Canadian Patents Database / Patent 2513969 Summary

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(12) Patent Application: (11) CA 2513969
(54) English Title: METHOD FOR FASTENING BUILDING MATERIALS TOGETHER
(54) French Title: METHODE POUR ATTACHER DES MATERIAUX DE CONSTRUCTION ENSEMBLE
(51) International Patent Classification (IPC):
  • E04B 1/62 (2006.01)
  • C09J 7/02 (2006.01)
  • E04D 5/14 (2006.01)
  • E04F 15/18 (2006.01)
(72) Inventors :
  • WIERCINSKI, ROBERT A. (United States of America)
  • SHAPIRO, LAWRENCE S. (United States of America)
  • SORRENTINO, ROBERT (United States of America)
(73) Owners :
  • W.R. GRACE & CO.-CONN. (United States of America)
(71) Applicants :
  • W.R. GRACE & CO.-CONN. (United States of America)
(74) Agent: SMART & BIGGAR
(74) Associate agent:
(45) Issued:
(22) Filed Date: 2005-07-28
(41) Open to Public Inspection: 2006-02-02
(30) Availability of licence: N/A
(30) Language of filing: English

(30) Application Priority Data:
Application No. Country/Territory Date
60/598,151 United States of America 2004-08-02

English Abstract





Methods and structures involving the use of a double-sided adhesive
membrane assembly having one adhesive surface with low initial tackiness to
permit a
substrate to be re-positionable even if pressed into contact against the
adhesive. The
method 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.


Note: Claims are shown in the official language in which they were submitted.




We claim:

1. ~Method for fastening two substrates together, comprising:
positioning between two substrates a membrane assembly having a sheet-like
body structure having opposing first and major faces, said first major face
comprising
a first pressure-sensitive adhesive surface which adheres said membrane to one
of said
substrates upon pressed contact, and said second major face thereof comprising
a
second pressure-sensitive adhesive surface having an initial tack that is less
than that
of said first pressure-sensitive adhesive surface, whereby a second substrate
placed
into pressing contact against said second pressure-sensitive adhesive surface
can be
repositioned into another contact placement without destroying the integrity
of the
surface of said second pressure-sensitive adhesive; and
mechanically fastening said two substrates together by driving at least one
mechanical fastener through said membrane assembly.

2. ~The method of claim 1 wherein said first pressure-sensitive adhesive is
applied to said first substrate and contact-pressed to adhere said membrane
assembly
to said first substrate, and said second substrate is subsequently contact-
pressed onto
said adhered membrane assembly prior to mechanically fastening said second
substrate.

3. ~The method of claim 1 wherein said first pressure-sensitive adhesive
surface is continuous.

4. ~The method of claim 1 wherein one or both of said substrates
comprises a pre-made building material selected from the group consisting of
wood,
plywood, oriented strand board, gypsum, concrete, mortar, brick, or tile.

5. ~The method of claim I wherein said membrane assembly comprises a
single adhesive layer having two opposing major surfaces, one of said surfaces
having
a powdered material, coating, fiber, mesh, or filler operative to decrease
initial tack
thereof.

6. ~The method of claim 1 wherein said membrane assembly comprises
two pressure-sensitive adhesive layers.

7. ~The method of claim 6 wherein said two pressure-sensitive adhesive
layers are separated by a reinforcement layer comprising a film, fabric, or
both.

15




8. The method of claim 7 wherein said film is comprises a polyolefin,
polyethylene terephthalate, polyamide, polystyrene, acrylic, polyvinylidene
chloride,
polyvinylidene flouride, aluminum, copper, steel, polycarbonate, or mixture
thereof.
9. The method of claim 7 wherein said fabric is a woven or non-woven
material comprising polyolefin, polyethylene terephthalate, polypropylene,
glass,
cellulose, cotton, or mixture thereof.
10. The method of claim 1 wherein said membrane assembly comprises a
first pressure-sensitive adhesive layer reinforced by a fabric, one of said
major
surfaces of said pressure-sensitive adhesive layer having a second pressure-
adhesive
layer that has an initial tack that is less than that of said first pressure-
sensitive
adhesive layer.
11. The method of claim 1 wherein said second pressure-sensitive
adhesive layer comprises a coating of embedded particles operative to decrease
the
initial tack of said second pressure-sensitive adhesive layer.
12. The method of claim 1 wherein said first pressure-sensitive adhesive
comprises a rubberized asphalt, a synthetic adhesive, or mixture thereof.
13. The method of claim 1 wherein said membrane assembly is provided
in a rolled form having a release sheet that is releasably attached to both of
said
adhesive surfaces.
14. The method of claim 13 wherein both sides of said release sheet are
releasably attached to said adhesive layers when said membrane assembly is
provided
in roll form.
15. A building material assembly made in accordance with the method
described in claim 1.
16. The method of claim 1 wherein said second pressure-sensitive
adhesive surface having an initial tack that is less than that of said first
pressure-
sensitive adhesive surface has an initial adhesion value of less than or equal
to 0.5
pounds per lineal inch and an aged adhesion value of greater than or equal to
3.0
pounds per lineal inch, said aged adhesion arising from mechanically fastening
said
substrates together by driving at least one mechanical fastener through said
membrane
assembly.
16




