Technical Field

[0001] The present disclosure relates to building materials, and particularly conformable or foldable air leakage sealing devices.

Background

[0002] Building materials and construction techniques have been used to provide energy conservation advantages for buildings and housing structures by limiting air leakage into or out of a conditioned space. For example, various techniques have been provided to attempt to limit air leakage through openings or gaps in interior or exterior walls separating conditioned and non- conditioned air spaces. Recessed lighting in buildings and homes is a source of air leakage through the building envelope. Prior techniques to minimize leakage have included providing insulated covers or using caulk and foams.

Summary

[0003] The present disclosure relates to a foldable sealing device including a core having first and second major faces separated by a thickness, an outer peripheral edge, and an inner peripheral edge defining an opening, a first adhesive covering at least a portion of the first major face, and a liner covering at least a portion of the first adhesive. The core includes a plurality of cuts through the thickness of the core and extending outwardly from the inner peripheral edge, and the core is configured to be adhered to a first surface and a second surface separated by a gap, the first surface not coplanar with the second surface.

[0004] The present disclosure further provides a foldable sealing device including a core having first and second major faces separated by a thickness, an outer peripheral edge, and an inner peripheral edge defining an opening, the core made from an acrylic, a first adhesive covering at least a portion of the first major face, a second adhesive covering at least a portion of the second major face, a liner covering at least a portion of the first adhesive, and a metallic foil covering at least a portion of the second adhesive. The core includes a plurality of cuts through the thickness of the core and extending outwardly from the inner peripheral edge, and the core is configured to be adhered to a first surface and a second surface separated by a gap, the first surface not coplanar with the second surface.

[0005] The present disclosure further provides an air leakage sealing device including a core having first and second major faces separated by a thickness, a first adhesive covering at least a portion of the first major face, a liner covering at least a portion of the first adhesive, and an outer layer covering at least a portion of the second major face and having a plurality of cuts that do not extend through the thickness of the core. In an exemplary embodiment, at least portions of the core proximate the cuts are configured to stretch relative to the outer layer when the core and the outer layer are folded from a planar configuration to a non-planar configuration.

[0006] The present disclosure further provides an air leakage sealing device including a core having first and second major faces separated by a thickness, an outer peripheral edge, and an inner peripheral edge, a first adhesive covering at least a portion of the first major face, and an outer layer attached to second major face, the outer layer comprising a metallic foil. At least a portion of the core is configured to stretch relative to the outer layer when the core and the outer layer are folded from a planar configuration to a non-planar configuration.

[0007] The above summary is not intended to describe each disclosed embodiment or every implementation. The Figures and the Detailed Description, which follow, more particularly exemplify illustrative embodiments. Brief Description of Drawings

[0008] The disclosure may be further explained with reference to the appended Figures, wherein like structure is referred to by like numerals throughout the several views, and wherein:

[0009] FIG. 1 is a front view of an exemplary sealing device according to the present disclosure.

[0010] FIG. 2 is a sectional view of an exemplary sealing device according to the present disclosure.

[0011] FIG. 3 shows airflow related to an exemplary building construction including first and second building components.

[0012] FIG. 4 shows a sectional view of an exemplary installed sealing device according to the present disclosure.

[0013] FIG. 5 shows a sectional view of an exemplary sealing device according to the present disclosure.

[0014] FIG. 6 shows a front view of an exemplary sealing device according to the present disclosure.

[0015] FIG. 7 shows a sectional view of an exemplary sealing device according to the present disclosure.

[0016] FIG. 8 shows a sectional view of an exemplary installed sealing device according to the present disclosure.

[0017] FIG. 9 shows a cross-section view of the test house of Procedure 1. [0018] FIG. 10 shows a cross-section, partially exploded view of an exemplary installed sealing device according to the present disclosure.

[0019] FIG. 11 shows a front view of an exemplary sealing device according to the present disclosure including an outer layer having a plurality of cuts.

[0020] FIG. 12 shows a sectional view of an exemplary sealing device according to the present disclosure including an outer layer having a plurality of cuts.

[0021] FIG. 13 shows a front view of an exemplary sealing device according to the present disclosure including an outer layer having folded extensions.

[0022] FIG. 14 shows a front view of an exemplary sealing device according to the present disclosure including an outer layer having a plurality of cuts.

[0023] FIG. 15 shows a front view of an exemplary sealing device according to the present disclosure including an outer layer having folded extensions.

[0024] FIG. 16 shows a front view of an exemplary sealing device according to the present disclosure including an outer layer having first and second foil layers.

[0025] FIG. 17 shows a sectional view of an exemplary sealing device according to the present disclosure including an outer layer having first and second foil layers.

[0026] FIG. 18 shows a sectional view of an exemplary sealing device according to the present disclosure.

[0027] FIG. 19 shows a sectional view of an exemplary sealing device in a roll form according to the present disclosure.

[0028] FIGS. 20a and 20b show installation of an exemplary sealing device in a roll form according to the present disclosure.

[0029] FIG. 21 shows a sectional view of an exemplary sealing device according to the present disclosure.

[0030] FIG. 22 shows a sectional view of an exemplary sealing device in a roll form according to the present disclosure.

