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Composition, method of use, and structural barrier systemComposition, method of use, and structural barrier system description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20090145067, Composition, method of use, and structural barrier system. Brief Patent Description - Full Patent Description - Patent Application Claims
1. Field of the Invention The present invention pertains to a substance for creating an environmental barrier and, more particularly, to a formulation and method of use for a liquid applied membrane to construct a structural barrier system that seals structural openings such as doors and windows. 2. Description of the Related Art Tremendous damage to buildings, both large and small, is caused by water leaking into rough openings and framing due to faulty window and door installations or leaky windows. Owners, builders, and insurance companies can face tremendous costs in the restoration and repair of this damage. Window and door installation failure can cause delays in construction, increased insurance premiums for builders and building owners, warranty liability for builders, and increased cost of home ownership for the general population. Even when builders carefully follow detailed installation instructions and recognized trade organization procedures, these window and door installation methods can leave the openings susceptible to water intrusion. Frequently, installation procedures are difficult to follow with multiple steps and layers of products have been used in an attempt to keep the water out. Complex installation procedures are often difficult to follow, and increasing the complexity of the installation procedure has not reduced the incidence of water intrusion and damage. In recent years there has been an increasing use of liquid applied flashing membranes in the construction industry, especially in the course of installing windows and doors. Window and door penetrations of the building envelope are prone to water and air intrusion, resulting in health risks, structural damage, and financial loss. In the past, metal flashings have been used for this purpose but have low performance rates due to metallic corrosion, fastener penetration, thermal transfer and difficulty of fabrication on site. Self-adhered, flexible flashing membranes, typically consisting of a polyethylene membrane weather side with an SBS rubberized asphalt compound as the adhesive side, have offered an alternative. These products were established in the industry as a quality concept, but the construction site environment, wet conditions, staining of other construction materials, and non-vapor-permeable characteristics have resulted in construction failures. Drawbacks to these materials include difficult application techniques, adhesive failure on moist substrates, lack of resistance to weather exposure, and narrow service temperature along with the inability to effectively integrate the through wall component with an existing water and air barrier system. One recent attempt to overcome the problem of attempting to apply a waterproof membrane to a complex penetration in the building envelope has been the development of liquid applied membranes. This concept consists of applying by brush, roll, trowel, or spray a material to the exterior construction wall penetration openings and at the exterior side of the wall sheathing or other substrates a product that becomes by way of cross-linking, solvent evaporation, coalescence or other such means of cure, a continuous membrane capable of resisting air and water penetration. A common problem with many of these materials is the inherent need for solvents, be they water, petroleum distillates, or other volatile materials required to reach a viscosity needed for the application technique. The volatile material is expressed into the surrounding atmosphere resulting in odor, health and fire danger, pollution, and other complications, most notably, loss of volume in the membrane. This loss in volume as the material cures creates tension at the crucial membrane-substrate interface, increasing the potential for adhesive and cohesive failure. These systems do not typically allow a continuous air and water barrier to be achieved across the interface of the component and the wall opening. The use of liquid applied flashing membranes in the construction of residential and commercial structures is known. Common drawbacks are shrinkage of membrane, weather resistance during construction schedule, limited water-ponding resistance, and long-term flexibility, as well as limited ability to integrate the through-wall component with the prepared opening. There is therefore a need for a liquid applied flashing membrane that can be applied under adverse conditions to irregular, moist substrates, forming a film membrane that renders the building envelope penetration or opening water and air proof, meets air barrier association requirements for air transmission through membranes, is elastic and weather durable, and does not emit dangerous or flammable materials. Such film will not shrink or pull away from the substrate under violent weather conditions, and it must be capable of inspection after completion, The material must meet Volatile Organic Compound (VOC) requirements in all of North America, must cure rapidly enough to maintain construction schedule deadlines, must be weather resistant to allow for extended exposure to exterior elements, and must allow water vapor transmission so the substrate can dry if it contains water when material is applied. The material must also be able to incorporate other products needed to transition water from a leaky building component, such as a window or door, to the exterior drainage plane of the structure. The disclosed embodiments of the various inventive features related to the composition, method of use, and resulting structural barrier system set forth herein overcome the foregoing challenges and meet the above-listed requirements. A formulation is provided for an elastomeric composition for coating of the building envelope penetration or opening to provide a water and air barrier that can be integrated with the through-wall component, whether it is a window or a door. In accordance with another embodiment, the applied composition provides a novel composite article that includes a construction wall opening coated with the aforementioned elastomeric composition. In accordance with a further embodiment, the applied composition has distinct properties of weather durability, vapor permeability, flexibility with no material shrinkage due to solvent loss during cure and no unusual bonding characteristics when applied to a wide variety of construction substrates under adverse conditions. The composition exhibits a shelf life up to a year, is chemically stable up to 400° F. and results in a coating that passes or exceeds current flashing standard requirements and that bonds sufficiently to itself and other construction substrates to provide integration of a through-wall component in a prepared opening. The composition is non-flammable, releases no isocyanates, does not support mold growth, and can be subjected to precipitation directly after application. In accordance with yet a further embodiment of the invention, a coating composition is provided that includes a liquid rosin that is a silyl-terminated polyether, a filler material, and a curing catalyst. Ideally, the coating composition includes the silyl-terminated polyether that is polypropylene oxide capped at respective termini by a silyl group represented by: —SiR1t(OR2)3-t, wherein, t is 0, 1 or 2, R1 and R2 are the same or different and independently an alkyl group. In accordance with a further embodiment, a method of forming a structural barrier system is provided, the method including applying a liquid flashing membrane material to a prepared surface, the material comprising a liquid rosin, a filler material, and a curing catalyst, wherein the liquid rosin is a silyl-terminated polyether, and applying a sheet of flashing to a selected area in the through-hole and at least partially on the liquid-applied flashing material. In accordance with still yet a further embodiment of the invention, a structural barrier system is provided that includes a liquid-applied flashing membrane applied to a through-hole formed in a structural member, the liquid-applied flashing material comprising a liquid rosin, a filler material, and a curing catalyst, wherein the liquid rosin is a silyl-terminated polyether, a sheet of flashing applied partially over the material and to a bottom surface of the through-hole and to extend horizontally on each side of the through-hole on exterior sheathing, and a window or door unit applied to the through-hole over the flashing and the cured liquid-applied flashing material. The foregoing and other features and advantages of the present invention will be more readily appreciated as the same becomes better understood from the detailed description of the invention when considered in conjunction with the following drawings, wherein: Continue reading about Composition, method of use, and structural barrier system... Full patent description for Composition, method of use, and structural barrier system Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Composition, method of use, and structural barrier system patent application. Patent Applications in related categories: 20090282765 - Refrigeration vapor intrusion retardant system and method of installation - Commercial meat and perishable product refrigeration buildings commonly suffer from infiltration of moisture which normally occurs at the roof/wall junction where the roof meets the walls. 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