17. The method of claim 1 wherein said membrane assembly comprises a a
carrier support film having two major opposing faces, first pressure-sensitive
adhesive
layer located on a first of said major opposing faces of said carrier support
film, and,
located on the other of said major opposing faces of said carrier support
film, at least
two pressure-sensitive adhesive layers, the outermost of which has an initial
adhesion
value of less than or equal to 0.5 pounds per lineal inch and an aged adhesion
value of
greater than or equal to 3.0 pounds per lineal inch, said aged adhesion
arising from
mechanically fastening said substrates together by driving at least one
mechanical
fastener through said membrane assembly.
18. A building material assembly made in accordance with the method of
claim 17.
19. A building material assembly, comprising:
a membrane assembly having a sheet-like body structure with opposing first
and major faces, said first major face comprising a first pressure-sensitive
adhesive
surface which adheres said membrane to a substrate upon pressed contact, and
said
second major face thereof comprising a second pressure-sensitive adhesive
surface
having an initial tack that is less than that of said fast pressure-sensitive
adhesive
surface, whereby another substrate placed into pressing contact against said
second
pressure-sensitive adhesive surface can be repositioned into another contact
placement without destroying said second pressure-sensitive adhesive;
said building material assembly further comprising substrate that is
releasably
adhered against said second pressure-sensitive adhesive surface; and
said building material assembly further comprising a release sheet liner that
is
removably attached to said first pressure-sensitive adhesive surface.
20. The building material assembly of claim 19 wherein said substrate
being releasably adhered to said membrane assembly is a surface component of a
floor, wall, roof, or deck.
21. The building material assembly of claim 19 wherein said second
pressure-sensitive adhesive surface having an initial tack that is less than
that of said
first pressure-sensitive adhesive surface has an initial adhesion value of
less than or
equal to 0.5 pounds per lineal inch and an aged adhesion value of greater than
or
equal to 3.0 pounds per lineal inch, said aged adhesion arising from
mechanically
17




fastening said substrates together by driving at least one mechanical fastener
through
said membrane assembly.
18

Note: Descriptions are shown in the official language in which they were submitted.


CA 02513969 2005-07-28
ATTORNEY CASE L38$~ialii ''":'
METHOD FOR FASTENING BUILDING MATERIALS TOGETHER
Inventors: Robert A. Wiercinski, Lawrence S Shapiro, and Robert Sorrentino
Field of the Invention
The present invention relates to methods for fastening two or more building
materials together to achieve improved structural integrity and sound-
deadening
IO effects, and more particularly to a two-sided adhesive membrane assembly
for
attaching flooring, decking, roofing, wall components, and the like to
mounting
substrates.
Background of the Invention
Adhesives are available for achieving improved structural integrity and
bonding between common building materials such as subfloor installations.
Heavy-
duty adhesives sold by ICI Paints under the tradename LIQUID NAILS~ are sold,
for
example, for increasing the structural integrity of walls and subfloor
systems. These
liquid adhesives can be used with plywood, foamboard, particle board, lumber
and
treated lumber, waferboard, and OSB. Such a construction adhesive provides for
"quiet" floor assemblies in that the adhesive is said to eliminate squeaking
between
boards and between the boards and nails.
Unfortunately, the decking, flooring, or other component must be attached
within fairly chart time, such as twenty minutes. Otherwise, a skin will begin
to form
on the adhesive that can impede the formation of a strong adhesive bond
between the
building materials. In addition, the liquid adhesive must be applied using a
caulking
gun so that the Liquid adhesive can be squeezed out of a plastic nozzle at the
end of a
cardboard tube. The application of the adhesive over relatively Large surface
areas
may thus become tiring, inconvenient, and time-consuming.
In view of the foregoing disadvantages, a novel method is needed for fastening
building materials together in a quick and convenient manner that achieves
noise
reduction and enhances structural integrity.
I


