WO2018017704A1

WO2018017704A1 - Method for making transferable weeping ports for flashing

Info

Publication number: WO2018017704A1
Application number: PCT/US2017/042836
Authority: WO
Inventors: Ronald Ellsworth Buchanan; Nathan Thomas TUTTLE; Nicholas John DRY
Original assignee: Quanex Ig System, Inc.
Priority date: 2016-07-19
Filing date: 2017-07-19
Publication date: 2018-01-25

Abstract

A method of making transferable weeping ports for flashing material includes the step of applying the material that is used to define the weeping port in the final flashing product to the inner surface of a release liner before the release liner is connected to the flashing material. The weeping port material can be applied to the release liner as a solid, semi-solid, plastic, or as a liquid that cools or cures to a solid, semi-solid, or plastic. The weeping port material is transferred to the sealant of the flashing material. When the user removes the release liner from the flashing material, the weeping port material remains with the sealant of the flashing material to define the weeping port when the sealant of the flashing material is pressed against the surface to which the flashing material is applied. The weeping port material allows condensation to seep away from window sills doors and the like where the flashing material is used.

Description

Method for Making Transferable Weeping Ports for Flashing

BACKGROUND OF THE DISCLOSURE

1 . Technical Field

The disclosure is related to manufacturing processes and, more particularly, to a manufacturing process for adding weeping ports to a flashing material.

Specifically, the disclosure relates to a method for making flashing material with weeping ports wherein the material that forms the weeping port is deposited onto the inner surface of a release liner that engages the inner surface of the flashing material before the flashing material and release liner are rolled up. The weeping port material is transferred to the sealant of the flashing such that the release liner can be removed leaving the weeping ports on the flashing material.

2. Background Information

Known prior art includes printing reverse images with an ink jet printer onto a release liner in order to transfer the printing from the release liner onto a vapor barrier used with a spacer of a multiple pane insulating glazing unit.

Those who sell flashing materials such as flashing tapes desire weeping ports to be defined by the flashing material in order to allow condensate to escape from behind the flashing. The weeping ports are defined by non-adhered locations between the sealant side of the flashing material and the surface against which the flashing material is applied. The non-adhered locations can be empty spaces, but non-adhered locations defined by material that prevents or limits the adhesion is preferred. The material can be a polymer having a hardness in the plastic range under normal working environments for flashing materials. An exemplary plastic range hardness is Shore D 55 up to Rockwell R 150.

One method of manufacturing flashing tape includes a step wherein a release liner is connected to the inner surface of a butyl sealant layer before the combination is rolled for storage and shipping. This material can be added at a rate of 70 - 90 feet / minute. SUMMARY OF THE DISCLOSURE

The disclosure provides a method of making transferable weeping ports for flashing material. The method includes the step of applying the material that is used to define the weeping port in the final flashing product to the inner surface of a release liner before the release liner is connected to the flashing material. The weeping port material can be applied to the release liner as a solid, semi-solid, plastic, or as a liquid. The weeping port material is transferred to the sealant of the flashing material. When the user removes the release liner from the flashing material, the weeping port material remains with the sealant of the flashing material to define the weeping port when the sealant of the flashing material is pressed against the surface to which the flashing material is applied. The weeping port material allows condensation to seep away from window sills doors and the like where the flashing material is used.

The disclosure also includes a method of manufacturing flashing tape with weeping ports wherein the weeping port material is initially applied to the release liner and then transferred to the flashing material of the flashing tape.

In one exemplary configuration, the weeping port material is applied across the entire width of the release liner or the entire width of the flashing tape material.

In another exemplary configuration, the weeping port material is applied from one edge of the release liner or from one edge of the flashing tape material to a location between the edges.

The preceding non-limiting aspects, as well as others, are more particularly described below. A more complete understanding of the processes and equipment can be obtained by reference to the accompanying drawings, which are not intended to indicate relative size and dimensions of the assemblies or components thereof. In those drawings and the description below, like numeric designations refer to components of like function. Specific terms used in that description are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of an exemplary manufacturing process for making flashing tape with weeping ports.

FIG. 2 is a view looking at the release liner along line 2-2 of FIG. 1 .

FIG. 3 is a section view of the release liner being connected to the flashing tape.

FIG. 4 is a section view of the release liner being removed from the flashing tape.