[0031] While the above-identified figures set forth various embodiments of the disclosed subject matter, other embodiments are also contemplated. In all cases, this disclosure presents the disclosed subject matter by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this disclosure.

Detailed Description

[0032] The present disclosure provides a foldable sealing device to seal a gap between two or more building component surfaces such that undesirable air leakage through the gap is reduced. The sealing device includes a core having a plurality of cuts, an adhesive, and a liner. The liner may be removed and the core adhered to one or more surfaces. A plurality of cuts and conformable core allow the device to bend and conform to the surfaces without buckling or otherwise introducing gaps, such that the sealing device is configured to be foldable between a first planar configuration and a second non-planar or three-dimensional configuration. The sealing device may be used to seal gaps between building components such as drywall or other wall material and a recessed light housing such that undesirable air leakage between a conditioned living space and attic, for example, is minimized.

[0033] FIGS. 1 and 2 show an exemplary sealing device 100 including a core 110 having first and second major faces 111, 112 separated by a thickness (t), an outer peripheral edge 113, and an inner peripheral edge 114 defining an opening 115. A first adhesive 120 covers, directly or indirectly, at least a portion of first major face 111 of core 110 and a liner 130 covers, directly or indirectly, at least a portion of first adhesive 120.

[0034] In an exemplary embodiment, opening 115 defined by inner peripheral edge 114 is circular and has a diameter (d) between about 5.0 cm and 17.0 cm, or of about 12.2 cm, and outer peripheral edge 113 is substantially circular and has a diameter (D) between about 7.0 cm and 23 cm, or of about 16.8 cm.

[0035] Core 1 10 includes a plurality of cuts 116. Cuts 116 facilitate bending and or manipulation of core 110 such that core 110 may conform to one or more surfaces while minimizing buckling or introduction of gaps when adhered to a surface. For example, a first portion 117 of first major face 111 may be adhered to a first surface and a second portion 118 including cuts 116 may be adhered to a second surface that is not coplanar with the first surface such that sealing device 100 is bent and/or stretched. Cuts 116 may allow sealing device 100 to bend and adhere to non-coplanar surfaces without buckling or introducing gaps.

[0036] In an exemplary embodiment, cuts 116 form a slit, opening, or other separation entirely through thickness (t) and extend outwardly from inner peripheral edge 114 towards outer peripheral edge 113. In various exemplary embodiments, cuts 116 are a straight cut extending between approximately 5 mm and 35 mm, 5 mm and 20 mm, or about 17 mm from inner peripheral edge 114. In some exemplary embodiments, cuts 116 may not extend entirely through thickness (t) of core 110, but may only extend through a portion of thickness (t) such that core 110 may be more compliant and/or readily cut or torn along cuts 116.

[0037] A suitable number of cuts 116 may be selected to facilitate bending or forming of sealing device 100 from an initial planar configuration, for example as shown in Fig. 1, to a final non-planar or three-dimensional configuration, as discussed further herein. In an exemplary embodiment, inner peripheral edge 114 defines a circular opening 115, and core 110 includes between 6 and 36, 12 and 30, or approximately 24 cuts around opening 115. In various exemplary embodiments, cuts 116 may be spaced between approximately every 10° to 60°, 12° and 30°, or approximately every 15°. In other exemplary embodiments, cuts 116 may be non- uniformly spaced.

[0038] Core 110 may be made of any suitable material that allows sealing device 100 to readily bend and conform to one or more surfaces without being undesirably torn or punctured. In an exemplary embodiment, core 110 is open or closed cell foam made from a polyethylene foam, such as a polyethylene foam rolled stock available from New England Foam of Hartford, CT, or an acrylic foam. In an exemplary embodiment, core 110 includes an acrylic material such as that of 3M VHB™ tapes, including 3M 5952 VHB™ or 3M 5925 VHB™, both available from 3M Company of St. Paul, Minnesota. Such materials may provide sufficient bonding and, in some embodiments, include adhesive layer 120 without requiring an additional adhesive. In another exemplary embodiment, core 110 is a substantially solid polymer. In various exemplary embodiments, suitable materials include polyolefms, polyethylenes, high density polyethylenes, low density polyethylenes, linear low density polyethylenes, linear ultra low density polyethylenes, polypropylenes, polybutylenes, vinyl copolymers, plasticized and/or unplasticized polyvinyl chlorides, polyvinyl acetates, olefmic copolymers, ethylene/methacrylate copolymers, ethylene/vinyl acetate copolymers, acrylonitrile-butadiene-styrene copolymers, ethylene/propylene copolymers, acrylic polymers and copolymers, other suitable materials known in the art and suitable combinations thereof. In an exemplary embodiment, core 110 is flame retardant and/or not air-permeable.

[0039] In an exemplary embodiment, core 110, first adhesive 120 and/or other materials of sealing device 100 are selected to exhibit desired thermal properties. In some exemplary embodiments, sealing device 100 may exhibit a short term temperature tolerance such that sealing device 100 exhibits no change in room temperature dynamic shear properties at temperatures between - 30° F and 300° F, and/or a long term temperature tolerance such that sealing device supports at least a 205 g load per 0.5 sq. in. in static shear for 10,000 minutes at temperatures between - 30° F and 250° F.

