposed thereon, recessed features formed therein, or combinations thereof, the features for providing a water drainage path.   
     
     
         2 . The vapor permeable laminate of  claim 1 , wherein the vapor permeable laminate has a water vapor permeance (ASTM E96-16) of at least about 500 ng·s −1 ·m −2 ·Pa −1 . 
     
     
         3 . The vapor permeable laminate of  claim 2 , wherein the water vapor permeance is from about 1,000 ng·s −1 ·m· −2 ·Pa −1  to about 2,000 ng·s −1 ·m −2 ·Pa −1 . 
     
     
         4 . The vapor permeable laminate of  claim 1 , wherein the substrate is selected from the group consisting of fiberglass, glass, metal, foam, polymer, plastic, elastomer, rubber, cellular solids, or combinations thereof. 
     
     
         5 . The vapor permeable laminate of  claim 1 , wherein the substrate comprises a material for reflecting radiant heat. 
     
     
         6 . The vapor permeable laminate of  claim 5 , wherein the material for reflecting radiant heat comprises a metal, a metalloid, an oxide thereof, a salt thereof, an alloy thereof, or combinations thereof. 
     
     
         7 . The vapor permeable laminate of  claim 5 , wherein the material for reflecting radiant heat comprises aluminum, titanium, iron, barium, silicon, or combinations thereof. 
     
     
         8 . The vapor permeable laminate of  claim 1 , wherein the substrate is in the form of an open mesh. 
     
     
         9 . The vapor permeable laminate of  claim 1 , wherein the intumescent coating has a coating weight of about 0.015 g/cm 2  to about 0.17 g/cm 2 . 
     
     
         10 . The vapor permeable laminate of  claim 1 , wherein the substrate has a thickness of about 0.05 g/cm 2  to about 0.15 g/cm 2 . 
     
     
         11 . The vapor permeable laminate of  claim 1 , wherein:
 the raised features, when present, have a height of about 1 mm to about 5 mm; and   the recessed features, when present, have a depth of about 1 mm to about 5 mm.   
     
     
         12 . The vapor permeable laminate of  claim 1 , wherein the intumescent coating comprises a composition, the composition comprising or being derived from:
 an intumescent compound;   a binder comprising a thermoplastic compound and a thermoset compound;   a catalyst; and   a blowing agent.   
     
     
         13 . The vapor permeable laminate of  claim 12 , wherein the intumescent compound comprises:
 a first expandable graphite compound having a mean particle size in a range of about 300 microns to about 1000 microns; and   a second expandable graphite compound having a mean particle size in a range of about 0.5 microns to about 250 microns, wherein a weight ratio of the first expandable graphite compound to the second expandable graphite compound is in a range of about 4:1 to about 1:4.   
     
     
         14 . The vapor permeable laminate of  claim 12 , wherein a weight ratio of the thermoplastic compound to the thermoset compound in the binder is in a range of about 10:1 to about 1:3. 
     
     
         15 . A building structure, comprising the vapor permeable laminate of  claim 1  affixed to a wall structure. 
     
     
         16 . A wrap for a structure or an installation, comprising:
 a substrate having a first substrate surface and a second substrate surface opposite the first substrate surface, the second substrate surface for facing an interior of the structure or the installation; and   an intumescent coating having a first coating surface and a second coating surface opposite the first coating surface, the second coating surface adjacent to the first substrate surface, the intumescent coating comprising a composition, the composition comprising or being derived from:
 an intumescent compound; 
 a binder comprising a thermoplastic compound and a thermoset compound; 
 a catalyst; and 
 a blowing agent, 
   the wrap having a water vapor permeance (ASTM E96-16) of at least about 500 ng·s −1 ·m −2 ·Pa −1 .   
     
     
         17 . The wrap of  claim 16 , further comprising:
 a plurality of raised features disposed on the first coating surface of the intumescent coating;   a plurality of recessed features formed in the first coating surface of the intumescent coating; or   combinations thereof, the features configured to provide a path for water drainage.   
     
     
         18 . The wrap of  claim 16 , wherein the substrate is selected from the group consisting of fiberglass, glass, metal, foam, polymer, plastic, elastomer, rubber, cellular solids, or combinations thereof. 
     
     
         19 . The wrap of  claim 16 , wherein the substrate comprises a material for reflecting radiant heat, the material for reflecting radiant heat selected from the group consisting of a metal, a metalloid, an oxide thereof, a salt thereof, an alloy thereof, or combinations thereof. 
     
     
         20 . A method for making a vapor permeable laminate, the method comprising:
 forming a layer comprising an intumescent composition on a surface of a substrate, the intumescent composition configured to expand in the presence of heat;   forming features on or in the layer, the features for providing a water drainage path; and   drying or curing the intumescent composition with the substrate to form the vapor permeable laminate.