CA 02513969 2005-07-28
ATTORNEY CASE L3886~01 f '''' "~
Summary of the Invention
In surmounting the disadvantages of the prior art, the present invention
provides a method for joining two or more building materials involving the use
of a
membrane assembly having differing pressure-sensitive surfaces on opposing
major
faces. The method is suitable for building applications whereby surface
components,
such as plywood, foamboard, particle board, lumber and treated lumber,
waferboard,
and OSB (oriented strand board), deck planks, floor planks, wall panels,
roofing tiles
or other surface components are mechanically fastened to deck joists, floor
boards,
wall studs, roofing decks, and other mounting substrates in a manner that is
fast and
to convenient while providing sound-deadening and structural integrity.
For decking and flooring applications in particular, the membrane assemblies
help to minimize unwanted noise, such as squeaking, that can arise when one
component (e.g., floor, plank) impacts or rubs against joists or floor boards.
Unwanted movement of the components is minimized by the additional adhesion,
and
~s energy, such as squeaking from sliding against nails, is absorbed by the
additional
adhesive surface of the membrane assembly. Decking becomes loose as a result
of
fatigue (due to repetitive foot traffic), differential thermal expansion,
difrerentiaI
moisture absorption. Foot traffic also causes noise due to the friction
between joists
and boards and also between these components and the nails used for fastening
them
2o together. Thus, the membrane assemblies of the invention help to prevent or
minimize the unwanted movement of the material components as well as to deaden
the sound created by their relative movements.
Thus, an exemplary method of the invention comprises positioning between
two substrates a membrane assembly having a sheet-like body structure having
2s opposing first and major faces, the first major face comprising a first
pressure-
sensitive adhesive surface which adheres the membrane assembly to one of the
substrates upon pressed contact, and the second major face thereof comprising
a
second pressure-sensitive adhesive surface having an initial tack that is less
than that
of the first pressure-sensitive adhesive surface and whereby a second
substrate placed
3o into pressing contact against the second pressure-sensitive adhesive
surface can be
repositioned into another contact placement without destroying the integrity
of the
surface of the second pressure-sensitive adhesive surface. It is also possible
that the
second pressure-sensitive adhesive surface provides minimal or no initial
tack, but
2


CA 02513969 2005-07-28
pTTO~Y CASE L3881r:~1 ;_::.;:
does provide a good adhesive bond over time after the components are placed
into
contact with one another and pressed together by force of the mechanical
fasteners
(e.g., nails or screws). The membrane assembly can be affixed first to either
of the
two substrates, preferably with the more aggressive adhesive surface first,
followed
by subsequent attachment to the other substrate, and then the fastener is
driven
through the substrates and membrane assembly.
The invention also relates to building structures made in accordance with the
above-described method. Further advantages and features are described herein
and
after.
l0 Brief Descriution of the Drawings
The following detailed description of exemplary embodiments may be more
readily appreciated in conjunction with the appended drawings, wherein
Fig. 1 is a cross-sectional illustration of an exemplary membrane assembly and
method as provided by novel methods of the present invention; and
Fig. 2 is a cross-sectional illustration of an exemplary membrane assembly and
method as provided by the present invention.
Detailed Description of Exemplary Embodiments
Fig. 1 illustrates an exemplary membrane assembly 10 of the invention,
having an optional reinforcement layer (designated by the "XXX" symbols), such
as
2U an embedded fabric or film. The membrane assembly 10 is attached to a first
substrate 20 before a second substrate 30 is fastened into place. A release
liner sheet
(not shown) is used to protect the membrane assembly until it is installed.
For
example, a release liner sheet preferably having silicone and/or wax on both
sides is
used for rolling the membrane assembly 10 up onto itself, thus separating the
two
adhesive surfaces of the membrane assembly. Preferably, the "stickier" or more
aggressive pressure-sensitive adhesive surface of the membrane assembly i 0 is
exposed (because the release liner sheet is removed because it is left
attached to the
less sticky upward facing adhesive surface) and is attached to the first
substrate 20,
and then the release liner sheet is removed before the second substrate 30 is
3o positioned over the attached membrane assembly i0 and fastened using nails,
screws,
or other mechanical fastener devices.
3


CA 02513969 2005-07-28
ATTOR1~IEY CASE L388b='t)1~ ..
The mechanical fastening of one substrate to another substrate, using the
double-adhesive-sided membrane assembly 10, will usually involve nails or
screws.
However, it is contemplated that other mechanical fasteners may include
staples,
spikes, clamps, and other devices.
s The exemplary membrane assembly 10 preferably has a sheet like body, and is
preferably flexible so that it can be shipped in roll form and unrolled at the
site of
installation. The sheet like body has opposing first and major adhesive
surfaces,
which are preferably continuous, in that they extend from one edge of the
membrane
to the other edge. The first adhesive surface, shown positioned against a
first substrate
20, is a pressure-sensitive adhesive operative to attach the membrane assembly
10
firmly against the first substrate 20 with hand pressure.
The first substrate 20, for example, may be a deck joist, roof joist, or wall
stud,
and the second substrate 30 thus a plank made of wood (treated lumber),
plywood,
plastic lumber, fir decking, mahogany decking, oriented strand board (OSB), a
composite, or material commonly used for such constructions. The first
substrate 20
could also comprise plywood, OSB, Masonite, fiberboard, while the second
substrate
30 could be flooring planks, hardwood ox softwood tongue in groove flooring
planks,
panels, boards, or tiles. In yet another embodiment, the first substrate 20
could also be
a roof deck (sloped or unsloped), while the second substrate 30 could be
roofing
components such as asphalt shingles, slate tiles, cedar shingles, metal tiles,
or plastic,
metal, felt, or composite sheeting. In many of these cases, the membrane
assembly 20
serves to providing a waterproofing barrier to prevent moisture from
accumulating
against the adjacent surfaces of the substrates (20 and 30), and may primarily
serve to
provide sound deadening effects such as preventing either substrate from
rubbing
against the membrane assembly 10 due to the securing effect of the two
adhesive
surfaces. The membrane assembly 20 also serves to increase the structural
rigidity of
the result structure.
In other exemplary embodiments of the invention, one or bath of said
substrates can comprise a pre-made building material selected from the group
consisting of wood, plywood, oriented strand board, gypsum, concrete, mortar,
brick,
or tile.
4