[0040] Core 110 has a thickness (t) sufficient to allow sealing device 100 to be easily handled and manipulated without introducing unnecessary bulk. In various exemplary embodiments, core 110 has a thickness (t) between 0.25 mm and 5 mm, 0.5 mm and 2.0 mm, or of about 0.75 mm. Such a thickness allows core 110 to exhibit sufficient strength while simultaneously being easily bendable and conformable so that sealing device 100 does not exhibit excessive buckling or creasing, for example, when adhered. That is, a relatively thicker core may limit the ability of sealing device 100 to adhere to complex surfaces without introducing gaps that could allow undesirable flow of air. Similarly, a thin core, or the absence of a core, could result in a sealing device that is difficult to handle or not sufficiently durable to provide reliable sealing over an extended period of time.

[0041] Liner 130 may be any suitable covering of adhesive 120 that may be removed to allow sealing device 100 to be installed when desired. In an exemplary embodiment, liner 130 is a coated paper, plastic, or other suitable material as known in the art. In another exemplary embodiment, a plurality of sealing devices 100 are provided in a stack or pad, and an outer surface of a second sealing device forms liner 130 for a first sealing device 100. An outermost sealing device 100 may easily be removed from the stack or pad before installation, and no additional liner is present to be removed.

[0042] FIG. 3 shows an exemplary building construction including first and second building components, drywall 350 and housing 360. In an exemplary embodiment, drywall 350 is positioned on an interior ceiling of a structure and housing 360 is positioned in an opening 370 of drywall 350. One or more gaps 371 may be present between drywall 350 and housing 360. If left unsealed, gaps 371 may allow air to flow between an unconditioned space 380, such as an attic or inner wall space, for example, and a conditioned space 390, as shown by arrows A and B. Additional air leakage may also occur through openings in housing 360 (not shown).

[0043] In an exemplary embodiment, drywall 350 forms a portion of a ceiling for example, and has a substantially planar first surface 351 defining opening 370. Housing 360 may be any housing of a building component, including a recessed light housing, electrical box, or other component. In an exemplary embodiment, a second surface 361 of housing 360 is not coplanar with first surface 351. In some exemplary embodiments, surface 361 of housing 360 is a curved or cylindrical interior surface.

[0044] An exemplary sealing device 100 may be installed for use by adhering to first surface 351 and second surface 361 to minimize unwanted airflow through gap 371. In an exemplary embodiment, liner 130 is removed to expose first adhesive 120. Exposed adhesive 120 is positioned against first surface 351 such that outer peripheral edge 113 of sealing device 100 substantially surrounds opening 370, and in an exemplary embodiment opening 370 is aligned with alignment feature or marking 103. Sealing device 100 may then be bent and/or stretched upwards from an initial planar configuration to a non-planar or three-dimensional configuration such that a portion of first adhesive 120 contacts surface 361 substantially perpendicular to first surface 351. In other exemplary embodiments, exposed adhesive 120 may be first positioned against second surface 361 and subsequently positioned against first surface 351, or bent to a desired configuration and substantially simultaneously positioned against first and second surfaces 351, 361. [0045] Cuts 116 facilitate bending of first major surface to consistently contact surface 361 without buckling or introducing gaps. In an exemplary embodiment, sealing device 100 is configured such that cuts 116 do not extend beyond an outer edge 362 of housing 360 when sealing device 100 is installed such that cuts 116 are not positioned over gap 371. The properties of core 110, as described herein, allow sealing device 100 to bend and/or stretch over gap 371 and around any corners or angles between first surface 351 and second surface 361. In this way, sealing device 100 may be altered from an initial planar configuration to a final non-planar or three-dimensional configuration in which first major face 111 is adhered to a substantially planar first surface 351 and a curved second surface 361 that is not coplanar with first surface 351.

[0046] In practice, gaps between construction materials, such as drywall and a lighting housing may not be uniform due to varying tolerances or imprecise installation. In an exemplary embodiment, sealing device 100 is configured to effectively minimize air leakage through gaps of varying sizes and relative positioning within normal tolerance ranges. For example, sealing device 100 includes a slit 119 extending entirely through thickness (t) between outer peripheral edge 113 and inner peripheral edge 114. Slit 1 19 allows a size of sealing device 100 to be varied to accommodate the geometry of one or more surfaces sealing device 100 may be adhered to. For example, a diameter (d) of opening 115 defined by inner peripheral edge 114 may be reduced by overlapping adjacent ends 105, 106 of sealing device 100. For example, ends 105, 106 of sealing device 100 may overlap between approximately 3.0 mm and 22 mm, for example. The ability of an installer to vary a size of sealing device 100 allows sealing device 100 to accommodate a housing 360 that is not axially aligned with an opening 370, for example, or a gap 371 that is not uniform.

[0047] A compliant and conformable core 110 allows sealing device 100 to be adhered to first and second non-coplanar surfaces separated by a gap. Core 110 may stretch and/or deform as it is bent from an initial planar configuration to a final non-planar or three-dimensional configuration. In an exemplary embodiment, a first portion of first major face 111 provides sufficient adhesion to a first surface, such as surface 351 , such that a second portion of first major face may slightly stretch as it is adhered to a second surface, such as surface 361, if necessary to provide a consistent seal. The combination of foam and adhesive materials as described herein allow the sealing device to readily bend, stretch, or otherwise conform to two non-coplanar surfaces.