DETAILED DESCRIPTION OF THE DISCLOSURE

The disclosure provides a method of manufacturing transferable weeping ports 2 for a flashing tape 4. Flashing tape 4 generally includes a sealant or flashing material (such as a butyl rubber-based sealant) carried on a substrate. Various sealant configurations are used in the art and the term "flashing material" is used herein to refer to all of these materials. Examples of flashing tape constructions (geometries and materials) are disclosed in US Patent Application Publications 20060083898, 20100139178, 201 10209424, 201301800203, and 20140134408 and US Patent 6,964, 136, the disclosures of these six references are incorporated by reference. Flashing tape 4 can be formed in lengths longer than its intended use wherein the user cuts the material to length. Flashing tape 4 also can be formed in predefined lengths for use around items having known sizes. The term flashing tape 4 as used herein is intended to include flashing products sold to the end user as tapes or preformed products.

In general, the method includes the step of applying a material 6 that is used to define weeping port 2 in a final flashing tape 4 product to an inner surface 8 of a release liner 10 before release liner 10 is connected to a flashing material 12 of flashing tape 4. Release liner 10 can be a paper or polymer film that typically includes a coating to prevent premature adhesion of the flashing material of flashing tape 4 to the substrate of flashing tape 4 when tape 4 is wound or to other packaging materials. Release liner 10 is typically thin and designed to be removed and discarded before flashing tape 4 is used. Weeping port material 6 is transferred to flashing material 12 when or after release liner 10 is connected to flashing material 12, when the combination is passed under one or more rollers 20 that imparts pressure to release liner 10 or the flashing tape 4 side of the combination (or both), or when the combination is rolled into a storage roll 22. In configurations wherein pressure is not specifically applied to achieve the transfer, the force applied to the combination when rolled for storage is typically enough to achieve the transfer of the weeping port material 6 from release liner 10 to flashing material 12. As shown in FIG. 4, when the user removes release liner 10 from flashing material 12, weeping port material 6 remains with flashing material 12 to define weeping port 2 when flashing tape 4 is pressed against the surface to which flashing tape 4 is applied. These weeping ports 2 allow condensation to seep away from window sills, doors, and the like where flashing tape 4 is used.

The weeping port material 6 added to flashing material 12 can be applied via extrusion or casting as a liquid or flowable material or can be laid as a solid, a semisolid, or a plastic across the flashing material. The weeping port material can be a polymer, a hot melt, a cured adhesive, a foam, a foamed polymer, a thermoplastic such as a hot-melt material, pre-formed strips of non-porous material such as polymeric filaments, and/or sections of nylon cords or shims. Weeping port material 6 forms weeping port 2 that is an adhesion blocker that prevents full adhesion when flashing material 12 is used. The solid, semi-solid, and plastic materials can be applied by laying or placing them onto, sliding them onto, or dropped them onto release liner 10. A light tack adhesive can be applied to the strips or to the release liner to hold the strips in place on release liner 10 if desired.

FIG. 2 depicts exemplary spacing and lengths of weeping port materials 6 applied to inner surface 8 of release liner 10. Each of these examples extends from at least one edge of release liner 10. When connected to flashing tape 4, weeping port materials 6 are disposed onto flashing material 12 to extend to or across the weeping edge of flashing tape 4.

In one example, a nine-inch wide butyl-based flashing tape 4 is manufactured and connected to release liner 10. Prior to joining release liner 10 with flashing tape 4, the disclosure provides a step of adding strips of weeping port material 6 to inner surface 8 of release liner 10 where is remains until connected to the butyl surface of flashing tape 4. These form non-adhered spots that define weeping ports 2 on flashing tape 4 when flashing tape 4 is placed into use. Weeping ports 2 can be raised with respect to the flashing material 12 of tape 4 as shown in FIG. 4.

As shown in FIG. 1 , the strips of weeping port material 6 can be added in-line without slowing the movement of release liner 10 by matching the application process (such as an extrusion head) with the speed with the release liner 10. The strips of weeping port material 6 can be added perpendicular to the machine direction or at a non-perpendicular, but non-zero, angle. The strips can extend entirely across the width of release liner 10 or partially across as shown in FIG. 2. These configurations allow the method to be used to form weeping ports 2 that extend entirely across the flashing tape 4 or only partially across the width of the flashing tape 4.