CA 02513969 2005-07-28
ATTORNEY CASE L3886;i11 'r-::
The first adhesive surface is preferably of sufficient tenacity that pressing
the
membrane assembly 10 against the first substrate 20, using hand pressure, is
sufficient
to adhere the membrane such that subsequent attempts to position the membrane
would disrupt portions of the adhesive surface (i.e., some adhesive would be
torn
from the membrane and remain stuck to the first substrate 20 if repositioned
after
pressing contact).
However, the second adhesive surface, located on the major face of the
membrane assembly, should have an initial adhesive tack that is substantially
less
than that possessed by the first adhesive surface, such that the second
substrate 30 can
1o be placed into pressing contact against the second adhesive surface and yet
re-
positioned if the need arises (without tearing apart the second adhesive
surface),
before the second substrate 30 is nailed or screwed into place against the
fast
substrate 20 and membrane assembly 10. As will be discussed further below, the
second adhesive surface may be renders Less initially tacky by coating it with
a
powdered material or embedding filler material (e.g., fibers) in the surface.
Alternatively, the second adhesive surface may be formulated with low tack
without
filler. Preferably, the second adhesive comprises a slightly tacky rubber,
filler, and no
plasticizer or tackifier. The filler Level may range from very high (90%
filler by
weight) or may be entirely free of filler. Preferred rubbers include polymers
2o comprising acrylic esters.
Once the second substrate is nailed or screwed into place against the
membrane assembly 10, the strength of the adhesive bond between the membrane
10
and second substrate 30 preferably increases. This increase in the strength of
the
adhesive bond may be brought about by a number of factors, such as the ability
of the
second adhesive to flow and make contact with the substrate, when subjected to
the
pressure exerted by the mechanical fastener over time against the second
substrate 30.
Alternatively, for a second adhesive layer coated with a filler (particles),
the adhesive
may flow around the powdered material and make contact with the substrate when
subjected to long term pressure after the second substrate 30 is mechanically
fastened
to the first substrate 20 (such as by nailing, screwing, clamping, or other
mechanical
pressure or force). The strength of the adhesive bond may also be later
enhanced or
arising as a matter of course through other means, such as the application of
heat (e.g.,
5


CA 02513969 2005-07-28
ATTORNEY CASE L3886-01 ..-
exposure to sunlight or elevated temperature of roof tops) depending on the
purpose
or application.
Fig. 2 illustrates another exemplary membrane assembly 10, which is adhered
onto the first substrate 20, such as a joist or stud, following which the
second
substrate 30, such as plywood, OSB, floor or deck slats are positioned over
the
installed membrane assembly 10, and then fastened by driving nails or screws
through
the top of the floor or desk slats 30 into the mounting substrate 20. The
exemplary
membrane assembly 10 is shown having a first adhesive layer 11 and a second
adhesive layer 13. The second adhesive layer 13 may be called a "less-
initially-
1o tacky" adhesive layer (in comparison to the first adhesive layer 11). This
less-
initially-tacky adhesive layer 13 may have this characteristic by comprising a
rubber
and little or no tackifier and piasticizer and/or by incorporating large
amounts of filler
which is operative to further reduce tack.
Optionally, the second adhesive layer 13 may be rendered less initially tacky
i5 by having a coating layer of particulates or filler material 14 on its
surface. In further
exemplary embodiments, the second adhesive layer 13 may incorporate a filler
material (e.g., particulate material} as well as have the coating of filler
material on its
outward surface.
Preferably, the less-initially-tacky adhesive layer 13 comprises an acrylic
ester
2o rubber. The glass transition temperature of this rubber is preferably less
than or equal
to --10 degrees C.
In a further exemplary embodiment of the invention, the membrane assembly
may have different adhesive layers. Turning to Fig. 2, therefore, the
exemplary
membrane assembly 10 is adhered onto a first substrate 20, such as a joist or
stud,
25 using a relatively aggressive first adhesive layer 11. In addition to the
first adhesive
layer 11, the membrane assembly 10 had a earner support layer 12, a second
adhesive
layer 13 on the face opposite the first adhesive layer 11, and an optional
third
adhesive layer 14 on the upper face of the second adhesive layer 13. After
this
membrane assembly 10 is installed, a second substrate 30, such as floor or
deck slats,
3o is positioned over the installed membrane assembly 10 and fastened by
driving nails
or screws through the top of the floor or deck slats 30, through the membrane
assembly 10, and finally into the mounting substrate 20. The third (and thus
6