[0048] In an exemplary embodiment, core 110 is relatively extensible and substantially inelastic such that core may experience less than complete recovery upon being stretched. In various exemplary embodiments, core 110 is made of a material having between about 75 % and 5 %, 50 % and 5 %, 30 % and 5 % or less than about 20 % recovery and/or an elongation at break of between about 5 % and 1000 %, 6.25 % and 875 %, or of about 640 %, as measured according to ASTM D882-A for example. In another exemplary embodiment, core 110 is made of a material having an elongation at break of between 100 % and 500%, 150% and 300 %, or of about 200 %>. A relatively extensible and substantially inelastic core 110 provides unique advantages in allowing sealing device 100 to minimize air flow through a gap between two non- coplanar surfaces. An exemplary sealing device 100 having such properties is readily stretched around corners and facilitates attachment to surfaces having complex geometries. A limited recovery minimizes a restoring force present in the stretched core and minimizes a force acting to pull the sealing device away from a surface to which it is adhered.

[0049] The ability of an exemplary sealing device 100 to readily conform to multiple non- coplanar surfaces may be indicated by the Young's modulus of the sealing device when the liner is removed. In various exemplary embodiments, sealing device 100 not including liner

130 has a Young's modulus between about .150 MPa and 1750 MPa. A Young's modulus that is too high may limit the ability of sealing device to stretch or otherwise conform in a desired manner, while a very low Young's modulus may result in a sealing device without plastic properties.

[0050] In order to effectively minimize airflow when installed, an exemplary sealing device 100 will not readily tear or break when bent or stretched at angles, for example between first and second non-coplanar surfaces that may be substantially perpendicular. In various exemplary embodiments, sealing device 100, with liner 130 removed, has a tensile strength between approximately 0.555 MPa and 10.5 MPa, or about 6.4 MPa, as measured according to ASTM D882-A, for example.

[0051] First adhesive 120 may be any suitable adhesive that allows sealing device 100 to be adhered to one or more surfaces, such as non-coplanar first and second surfaces 351, 361 separated by gap 371, over an extended period of time and through many thermal cycles. In an exemplary embodiment, first adhesive 120 includes a pressure sensitive adhesive that may allow sealing device 100 to be slightly repositioned before final installation, and may include tackified rubber adhesives, natural rubbers, olefins, silicones, polyisoprenes, polybutadienes, polyurethanes, styrene-isoprene-styrene and styrene-butadiene-styrene block copolymers, other elastomers, tackified or untackified acrylic adhesives such as copolymers of isooctylacrylate and acrylic acid. In an exemplary embodiment, first adhesive 120 is a pressure sensitive silicone adhesive that provides high bonding while allowing sealing device 100 to be repositioned during installation and/or removed with minimal surface damage or residue after a period of use. In other exemplary embodiments, first adhesive 120 results in a permanent attachment such that sealing device 100 cannot be removed without damaging a surface, sealing device 100, or leaving a reside.

[0052] In an exemplary embodiment, sealing device 100 may include one or more tabs 190 (Fig. 1) positioned around outer and/or inner peripheral edges 113, 114 that facilitate removal of sealing device 100. Tabs 190 provide a feature that a user may grip to remove sealing device from a surface. In some exemplary embodiments, tabs 190 may be folded approximately 180 degrees such that tabs 190 do not visibly extend beyond a cover or architectural trim, for example, when sealing device is installed, and may have a thickness that differs from a thickness (t) of core 110.

[0053] In an exemplary embodiment, a force is applied in a direction substantially parallel to a surface to which sealing device 100 is bonded and away from opening 115. When initial resistance to shearing stress is overcome, core 110 may begin to deform while adhesive 120 elongates, orients, and undergoes elongational stiffening. Elongational stiffening transfers stress to an interface between the surface and adhesive, resulting in debonding with substantially no Alimentation in the adhesive layer and a clean removal of sealing device 100 from a surface. In various exemplary embodiments, one or more tabs 190 may be included that can be used simultaneously or sequentially to remove sealing device 100.

[0054] An exemplary sealing device may include one or more additional layers or components in addition to a core, adhesive, and liner. Fig. 5 shows a cross-sectional view of an exemplary sealing device 500 including a core 510 having first and second major faces 511, 512 separated by a thickness (t), an outer peripheral edge 513, and an inner peripheral edge 514 defining an opening 515 and an outer layer 540. A first adhesive 520 covers, directly or indirectly, at least a portion of first major face 511 of core 510 and a liner 530 covers, directly or indirectly, at least a portion of first adhesive 520. Outer layer 540 covers, directly or indirectly, at least a portion of second major face 512.

