Peel and stick roofing membranes with cured pressure-sensitive adhesives

• US 10,132,082 B2
• Filed: 09/18/2014
• Issued: 11/20/2018
• Est. Priority Date: 09/18/2013
• Status: Active Grant

• Current Assignee: Holcim Technology, Ltd. (Holcim Limited)
• Original Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Inventors: Tang, Jiansheng, Hubbard, Michael J
• Primary Examiner(s): Dodds, Scott W
• Application Number:
  US15/021,787
• Publication Number:
  US 20160230392A1
• Time in Patent Office: 1,524 Days
• Field of Search: 156332
• CPC Class Codes: B32B 2255/10 on synthetic resin layer or on natural or synthetic rubber layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/748 Releasability
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 25/04 comprising rubber as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/043; next to a bituminous or tarry layer B32B11/044; next to a water setting substance layer B32B13/042; next to a metal layer B32B15/06; next to a glass layer B32B17/063; next to a layer formed of natural mineral fibres or particles B32B19/043; next to a wood layer B32B21/045; next to a cellulosic plastic layer B32B23/046
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 7/06 permitting easy separation
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C09J 133/00 Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides, or nitriles thereof; Adhesives based on derivatives of such polymers
• CPC Class Codes: C09J 2301/302 the adhesive being pressure-sensitive, i.e. tacky at temperatures inferior to 30°C
• CPC Class Codes: C09J 2301/304 the adhesive being heat-activatable, i.e. not tacky at temperatures inferior to 30°C
• CPC Class Codes: C09J 2301/40 characterized by the presence of essential components
• CPC Class Codes: C09J 2423/16 Presence of ethen-propene or ethene-propene-diene copolymers
• CPC Class Codes: C09J 2423/166 in the substrate
• CPC Class Codes: C09J 2433/00 Presence of (meth)acrylic polymer
• CPC Class Codes: C09J 7/22 Plastics; Metallised plastics
• CPC Class Codes: C09J 7/243 Ethylene or propylene polymers
• CPC Class Codes: C09J 7/38 Pressure-sensitive adhesives [PSA]
• CPC Class Codes: C09J 7/385 Acrylic polymers
• CPC Class Codes: E04D 5/06 : by making use of plastics
• CPC Class Codes: E04D 5/08 : by making use of other materials
• CPC Class Codes: E04D 5/10 : by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
• CPC Class Codes: E04D 5/148 : fastening by gluing

Abstract

A membrane composite comprising a polymeric membrane panel, an adhesive layer, and a release member, where the adhesive layer is a pressure-sensitive adhesive that is at least partially cured, and where the adhesive layer has a thickness of at least 102 μm.

Claims

1. A process for forming a roofing membrane composite, the process comprising:

(a) heating a melt-extrudable, UV-curable pressure-sensitive adhesive to allow the adhesive to flow, where the adhesive consists of a polyacrylate elastomer and, optionally, one or more of photoinitiators, solvents, plasticizers, and resins selected from the group consisting of natural resins and hydrocarbon resins;

(b) applying the adhesive to a planar surface of a thermoplastic or cured rubber roofing membrane panel for providing a weatherproof polymeric barrier to a building structure, to thereby form a coating layer of adhesive having a thickness of at least 152 μ

m, where the roofing membrane panel has a thickness of from about 500 μ

m to about 3 mm;

(c) subjecting the coating layer of the adhesive to UV radiation to thereby effect crosslinking of the adhesive to form a cross-linked infinite polymer network;

(d) applying a release member to the adhesive coating layer to form a roofing member composite; and

(e) winding the composite.

2. The process of claim 1, where said step of heating heats the adhesive to a temperature of from about 120 to about 160°

C.

3. The process of claim 1, where said step of subjecting the coating to UV radiation includes subjecting the adhesive to a UV dosage of from about 50 to about 230 millijoules/cm².

4. The process of claim 1, where said step of subjecting the coating to UV radiation includes subjecting the adhesive to at least 150 milliWatts/cm² of UV energy.

5. The process of claim 1, where said step of subjecting the coating to UV radiation includes subjecting the adhesive to at least 200 milliWatts/cm² of UV energy.

6. The process of claim 1, where the adhesive includes one or more units deriving from butyl acrylate or 2-ethylhexyl acrylate.

7. The process of claim 1, where the adhesive has a Tg of less than 0°

C.

8. The process of claim 1, where the roofing membrane panel has a width of from about 1 to about 20 meters.