CA 02513969 2005-07-28
ATTORNEY CASE L388o-01
outermost) pressure-sensitive adhesive layer (14) preferably comprises a
slightly
tacky rubber (e.g., pressure-sensitive adhesive containing and/or coated with
a filler or
particulate material to reduce initial tack), while the second adhesive layer
13 would
operate to adhere the third adhesive layer 14 to the carrier layer I2 and
could
therefore could have an aggressive initial adhesive or tack quality. (e.g.,
aggressively
bonding upon mere contact).
The physical dimensions and thiclanesses for the various exemplary
component layers of the membrane assembly 10 may be as conventionally employed
for waterproofing membranes or sound-deadening membranes as the case may be.
to For example, the total thickness of the one or more adhesive layers (11,
13, 14) may
be 0.5-100 mils. If the outermost layer I4 comprised particles alone rather
than a
particle-filled adhesive, then the thickness of the outermost layer i4 would
be
relatively thin depending on the average size of the particles. Where the
first adhesive
layer i 1 is used for providing attachment to a building material substrate,
such as roof
joists, floor joists, or wall studs, roof deck, or floor deck. The thickness
of the first
waterproofing adhesive layer I I may be 5-80 mils, and more preferably 10-60
mils.
The thickness of the second and third adhesive layers (I3, 14) may be 0.5-20
mils
each. Use of larger thicknesses may be particularly suitable for achieving
sound
deadening properties with respect to the securing of the second substrate 30.
If the
optional reinforcement layer I2 is a film, thicknesses may be in the range of
0.5-20
mils, while a woven or nonwoven fabric may have a weight in the range of O.S-
5.0
ounces/yard. The membrane assembly 10 may have an edge-to-edge width of O.OI-
10.0 meters or more. Preferably, the width is approximately equal to that of
the floor
joist, roof joist, or wall stud to which the first adhesive layer 1 I is
attached.
zs As previously mentioned, the membrane assemblies 10 of the invention can be
transported in roll form or they may be used pre-attached to the substrate. In
any
event, a release liner sheet (not shown) preferably having a releasable
coating on both
sides, can be used to protect the adhesive surfaces and then removed before
installation. The releasable property may be achieved by coating a paper or
plastic
film with silicone, wax, or other release agent. Plastic films used for this
purpose
include plastic materials such as polyolefins (e.g., polyethylene,
polypropylene) and
polyester (e.g., polyethylene terephthalate}.
7


CA 02513969 2005-07-28
,, ; f,.. .:.
ATTORNEY CASE L38isis=Ol ~'"-~'
Once at the application site, a rolled membrane assembly 10 can be unrolled
such that the release sheet remains temporarily attached to less-initially-
tacky
adhesive surface (such as designated as 13/14 in Fig. 2), while the first
adhesive layer
I I is exposed and hence may be installed upon or to a first (mounting)
substrate 20.
The pressure-sensitive adhesive layers (e.g., 11, 13, 14) may comprise
polymeric materials such as styrene isoprene styrene (SIS), styrene butadiene
styrene
(SBS), styrene ethylene butadiene styrene (SEBS), natural rubber, butadiene,
acrylic
rubber, neoprene, silicone, isoprene, or mixture thereof. Adhesive
compositions
employed in the invention may also comprise a rubber-modified asphalt or
bitumen,
1o as would be known to those skilled in watezproofing building foundations,
walls, and
roofing structures. The pressure-sensitive adhesive layer may also comprise
one or
more tackifiers and/or plasticizers (which can be used to increase adhesion
when
compared to rubber alone) and/or one or more fillers and particles (which can
be used
to decrease adhesion, including initial tack).
Usually, tackifier components exhibit tower molecular weight and glass
transition temperature (Tg) than the rubber being modified. For a given xubber
type
and grade, the tackifier and plasticizer are selected to achieve the desired
balance of
properties, it is expected that those skilled in the art of adhesives or
adhesive
formulations would be able to achieve desired pressure-sensitive adhesive
properties
zo using various components, as contemplated by the present invention. For
example, it
is known that polymers comprising acrylic esters (e.g., butyl acrylate, ethyl
hexyl
acrylate and other acrylic esters with four or more carbons in the ester
chain) are
inherently pressure sensitive, although some of these are generally less
initially tacky
when compared to certain other adhesive systems (e.g., rubber modified
bitumen, SIS,
zs etc., with plasticizer and tackifier or other combinations of rubber,
plasticizer, and
tackifier).
The second pressure-sensitive adhesive layer 13, which may otherwise be
considered a "less-initially-tacky" adhesive layer (i.e., the surface of
adhesive having
the less-intially tacky adhesive face) may include, or be coated with,
particulate
3o materials to decrease initial tackiness (i.e., adhesive bond strength upon
first physical
contact).
8