[0055] In an exemplary embodiment, outer layer 540 provides one or more stiffening components that allow sealing device 500 to be readily bent and formed by a user during installation while better retaining a formed shape. Shape retention facilitates handling and installation by a user, and can reduce the bonding strength needed to adhere sealing device 500 to a surface for an extended period of time. For example, when sealing device 500 is folded for installation and attached to one or more generally horizontal surfaces, a stiffening layer assists in retaining sealing device 500 in the folded configuration and against a profile of one or more surfaces to which sealing device is attached while gravitational forces, for example, could otherwise act to unfold sealing device 500 into a vertical configuration. [0056] In an exemplary embodiment, outer layer 540 includes metallic foil 541 and a second adhesive 542. Second adhesive covers at least a portion of first major face 511, directly or indirectly, and attaches metallic foil 541 to core 510. In other exemplary embodiments, metallic foil 541 may be joined directly to core 510 through welding, fasteners, or other suitable technique as known in the art. In an exemplary embodiment, metallic foil 541 has a thickness less than a thickness of core 510.

[0057] Metallic foil 541 may provide thermal advantages in an exemplary sealing device 500. In an exemplary embodiment, metallic foil 541 provides a radiant barrier or protection layer for the remainder of sealing device 500 from the thermal energy of a light source, or other heat source, within a housing or otherwise proximate sealing device 500. In various exemplary embodiments, outer layer 540 may include other suitable radiant barriers, a thermal insulating polymer material, or other suitable components. In some exemplary embodiments, architectural trim or other components may provide thermal protection as an alternative or in addition to metallic foil 541.

[0058] In some exemplary embodiments, outer layer 540, and/or metallic foil has an inner peripheral edge 514 defining an opening having a diameter (d2) that differs from diameter (d) of an opening defined by core 510. For example, a metallic foil defining an opening having a diameter (d2) that is smaller than diameter (d) provides additional thermal protection to core 510 by extending and at least partially covering an inner surface 510a, for example, of core 510 when sealing device 500 is installed.

[0059] Figs. 6 through 8 show another exemplary sealing device 600 including additional features to facilitate attachment of architectural features such as a cover plate, trim, or other component. In an exemplary embodiment, sealing device 600 may include a core 610, first adhesive 620, liner 630 and/or outer layer 640, similar to sealing device 500 described above. Sealing device 600 further includes attachment component 650 that covers a portion of second major face, directly or indirectly.

[0060] Attachment component 650 includes one or more of an adhesive, hook and loop fasteners, snap-fit connectors or other suitable mechanical connectors known in the art that may be attached to a corresponding feature or surface of a cover plate, trim, or other component 690 to a housing 660, such as a recessed light housing. In an exemplary embodiment, attachment component includes a reclosable fastener, such as DUAL LOCK™ reclosable fasteners, available from 3M Company of St. Paul, Minn. A compatible reclosable fastener is attached to a cover plate, for example, such that the cover plate may be held in place without the need for additional fasteners. [0061] Cover plate, trim, or other component 690 may be removable and repositionable, replaceable, or permanently attached such that component 690 cannot be removed without damage to component 690 and/or attachment component 650. In an exemplary embodiment, best viewed in Fig. 10, cover plate 690 includes a polymeric film or plate 691 that may be attached to sealing device 600 directly or by attachment component 650. In various exemplary embodiments, film 691 may be pre-sized or cut to fit a desired application, or may be adjustable during installation by application of heat, for example. In one exemplary embodiment, core 610, first adhesive 620, liner 630 and/or outer layer 640 are provided separately from film or plate 691 and/or attachment component 650, for example as a kit. Core 610, first adhesive 620, liner 630 and/or outer layer 640 may be installed as described herein, and film or plate 691 and/or attachment component 650 may then be attached. In an exemplary embodiment, outer layer 640 provides a suitable surface that attachment component 650 may be readily joined to.

[0062] In an exemplary embodiment, film or plate 691 may be heated to shrink film or plate 691 to an appropriate size. For example, after film or plate 691 is attached, application of heat causes film or plate 691 to shrink and/or stretch. Wrinkles or other disruptions in the film or plate 691 are minimized to provide an optically desirable appearance.

[0063] Attachment component 650 may be selected to provide a sufficient attachment to outer layer 640, or other component of sealing device 600, while being removable and repositionable, replaceable, or permanently attached. In an exemplary embodiment, attachment component 650 is an adhesive tape such as 3M 2145 window film mounting tape, available from 3M Company of St. Paul, Minnesota, or other suitable tape known in the art that may join outer layer 640 or other component of sealing device 600 with film or plate 691. An exemplary adhesive tape provides sufficient attachment to maintain cover plate 690 in position, while allowing cover plate 690 to be removed as desired, for example when changing a light bulb. In an exemplary embodiment, attachment component 650 is positioned around an entire periphery of sealing device 600. In some embodiments, attachment component 650 appears substantially optically clear to an observer.

[0064] Film or plate 691 may be any suitable optical film or plate. In various exemplary embodiments, film or plate 691 is a polycarbonate, ceramic, glass, polymer, or other suitable material that may be included in sealing device 600. In an exemplary embodiment, optical film or plate 691 includes a polyethylene ethyl vinyl acetate. Film or plate 691 may be precut to a desired size or may be shrunk by application of heat during installation, as described above.

