Protective Air Barrier Sealant for Conditioned and Unconditioned Building Walls

Abstract

A protective air barrier air barrier sealant and methods of applying the same, including a high density polyurethane chemistry provided in an amount, volume, and density effective for providing a protective air barrier for an enclosure, wherein the polyurethane material is combined with at least one UV, fire and antimicrobial protectant for providing UV protection to UV-exposed surfaces.

What is claimed is: 
     
         1 . An air barrier sealant comprising:
 a polyurethane material;   wherein the air barrier sealant has a top exposed surface that is spaced apart from a bottom surface by a thickness;   wherein the bottom surface substantially covers a surface of an object by the bottom surface adhering to the object surface;   wherein the air barrier sealant has a tensile strength of not less than about 200 kPa.   
     
     
         2 . The air barrier sealant of  claim 1 , wherein the polyurethane material is a closed cell polyurethane material. 
     
     
         3 . The air barrier sealant of  claim 1 , further comprising a second material with a colorant. 
     
     
         4 . The air barrier sealant of  claim 1 , wherein the object is a piece of ductwork, the piece of ductwork comprising an air duct boot, a wall cap, and/or a roof cap. 
     
     
         5 . The air barrier sealant of  claim 4 , wherein the piece of ductwork is substantially rectangular. 
     
     
         6 . The air barrier sealant of  claim 4 , wherein the piece of ductwork is substantially circular. 
     
     
         7 . The air barrier sealant of  claim 1 , wherein the air barrier sealant is a dual component formulation. 
     
     
         8 . An air barrier sealant comprising:
 a polyurethane material;   wherein the air barrier sealant has a top exposed surface that is spaced apart from a bottom surface by a thickness;   wherein the bottom surface substantially covers a surface of a substrate by the bottom surface adhering to the substrate;   wherein the air barrier has a tensile strength equal to a tensile strength of the substrate.   
     
     
         9 . The air barrier sealant of  claim 8 , wherein the air barrier sealant has a pull adhesion of not less than about 110 kPa. 
     
     
         10 . The air barrier sealant of  claim 8 , wherein the polyurethane material is a closed cell polyurethane material having no more than 8% open cells. 
     
     
         11 . The air barrier sealant of  claim 8 , wherein the second material includes a colorant. 
     
     
         12 . The air barrier sealant of  claim 8 , wherein the air barrier sealant is a dual component formulation. 
     
     
         13 . A method for providing an air barrier sealant comprising:
 providing a polyurethane material in a first container;   providing a material with suspended UV, fire and/or antimicrobial protectants in a second container;   mixing an amount of the polyurethane material from the first container and an amount of the material with suspended UV, fire, and/or antimicrobial protectants from the second container to create a mixture;   applying the mixture to a substrate surface;   the mixture expanding from the substrate surface to produce a substantially uniform thickness;   thereby creating an air barrier on the substrate surface.   
     
     
         14 . The method of  claim 13 , wherein the polyurethane material in the first container is under a pressure of about 1500 psi. 
     
     
         15 . The method of  claim 13 , wherein the polyurethane material in the first container is maintained at a temperature between about 130 degrees Fahrenheit to about 150 degrees Fahrenheit. 
     
     
         16 . The method of  claim 13 , wherein the substantially uniform thickness is not more than about 1 inch. 
     
     
         17 . The method of  claim 13 , wherein mixing the amount of the polyurethane material from the first container and the amount of the material with suspended UV, fire, and/or antimicrobial protectants from the second container to create the mixture is performed in air by spraying the amount of the polyurethane material from the first container and spraying the amount of the material with suspended UV, fire, and/or antimicrobial protectants from the second container, wherein the amount of the polyurethane material and the amount of the material with suspended UV, fire, and/or antimicrobial protectants mix in the air. 
     
     
         18 . The method of  claim 13 , wherein a tensile strength of the air barrier on the substrate surface is not less than about 200 kPa. 
     
     
         19 . The method of  claim 13 , wherein a tensile strength of the air barrier on the substrate surface is at least equivalent to a tensile strength of the substrate. 
     
     
         20 . The method of  claim 13 , wherein the material with suspended UV, fire and/or antimicrobial protectants includes a colorant.