CA 02513969 2005-07-28
f . ...
ATTORNEY CASE L3$t3~6-Ol '~:::'>~
Exemplary particulate materials useful for incorporating into and/or coating
the Iess-initially-tacky adhesive layer {or surface) include calcium
carbonate, sand,
silicate sand, cement, talc, titanium dioxide, carbon black, slate dust,
granite dust,
clay, diatomaceous earth, limestone, metakaolin clay, smectite clay, shale,
fly ash,
silica fume, granulated blast furnace slag, alkaline or alkaline earth metal
nitrites or
nitrates, halides, sulfates, carboxylates, such as calcium, potassium, sodium
salts, or
mixtures thereof. Aluminum oxide trihydrate particles are also believed to be
suitable. A number of particulate materials which are also believed to be
suitable for
the purposes of the present invention are disclosed in US Patents 5,496,61 S
of Bartlett
io et al. and 6,SOO,S20 of Wiercinski et al.
Other materials believed to be suitable for decreasing initial tackiness of
the
second adhesive layer 13 may include fibrous materials such as cellulose,
polymeric
fibers (e.g., polyolefin), cotton, hemp, glass, and other materials.
Exemplary less-initially-tacky, pressure-sensitive adhesive layers 13 (if
outermost) or 14 may comprise a combination of the adhesive materials and
optional
particulate and/or fibrous materials as described above. The adhesive material
of the
less-initially-tacky adhesive layer (outermost) 13 and/or 14 may be chosen
such that it
is different from, because it has lower adhesive bond strength than, the
adhesive
material chosen for the first pressure-sensitive adhesive layer 11. Indeed,
the
adhesive material for both adhesive layers 11 and 13 could comprise the same
components (except filler levels), but the second second adhesive layer 13 may
be
rendered less-initially-tacky in comparison by including lower amounts of
plasticizes
and/or rubber tackifying agents (or omitting them entirely), and/or by
including
particulate andlor fibrous materials such as described above.
Exemplary less-initially-tacky pressure sensitive layers 13 of the present
invention have an adhesion value of less than or equal to 1 pounds per lineal
inch
when tested in accordance with a standard initial adhesion test. Preferably,
the
outermost less-initially-tacky pressure-sensitive adhesive layers (13 or 14)
of the
present invention have an adhesion value of less than or equal to 0.5 pounds
per lineal
3o inch when tested in accordance with a standard initial adhsion test. The
standard test
is described as follows. A 3" x 8" piece of 2 sided tape is used for the test.
The
release liner is left in contact with the pressure sensitive layer 11. The
less-initially-
tacky, pressure-sensitive adhesive layer I3 is applied to a 3" x 8" plywood
surface.
9


CA 02513969 2005-07-28
ATTORNEY CASE L3813ir01 t~_:;:.:.:
All materials are at 75 degrees F. The membrane assembly is rolled with a 30
lb
roller. Four 1 sec. passes are made in the long direction of the sample. The
tape is
peeled off of the plywood substrate at an angle of 180 degrees, at a peel rate
of two
inches per minute, fifteen minutes after rolling.
Exemplary Less-initially-tacky pressure sensitive layers (13 if outermost or
14)
exhibit significantly improved adhesion, when compared to that measured in the
initial test (hereinafter "initial" adhesion) after extended contact with a
substrate
under pressure (hereinafter "aged" adhesion value). The initial adhesion value
is
greater than or equal to 0.5 pounds per lineal inch. Preferably, the aged
adhesion
value is greater than or equal to three pounds per lineal inch. The test is
described as
follows. A 3" x 8" piece of two- sided tape is used for the test. A release
liner is left
in contact with the pressure sensitive Layer 11. The less-initially-tacky,
pressure-
sensitive adhesive layer 13 is applied to a 3" x 8" plywood surface. All
materials are
at 75 degrees F. The membrane assembly is rolled with a 30 Ib roller. Four I
sec.
passes are made in the long direction of the sample. Another 3" x 8" sample of
plywood is placed on the surface comprising the release liner. Six self
tapping screws
are fastened through the assembly, spaced evenly apart. Four screws are
located near
the comers one inch from the shortest edges, and two midway along the
longitudinal
sides, with all screws being approximately 0.5 inches from the long sides of
the
2o rectangular sample. The test assembly is aged at zoom temperature for 48
hours, and
screws removed. The less-initially-tacky pressure sensitive layer I3 is peeled
off the
plywood substrate at an angle of I 80 degrees at a rate of two inches per
minute.
Accordingly, an exemplary "less-initially-tacky" adhesive layer (e.g., I3) of
the present invention will have adhesion value of less than or equal to 0.5
pounds per
2s lineal inch when tested in accordance with a standard initial adhesion
test. After 48
hours of compressed contact against a plywood substrate, this adhesive layer
13 will
have an adhesion value of greater than or equal to three pounds per lineal
inch.
The choice of adhesives and adhesive formulations and optional reinforcement
sheet materials for a given membrane assembly IO of the invention may well
depend
3o upon the nature of the application at hand. The substrate may comprise
materials such
as wood, gypsum, metal (e.g., steel, aluminum), concrete, or synthetic
polymers (e.g.,
plastic, resins).