[0065] In another exemplary embodiment, cover plate 690 includes a rigid film or cover 691. A rigid film or cover and appropriate attachment component 650 may allow cover plate 690 to be removed and repositioned, for example when changing a light bulb. In other exemplary embodiments, a new cover plate 690 and attachment component 650 may be used each time cover plate 690 is removed.

[0066] Outer layer 640, or other component of sealing device 600, provides a suitable surface for attaching a cover plate 690, or other component. While wall surfaces or other building components may be textured or otherwise difficult to adhere to, attachment component 650 may be easily and readily attached to outer layer 640 or other component of sealing device 600 by a user. In this way, further air leakage associated with a gap between wall surfaces and/or building components may be minimized while providing an easily removable and/or replaceable device and aesthetically pleasing appearance.

[0067] Figs. 11 and 12 show an exemplary sealing device 700 that may be used to seal a gap between two or more building component surfaces such that undesirable air leakage may be reduced. Sealing device 700 includes a core 710 having first and second major faces 711, 712 separated by a thickness, a first adhesive 720 covering at least a portion of first major face 711, a liner 730 covering at least a portion of the first adhesive and an outer layer 740 covering at least a portion of the second major face, directly or indirectly, and comprising a plurality of cuts 746. In an exemplary embodiment, cuts 746 do not extend through the thickness of core 710. Liner 730 may be removed and core 710 adhered to one or more surfaces. A plurality of cuts in outer layer 740 and a conformable core allow sealing device 700 to bend and conform to surfaces without buckling or otherwise introducing gaps, such that the sealing device is configured to be foldable between a first planar configuration and a second non-planar or three-dimensional configuration. At least portions of core 710 proximate cuts 746 are configured to stretch relative to outer layer 740 when core 710 and outer layer 740 are folded from a planar configuration to a non-planar configuration. Sealing device 700 may be used to seal gaps between building components such as drywall or other wall material and a recessed light housing, for example, such that undesirable air leakage is minimized.

[0068] In various exemplary embodiments, outer layer 740 may include a stiffening layer, metallic foil, and/or other suitable components. For example, outer layer 740 may include a metallic foil 741 attached, directly or indirectly, to core 710 by an adhesive 742. In some exemplary embodiments, outer layer has an emissivity of less than 30 %, less than 20 %, or less than 15%. Outer layer 740 may thus add stiffness to core 710 and/or protect core 710 from thermal energy or ultraviolet radiation, for example, and as described herein.

[0069] Adhesive 742 may be applied to an entire surface of core 710 or to selected areas. In an exemplary embodiment, core 710 includes areas 718 in which adhesive 742 is not present and/or that are not otherwise adhered to outer layer 740. Areas 718 provide locations in which core 710 may stretch, bend, or otherwise move relative to outer layer 740. For example, when sealing device 700 is bent from an initial configuration to a final non-planar or three-dimensional configuration, core 710 may flex and stretch. Cuts 746 of outer layer 740 are able to open and/or move relative to core 710 when core 710 stretches. Such a configuration allows sealing device 700 to be adhered to first and second non-coplanar surfaces separated by a gap without buckling, bulging, or introducing gaps that could allow undesirable air leakage.

[0070] In an exemplary embodiment, outer layer 740 includes extensions 749 that may be folded back or positioned to cover a portion of core 710. As core 710 stretches and/or deforms when bent from an initial planar configuration to a final non-planar or three-dimensional configuration, for example, cuts 746 may open and otherwise expose portions of core 710. Such portions of core 710 may stretch or flex relative to outer layer 740, and extensions 749 provide additional coverage of core 710, as shown in Fig. 13, for example.

[0071] Cuts in sealing devices described herein may have any suitable shape, size and configuration to allow sealing device to bend or flex from an initial planar configuration to a final non-planar or three-dimensional configuration, for example, while minimizing buckling or introduction of gaps. In various exemplary embodiments, cuts may be in the form of a slit, square, triangle, arcuate, irregular, or other suitable shape. An exemplary sealing device 800, shown in Fig. 14, includes cuts 846 having a substantially square shape. Cuts 846 in the form of a square provide a large surface area to which extensions 849, for example, may be adhered to cover core 810 when folded back (Fig. 15). A protrusion 848a in cut 846 provides additional exposed area that extensions 849 may be adhered to.

[0072] In an exemplary embodiment, extensions 849 may be folded to at least partially cover cuts 846 and partially cover another portion of outer layer 840. Core 810 may stretch and/or flex, for example proximate cuts 846, relative to outer layer 840. As core 810 stretches and or flexes, a first portion 849a of extension 849 may move slightly relative to an adjacent portion 840a of outer layer 840.

