Peel and stick roofing membranes with cured pressure-sensitive adhesives

• US 10,519,663 B2
• Filed: 11/02/2018
• Issued: 12/31/2019
• 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:
  US16/179,084
• Publication Number:
  US 20190071872A1
• Time in Patent Office: 424 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:

heating a melt-extrudable, UV-curable pressure-sensitive adhesive composition to allow the adhesive to flow, where the adhesive composition comprises a polyacrylate elastomer and, optionally, one or more of photoinitiators, solvents, plasticizers, and resins;

applying the adhesive composition to a planar surface of a roofing membrane panel, where the membrane panel is adapted to provide a weatherproof polymeric barrier to a building structure, to thereby form an adhesive layer having a thickness of at least 152 μ

m;

subjecting the adhesive layer to UV radiation to thereby effect crosslinking of the polyacrylate elastomer to form a cured adhesive layer comprising a cross-linked infinite polymer network;

applying a release member to the cured adhesive layer to form a roofing member composite; and

winding the composite.

2. The process of claim 1, where said step of heating heats the adhesive composition 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 layer 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 layer 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 layer to at least 200 milliWatts/cm2 of UV energy.

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

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

C.

8. The process of claim 1, where the polyacrylate elastomer includes polymerized units that serve as photoinitiators.

9. The process of claim 1, where the polyacrylate elastomer is characterized by a number average molecular weight of from about 100 to about 350 kg/mol.

10. The process of claim 1, where the polyacrylate elastomer is characterized by a Brookfield viscosity at 150°

C. of from about 20,000 to about 70,000 cps.

11. The process of claim 1, where the roofing membrane panel is a thermoplastic or cured rubber membrane.

12. The process of claim 1, where the roofing membrane panel is EPDM.

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

14. The process of claim 1, where the roofing membrane panel has a thickness of from about 500 μ

m to about 3 mm.

15. The process of claim 1, where the cured adhesive layer is in contact with substantially all of one planar surface of the membrane panel.

16. The process of claim 1, where the membrane composite is characterized by a peel strength, when adhered to a stainless steel panel and tested according to PSTC 101, of at least 3.0 psi.

17. The process of claim 1, where the membrane composite is characterized by a dead load shear, when adhered to a stainless steel panel and tested according to PSTC 107, of at least 0.5 hour.