CA 02513969 2005-07-28
ATTORNEY CASE L38gfi-tll ø~%~'v
Accordingly, further exemplary embodiments of the invention include
structures or assemblies made froze the methods described above, wherein the
second
substrate 30 is mechanically fastened, using nails, screws, or other
mechazzical
fasteners, to the first substrate 20, through the membrane assembly 10.
Preferred structures are those wherein both substrates are made of wood,
plywood, or oriented strand board {OSB), and nails or screws are used for
mechanically securing them together, using the membrane assembly 10 to provide
adhesive sealing at their interfaces. In floors, roof, and deck structures,
wood will
probably be made using pine, spruce, fir, or engineered lumber; while the
second
substrate may be wood, plywood, OSB, gypsum board, a floor (hard wood, ceramic
tiles, fber board), roofing tiles or sheets (e.g., fiberglass), or decking
(e.g., pine,
mahogany, engineered plastics).
The use of the membrane assembly 10, as previously mentioned, is operative
to provide a number of benefits. For example, it can prevent water or moisture
from
accumulating at the surfaces of the respective first substrate 20 and second
substrate
30; it can provide enhanced stzuctural integrity (when compared to using only
the
fastenez-s); and it can provide sound deadening. As for the last mentioned
benefit, the
two-adhesive-sided mezxzbrane assembly 10 would be particularly helpful in
providing
a quiet construction using plywood or oriented strand board which has been
nailed or
2o screwed onto floor joists, wall studs, roof joists, or other mounting
substrates. In
floors, any squeaking caused by Loose decking (caused by traffic} or sliding
along
joists or nails or screws (caused by warpage, contraction, expansion, etc.)
will tend to
be minimized by the membrane assembly I0.
For example, the membrane assembly IO can minimize squeaking in deck or
2s flooring construction in at least two ways: by providing better/fitller
adhesion between
the decking/floozing and joists (in contrast to the nails or screws alone);
and by
dampening any sound that may be created as decking impacts or rubs against
itself,
the joists, or fasteners.
As an alternative method of the invention, the membrane assembly 10 can be
30 installed by first applying the less-initially-tacky adhesive surface (e.g,
designated at
13 in Fig. 2) first against the first substrate 30 (e.g., floor or decking
component),
which is then applied by attaching the first pressure-sensitive adhesive
surface
11


CA 02513969 2005-07-28
ATTORNEY CASE L3886-OI '= : v'v
(designated at 11 in Fig. 2) directly to a deck or floor joist, roof
structure, or other
mounting substrate 20.
Thus, further exemplary embodiments of the invention comprise a building
material substrate, such as a floor or roof tile having slidably attached
thereto (e.g., it
is attached but re-positionable) a membrane assembly, the membrane assembly
having two major opposing adhesive faces, the first adhesive face thereof
comprising
a pressure-sensitive adhesive surface, the second opposing adhesive face
thereof
comprising a pressure-sensitive adhesive surface having a less-initially-tacky
pressure
sensitive adhesive face in comparison to said first adhesive face. In this
exemplary
to embodiment, the less-initially-tacky pressure-adhesive face would be
installed, pre-
attached to a substrate 30 (e.g., floor or roofing tile), and a protective
release liner
sheet would be removed to expose the first pressure-sensitive adhesive layer,
which is
attached onto the mounting substrate, such as joists or other building
mounting
surface.
Thus, further exemplary embodiments of the invention include building
materials, such as floor, wall, ceiling, roof, or decking boards, tiles, or
other such
surface components having a repositionable two-sided adhesive membrane
assembly
(10) attached releasably thereto using the less tacky adhesive surface (e.g.,
13). The
present invention thus contemplates the use of "pre-made" building materials
as
substrates, in the sense that these substrates are provided in solid form
(e.g., not as
wet fresh concrete cast into place against the membrane and allowed to
harden).
Thus, an exemplary building material assembly, comprises a membrane
assembly having a sheet-like body structure with opposing first and major
faces, the
first major face comprising a first pressure-sensitive adhesive surface which
adheres
the membrane to a first substrate upon pressed contact, and the second major
face
thereof comprising a second pressure-sensitive adhesive surface having an
initial tack
that is less than that of the first pressure-sensitive adhesive surface,
whereby a second
substrate placed into pressing contact against the second pressure-sensitive
adhesive
surface can be repositioned into another contact placement without destroying
the
integrity of the surface of the second pressure-sensitive adhesive; the
building
material assembly further comprising a substrate that is releasably adhered
against the
second pressure-sensitive adhesive surface; and the building material assembly
further
comprising a release sheet liner that is removably attached to the first
pressure-
t2