[0073] Figs. 16 and 17 show an exemplary sealing device 900 that may be used to seal a gap between two or more building component surfaces such that undesirable air leakage may be reduced. Sealing device 900 includes a core 910 having first and second major faces 911, 912 separated by a thickness, a first adhesive 920 covering at least a portion of first major face 911, a liner 930 covering at least a portion of the first adhesive and an outer layer 940 covering at least a portion of the second major face, directly or indirectly. Outer layer 940 includes first and second layers 940a, 940b, such as first and second foil layers joined to core 910, such as by a second adhesive 942, for example. In some exemplary embodiments, a third adhesive 943 joins first and second foil layers 940a, 940b. [0074] First and second foil layers 940a, 940b comprise a first and second plurality of cuts 946a, 946b, respectively. First plurality of cuts 946a are offset from second plurality of cuts 946b. When sealing device 900 is bent or flexed from an initial planar configuration to a final non-planar or three-dimensional configuration, for example, core 910 may stretch and/or flex, for example proximate cuts 946, relative to outer layer 940. As core 910 stretches and or flexes, first and second cuts 946a, 946b may slightly open while core 910 remains covered due to the presence of first and second foil layers 940a, 940b. Accordingly, core 910 may remain protected from thermal energy or ultraviolet radiation, for example.

[0075] Sealing devices as described herein may be provided in any suitable form and may be pre-cut, sized for a desired application, or configured to be cut by a user as appropriate for a particular application. Figures 18 and 19 show an exemplary sealing device 1000 provided in the form of a roll 1001 that may be used to seal a gap between two or more non-planar building component surfaces, for example. Sealing device 1000 includes a core 1010 having first and second major faces 1011, 1012 separated by a thickness, a first adhesive 1020 covering at least a portion of first major face 1011, a liner 1030 covering at least a portion of first adhesive 1020 and an outer layer 1040 covering at least a portion of the second major face, directly or indirectly.

[0076] In an exemplary embodiment, outer layer 1040 includes a plurality of cuts 1046 that do not extend through the thickness of core 1010. A plurality of cuts 1046 in outer layer 1040 and a conformable core 1010 allow sealing device 1000 to bend and conform to surfaces without buckling or otherwise introducing gaps, such that sealing device 1000 is configured to be foldable between a first planar configuration, for example as it us unrolled, and a second non- planar or three-dimensional configuration.

[0077] In an exemplary embodiment, cuts 1046 may be present only on a first portion 1040a of outer layer 1040, for example extending from a first peripheral edge 1013, and not present on a second portion 1040b of outer layer 1040, for example at a second peripheral edge 1014. Cuts 1046 may be positioned and configured as appropriate for a particular application. In various exemplary embodiments, cuts 1046 are positioned between about every 4 mm and 40 mm, 8 mm and 30 mm, or about every 15 mm, along first peripheral edge 1013.

[0078] Figs. 20a and 20b show an exemplary installation of sealing device 1000 to seal a gap 1071 between building components. Exemplary sealing device 1000 may be installed for use by unrolling and cutting to a desired length, removing liner 1030, and adhering first adhesive 1020 to a first surface 1051. At an intermediate stage shown in figure 20a, first adhesive 1020 is adhered to first surface 1051. A portion of sealing device 1000 including first portion of outer layer 1040a and cuts 1046 extends outwardly and in an exemplary embodiment is not adhered to first surface 1051.

[0079] Fig. 20b shows a final stage in which a portion of sealing device 1000 is folded, bent, and/or stretched to adhere to second building construction surface 1052. As sealing device 1000 is folded, bent, and/or stretched, core 1010 may stretch or flex relative to outer layer 1040. In an exemplary embodiment, cuts 1046 widen or open as core 1010 stretches and flexes more than outer layer 1040.

[0080] Figs. 21 and 22 show an exemplary sealing device 2000 provided in the form of a roll 2001 that may be used to seal a gap between two or more building component surfaces, for example. Sealing device 2000 includes a core 2010 having first and second major faces 2011, 2012 separated by a thickness, a first adhesive 2020 covering at least a portion of first major face 2011, and a liner 2030 covering at least a portion of first adhesive 2020.

[0081] Sealing device 2000 includes an outer layer 2040 covering a portion of the second major face, directly or indirectly, such as a stiffening layer or thermal layer. In an exemplary embodiment, outer layer 2040 includes a first portion 2040a and, in some exemplary embodiments, a second portion 2040b. First portion 2040a may be made of any suitable layer as described herein, such as a metallic foil 2041 and a second adhesive 2042. Second portion 2040b, if present, may include a second release liner 2030b, adhesive 2043, exposed second surface 2012 of core 2010, or other suitable layer as described herein or known in the art.

[0082] A foil layer positioned over only a portion of core 2010 facilitates flexing, bending, and/or stretching of core 2010 relative to foil layer 2041. For example, sealing device 2010 may be adhered to a first construction surface, such as an inner surface of a recessed light housing, and a second building construction surface, such as a ceiling. First portion 2040a of sealing device including foil layer 2041 may be positioned within the housing to provide stiffening and/or thermal protection to core 2010, and second portion 2040b including a liner 2030b, exposed core, or other layer may be positioned over a gap and/or outside of the housing. Foil layer 2040a or other layer does not completely cover core 2010 and core 2010 is able to flex, bend, and/or stretch relative to outer layer 2040.

[0083] In an exemplary embodiment, second release liner 2030b may be removed before or after installation to provide a surface or adhesive that an additional component, such as architectural trim, may be attached to.