Flashing material 12 can be a butyl-based sealant. When a strip of weeping port material 6 in the form of a heated material - such as a hot melt thermoplastic - is applied to release liner 10, the heated strip of weeping port material 6 (heated above the material's melt temperature) can be brought into contact with the butyl which joins the strip of weeping port material 6 with the butyl with a force stronger than the force between the thermoplastic and release liner 10 so that the strip of weeping port material 6 remains with the flashing material 12 when release liner 10 is removed (FIG. 4) to define a weeping port 2.

The spacing between the strips of weeping port material 6 can be adjusted as desired.

Applying the weeping material strips to release liner 10 allows placement of the strips and the joining of the strips to flashing material 12 without damage to flashing material 6. When a hot melt weeping port material 6 is applied to release liner 10, it can be permitted to cool to a degree that allows adhesive between the cooled hot melt and the flashing material 12 without damage to the flashing material 12. When the sealant is butyl-based, one would not want to add a strip of weeping port material 6 that is hot enough to melt through the butyl sealant. Depositing on release liner 10 prior to engagement with flashing material 12 avoids this issue. Placing solid strips of weeping port material 6 onto release liner 10 with mechanical fingers or other devices that engage release liner 10 can be performed because the mechanical fingers are not disturbing flashing material 12. The width, thickness, angle and pattern of the weeping port strips 6 can be adjusted at application or after initial application to release liner 10 without disturbing flashing material 12.

The method includes the use of a standard hot melt extrusion pump 30 with a flexible hose and an application head. The method applies the flowable weeping port material 6 above room temperature for application to release liner 10. The weeping port material 6 is drawn from a reservoir 32 and applied as a liquid in the cross direction of moving release liner 10 or a vector thereof. The line speed with the release liner 10 is matched to create the desired angle. Tip size and pressure can be used to control application volumes and shape. The number of tips also control how strips 6 are applied. In other configurations, release liner 10 can be stopped for the application of weeping port material 6.

When these strips 6 are connected to flashing material 12, they define areas that will not adhere to a surface when flashing tape 4 is applied. These areas of non-adherence allows water to seep out from behind the flashing tape 4.

In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. Moreover, the descriptions and illustrations of the exemplary configurations are examples and the claimed invention is not limited to the exact details shown or described. Throughout the description and claims of this specification the words "comprise" and "include" as well as variations of those words, such as "comprises," "includes," "comprising," and "including" are not intended to exclude additives, components, integers, or steps.

Claims

1 . A method for making transferable weeping ports for a flashing material comprising the steps of: applying a weeping port material to an inner surface of a release liner; and connecting the release liner to a flashing material of a flashing tape with the weeping port material engaging the flashing material.

2. The method of claim 1 , wherein the step of applying a weeping port material to an inner surface of a release liner includes the step of applying the weeping port material on the inner surface of the release liner in the form of a strip.

3. The method of claim 2, wherein the step of applying the weeping port material on the inner surface of the release liner in the form of strip includes the step of applying a flowable hot melt material in the form of a strip.

4. The method of claim 3, further comprising the step of cooling the weeping port material to a temperature lower than the melting point of the flashing material prior to the step of connecting the release liner to the flashing material.

5. The method of claim 2, wherein the step of applying the weeping port material on the inner surface of the release liner in the form of a strip includes the step of applying the strip with an adhesive.

6. The method of claim 1 , wherein the step of applying a weeping port material to an inner surface of a release liner includes the step of applying the weeping port material across an entire width of the release liner.

7. The method of claim 1 , wherein the step of applying a weeping port material to an inner surface of a release liner includes the step of applying the weeping port material across only a portion of a width of the release liner.

8. The method of claim 1 , wherein the step of connecting the release liner to a flashing material of a flashing tape further comprises the step of applying pressure the at least one of the release liner and flashing tape.

9. The method of claim 1 , wherein the step of applying a weeping port material to an inner surface of a release liner occurs while the release liner is moving.

10. The method of claim 9, wherein the step of applying a weeping port material to an inner surface of a release liner includes applying the weeping port material from a hot melt extrusion pump.

1 1 . The method of claim 9, wherein the step of applying a weeping port material to an inner surface of a release liner includes applying solid strips of weeping port material with an adhesive.

12. The method of claim 1 , further comprising the step of winding the flashing tape and release liner into a storage roll.

13. The method of claim 12, further comprising the step of removing the release liner from the flashing tape without removing the weeping port material.

14. The method of claim 1 , wherein the weeping port material has a solid, semisolid, or plastic phase that is harder than the flashing material.