CA 02513969 2005-07-28
' ~;,:;:;:.,.
ATTORNEY CASE L388~ti-Oi ::
sensitive adhesive surface. Thus, the release sheet can be removed, and the
releasably
attached substrate (e.g., floor, wall, roof, ceiling, or other building
surface component)
can be adhered to and mechanically fastened to a mounting surface, such as a
joist,
beam, panel, or other mounting structure.
The following examples are used for illustrating certain embodiments of the
invention, and are not intended to limit the scope of the invention.
Example 1
This example provides a demonstration that the less-initially-tacky pressure
sensitive layer 13 (outermost, see e.g., Fig. I) exhibits low initial adhesion
value, but
to thereafter demonstrates stronger "aged" adhesion value (e.g., stronger
adhesion after a
period of time during which it is pressed against a substrate).
Exemplary less-initially-tacky pressure sensitive layers 13 exhibit an
{initial)
adhesion value of less than or equal to 0.5 pounds per lineal inch when tested
in
accordance with standard peel adhesion test, which is described again
hereinbelow as
is follows. Preferably, the less-initially-tacky pressure-sensitive adhesive
layers exhibit
an initial adhesion value of less than or equal to 0.5 pounds per lineal inch
when
tested in accordance with a standard peel adhesion test. A 3" x 8" piece of
two-sided
tape is used. A release liner is le$ in contact with the pressure sensitive
layer 1 I . The
less-initially-tacky, pressure-sensitive adhesive layer 13 is applied onto a
3" x 8"
2o plywood surface. All materials are at 75 degrees F. The assembly is rolled
with a 30
lb. roller. Four i sec. passes are made in the long direction of the sample.
Tfie tape is
peeled off of the plywood substrate at an angle of 180 degrees, at a peel rate
of two
inches per minute, fifteen minutes after rolling.
Exemplary less-initially-tacky pressure sensitive layers 13 were found to
25 exhibit significantly improved adhesion, compared to initial adhesion
measurements,
after long-teen contact with a substrate under pressure. The adhesion value is
found
to be greater than or equal to 0.5 pounds per lineal inch. Preferably, the
adhesion
value is greater than or equal to three pounds per lineal inch. The test is
described
below. A 3" x 8" piece of 2 sided tape is used for the test. The release liner
is left in
30 contact with the pressure sensitive layer 11. The less-initially-tacky,
pressure-
sensitive adhesive layer 13 is applied to a 3" x 8" plywood surface. All
materials are
at 7S degrees F. The assembly is rolled with a 30 lb roller. Four I sec.
passes are
13


CA 02513969 2005-07-28
ATTORNEY CASE L38$6-Ql
made in the long direction of the sample. Another 3" x 8" sample of plywood is
placed on the surface comprising the release liner. Six self tapping screws
are
fastened through the assembly, spaced evenly apart with screws located near
each of
the four comers and two along the longitudinal sides, all six screws being
approximately 0.5-1 inch from the edges of the rectangular sample. The test
assembly
is aged at room temperature for 48 hrs. The screws are removed. The less-
initialiy-
tacky pressure sensitive layers 13 is peeled off the first plywood substrate
at an angle
of 180 degrees F at a rate of two inches per minute. The average adhesion
value is
reported. Adhesion is highest where the screws are applied; but adhesion is
lower at
to distances furthest from the screws.
Results for two different less-initially tacky pressure sensitive layers 13
(one
comprising a high level of filler and the other comprising a low level of
filler) and a
(non-particulate-filled) pressure-sensitive adhesive layer 11 are shown in the
table
below. It was observed that the less-initially-tacky pressure sensitive layers
13
exhibited initial adhesion values less than or equal to 0.5 pounds per lineal
inch, and
"long term" adhesion values of greater than or equal to 0.5 pounds per lineal
inch
(after 48 hours in compressed contact with substrate).
The formulation comprising the acrylic with 4% filler has very low initial
adhesion but excellent long term adhesion peel strength. In contrast, the
exemplary
2o pressure sensitive layer 11, which was based on a styrene-isoprene-styrene
adhesive
(SIS), exhibited excellent initial adhesion.
Table I
AdhesiveAdhesive Time Aged Adhesion
Value


Layer Formulation (hrs) (ptl)


13 Acrylic with 85~60.25 not measurable
filler


13 Acrylic with 859648 .8
filler


13 Acrylic with 4% 0.25 .3
filler


13 Acxylic with 4~o 48 5.8
filler


11 StS Adfiesive 0.25 3.9


The foregoing embodiments are provided for illustrative purposes are not
intended to limit the scope of the invention.
14

A single figure which represents the drawing illustrating the invention.

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Admin Status

Title Date
Forecasted Issue Date Unavailable
(22) Filed 2005-07-28
(41) Open to Public Inspection 2006-02-02
Dead Application 2011-07-28

Abandonment History

Abandonment Date Reason Reinstatement Date
2010-07-28 FAILURE TO PAY APPLICATION MAINTENANCE FEE
2010-07-28 FAILURE TO REQUEST EXAMINATION

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Filing $400.00 2005-07-28
Registration of Documents $100.00 2006-07-26
Maintenance Fee - Application - New Act 2 2007-07-30 $100.00 2007-07-04
Maintenance Fee - Application - New Act 3 2008-07-28 $100.00 2008-07-03
Maintenance Fee - Application - New Act 4 2009-07-28 $100.00 2009-07-03
Current owners on record shown in alphabetical order.
Current Owners on Record
W.R. GRACE & CO.-CONN.
Past owners on record shown in alphabetical order.
Past Owners on Record
SHAPIRO, LAWRENCE S.
SORRENTINO, ROBERT
WIERCINSKI, ROBERT A.
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.

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Abstract 2005-07-28 1 15
Description 2005-07-28 14 813
Claims 2005-07-28 4 166
Drawings 2005-07-28 2 20
Representative Drawing 2006-01-06 1 8
Cover Page 2006-01-24 1 36
Correspondence 2005-09-13 1 26
Assignment 2005-07-28 4 155
Assignment 2006-08-03 1 39
Assignment 2006-07-26 5 189