Building Construction Applications for Porous Material

Abstract

A barrier membrane for use in building construction may be manufactured by forming a polymeric film coating on release paper or film; or on nonwoven textiles, paper, fiberglass, or other structural substrate to improve tensile strength. Alternatively, the film may be fully or partially formed and then bonded to a structural substrate. A porous film coating or laminate may be formed using PVDF, PVC, and various polyolefins. A typical membrane may be less than 100 mil thick and greater than 50% porous, and may have a hydrostatic head while retaining gas permeability. Some embodiments may contain active ingredients to combat bacterial or fungal growth, repel insects, or absorb environmental pathogens. The active ingredients may be applied after the porous film is manufactured or may be incorporated during the film manufacturing process.

1 . A vapor barrier for building construction comprising:
 a microporous polymer film manufactured from a process comprising:
 forming a solution with a dissolved polymer in a first liquid and a second liquid; 
 applying said solution to a carrier; 
 removing enough of said first liquid to begin gelling said polymer; and 
 after said gelling has begun, removing said second liquid; 
   said film being manufactured with a reinforcement material; and   said vapor barrier being applied to an exterior barrier of a building as part of a sequence of exterior barrier layers.   
     
     
         2 . The vapor barrier of  claim 1 , said reinforcement being one of a group composed of nonwoven reinforcement or woven reinforcement. 
     
     
         3 . The vapor barrier of  claim 1 , said microporous polymer film comprising an anti-microbial material. 
     
     
         4 . The vapor barrier of  claim 3 , said anti-microbial material being added after said gelling of said polymer. 
     
     
         5 . The vapor barrier of  claim 3 , said anti-microbial material being added prior to said gelling of said polymer. 
     
     
         6 . The vapor barrier of  claim 1 , said external barrier layers being a sequence of layers comprising the following layers in the order presented:
 an internal surface material;   an insulating material;   an exterior sheathing;   said vapor barrier; and   an external surface material.   
     
     
         7 . The vapor barrier of  claim 1 , said external barrier layers being a sequence of layers comprising the following layers in the order presented:
 an internal surface material;   said vapor barrier;   an insulating material;   an exterior sheathing; and   an external surface material.   
     
     
         8 . The vapor barrier of  claim 1 , said polymer being a PVDF homopolymer. 
     
     
         9 . The vapor barrier of  claim 1 , said polymer being a PVDF copolymer with hexofloropropolyne. 
     
     
         10 . A method comprising:
 constructing an exterior barrier to a building comprising a sequence of exterior barrier layers;   as one of said sequence of exterior barrier layers, placing a microporous polymer film manufactured from a process comprising:
 forming a solution with a dissolved polymer in a first liquid and a second liquid; 
 applying said solution to a carrier; 
 removing enough of said first liquid to begin gelling said polymer; and 
 after said gelling has begun, removing said second liquid; 
   said microporous polymer film being manufactured with a reinforcement material.   
     
     
         11 . The method of  claim 10 , said reinforcement being one of a group composed of nonwoven reinforcement or woven reinforcement. 
     
     
         12 . The method of  claim 10 , said microporous polymer film comprising an anti-microbial material. 
     
     
         13 . The method of  claim 12 , said anti-microbial material being added after said gelling of said polymer. 
     
     
         14 . The method of  claim 12 , said anti-microbial material being added prior to said gelling of said polymer. 
     
     
         15 . The method of  claim 10 , said external barrier layers being a sequence of layers comprising the following layers in the order presented:
 an internal surface material;   an insulating material;   an exterior sheathing;   said microporous polymer film; and   an external surface material.   
     
     
         16 . The method of  claim 10 , said external barrier layers being a sequence of layers comprising the following layers in the order presented:
 an internal surface material;   said microporous polymer film;   an insulating material;   an exterior sheathing; and   an external surface material.   
     
     
         17 . The method of  claim 10 , said polymer being a PVDF homopolymer. 
     
     
         18 . The method of  claim 10 , said polymer being a PVDF copolymer with hexofloropropolyne.