Barrier composite with an integral release layer and method of making same
A barrier composite has a barrier layer that is water resistant, and adhesive for applying the barrier composite to an external wall surface and an integral release layer to allow the adhesive to release such that a roll or barrier composite can be unspooled and attached directly the said wall surface without removing a release liner. A barrier composite may also include a plurality of stand-offs extending to an exterior surface of the barrier composite and configured to allow precipitation that has passed through the outer shingles to flow down along the barrier composite. The integral release layer may be configured on, in or over the stand-offs. The stand-offs may be configured with a material that prevents the adhesive from adhering or that splits or fractures to produce stand-off deposits. Alternatively, the adhesive may be configured to wick into the stand-offs and then split producing adhesive deposits on the stand-offs.
1 . A method of adhering a drainage barrier composite to a wall surface comprising:
a) providing a barrier layer composite roll comprising:
a barrier layer that is water resistant, wherein liquid water will not pass through the barrier composite for 5 minutes with a 25 mm water column;
an adhesive, wherein the adhesive is attached to an interior surface of the barrier layer;
an integral release material;
wherein the integral release material is configured on the barrier layer opposite said interior surface of the barrier layer to form bonded areas of the integral release material that are bonded to the barrier layer and non-bonded areas of the integral release material that are not bonded to the barrier layer;
wherein the barrier composite roll has a plurality or layers with an adhesive layer of a first layer of barrier composite adjacent the integral release material of a second layer of the barrier composite; and
wherein the non-bonded areas of the integral release material of said second layer of the barrier composite are configured to fracture and stick to said adhesive layer of said first layer of barrier composite when the barrier composite roll is unspooled
b) unrolling the draining barrier composite and during unrolling separating a portion of the integral release layer onto the adhesive layer; and
c) pressing the adhesive layer of the barrier composite onto said exterior wall surface to adhere the barrier composite to said exterior surface.
2 . The method of claim 1 , wherein the integral release material is an integral release film.
3 . The method of claim 2 , wherein the integral release film is a polymeric film.
4 . The method of claim 3 , wherein the integral release material is a continuous polymeric over the barrier layer.
5 . The method of claim 1 , wherein the non-bonded areas form no more than 75% of a surface area of the integral release film.
6 . The method of claim 1 , wherein the non-bonded areas form no more than 50% of a surface area of the integral release film.
7 . The method of claim 1 , wherein the non-bonded areas form no more than 75% of a surface area of the integral release film and are discrete areas.
8 . The method of claim 7 , wherein the integral release film is a polymeric film.
9 . The method of claim 1 , wherein the adhesive is a pressure sensitive adhesive.
10 . The method of claim 1 , wherein the barrier layer further comprises stand-offs configured on an opposite side of the barrier layer from the adhesive layer;
wherein said stand-offs have a height of at least 0.2 mm; and
wherein the integral release material extends over the stand-offs; and wherein the stand-offs provide water drainage when attached to said exterior wall surface.
11 . The method of claim 10 , wherein the bonded portions of the integral release film are configured between the stand-offs and wherein the integral release layer is not attached to an extended end of the stand-offs.
12 . The method of claim 10 , wherein the bonded portions of the integral release film are bonded by melt lamination.
13 . The method of claim 12 , wherein the stand-off layer is a continuous stand-off layer extending over the barrier layer.
14 . The method of claim 13 , wherein the continuous stand-off layer comprises compressed portions that form the stand-offs.
15 . The method of claim 14 , wherein the integral release film is melt bonded to the compressed portions of the continuous stand-off layer.
16 . The method of claim 14 , wherein the integral release film is attached to the compressed portions of the continuous stand-off layer by an adhesive.
17 . The method of claim 10 , wherein the stand-off precursor is a multilayer fabric having an exterior layer and a barrier-side layer attached to the barrier layer.
18 . The method of claim 10 , wherein the stand-offs have an area density at least 25%.
19 . The method of claim 10 , wherein the stand-offs are discrete stand-offs.
20 . The method of claim 10 , wherein the stand-offs are elongated stand-offs having a length that is at least twice a width.