[0084] In some exemplary embodiments, outer layer 2040 includes a plurality of cuts as described herein, such as cuts 2046 that do not extend through the thickness of core 2010. A plurality of cuts 2046 in outer layer 2040 and a conformable core 2010 further allow sealing device 2000 to bend and conform to surfaces without buckling or otherwise introducing gaps, such that sealing device 2000 is configured to be foldable between a first planar configuration, for example as it us unrolled, and a second non-planar or three-dimensional configuration.

[0085] A sealing device according the present disclosure provides significant advantage in minimizing air leakage, providing energy savings while having relatively low manufacturing costs and easy installation. Exemplary sealing devices may be installed with less time and difficulty as compared to caulk or foam or an insulated housing installed to block air leakage through gaps around a recessed light housing, for example. The sealing device may limit air flow sufficient to assist in addressing relevant state building codes, and may be used alone or in combination with desired components or architectural trims to achieve desired performance and aesthetic qualities. In some exemplary embodiments, the sealing device may be easily removed without leaving undesirable adhesive residue.

Examples

[0086] The characteristics, operation, and advantages of the present invention will be further described with regard to the following detailed non- limiting examples. These examples are offered to further illustrate the various specific and preferred embodiments and techniques. It should be understood, however that many variations and modifications may be made while remaining within the scope of the present invention. Procedure 1: Air Leakage Test

[0087] The effectiveness of a sealing device may be characterized by measuring air leakage at a specified pressure. A test house was constructed of oriented strand board (OSB) including a simulated conditioned air space and attic dimensioned according to Fig. 9. The volume of the conditioned air space was approximately 138.1 ft ³ . A 6.375" hole was cut into the ceiling of the conditioned space and a Commercial Electric 6 in. IC airtight recessed light fixture, model number CAT7ICATA, rated as meeting the airflow requirements of the Washington state energy code (ASTM E283) available from The Home Depot, Inc. was attached to the attic side of the ceiling according to the manufacturer instructions. Air was blown into the simulated conditioned space through a 10 foot long, 4" inner diameter, PVC pipe having a plastic direct drive duct fan, Product # 19135K65, available from McMaster-Carr Supply Company, and adjustable outlet valve at a first end and joined to the house by a flexible house at the second end. The duct fan was operated to pressurize the space to approximately 75 Pascals for the ACH75 measurement. Air velocity was measured approximately at a midpoint of the pipe using a VELOCICALC 9565 ventilation meter available from TSI Inc. of Shoreview, MN. The average velocity value over a two minute period was used in the calculations below. [0088] Cubic foot per hour leakage values (CFH) were calculated according the following:

Correct on Factor 1.2

[0089] Air Changes per Hour (ACH) values were calculated according to the following:

CFH

ACH =

Volume of the Conditioned Space (138.1 ft ³ )

Example 1

[0090] A sealing device according to Fig. 5 was installed to block a gap between the OSB ceiling and the recessed light fixture. An inner peripheral edge defined an opening having a diameter (d) of approximately 130.2 mm and an outer peripheral edge had a diameter (D) of approximately 193.7 mm. A thickness (t) of a core was approximately 0.92 mm. The sealing device had a Young's modulus, measured according to ASTM D882-A, of approximately 266.7 MPa and a tensile strength measured according to ASTM D882-A of approximately 7.14 MPa. The Air Leakage Test of Procedure 1 was conducted to characterize the effectiveness of the sealing device. The result is summarized in Table 1.

Comparative Examples A through H

[0091] The Air Leakage Test of Procedure 1 was conducted for several conditions. In Comparative Example A, the opening cut in the OSB ceiling was unchanged after installation of the recessed light fixture. In Comparative Example B, the opening cut in the OSB ceiling was completely taped over with several layers of duct tape to simulate a condition of no leakage at the opening. Comparative Examples C, D, E, F, G, H and I were conducted with various trim conditions, including no trim, Commercial Electric Shower Trim HBR70WH, Halo 172PS, Halo 300P, Halo 31 OP, Halo 426 and Halo 78P trims, respectively. The trim of Comparative Example C includes a trim, gasket and transparent plate. The presence of a plate covering an entire opening to the recessed light fixture provides an additional mode of limiting air leakage through openings in the recessed light fixture, for example. The shower style trims of Comparative Examples C and D performed slightly better than Comparative Examples E through H.

[0092] The sealing device of Example 1 was effective in limiting air leakage and exhibited performance similar to Comparative Example A simulating no leakage through the opening in the OSB ceiling. Accordingly, the sealing device of Example 1 provides significant advantage in minimizing air leakage, providing energy savings while having relatively low manufacturing costs and easy installation. In practice, the sealing device of Example 1 could be used in combination with other trim options, further limiting air leakage.

Table 1

[0093] The present invention has now been described with reference to several embodiments thereof. The foregoing detailed description and examples have been given for clarity of understanding only. No unnecessary limitations are to be understood therefrom. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the exact details and structures described herein, but rather by the structures described by the language of the claims, and the equivalents of those structures. Any feature or characteristic described with respect to any of the above embodiments can be incorporated individually or in combination with any other feature or characteristic, and are presented in the above order and combinations for clarity only. That is, the present disclosure contemplates all possible combinations and arrangements of various features of each of the exemplary embodiments and components describe herein, and each component may be combined or used in conjunction with any other component as desired for a particular application.