Bonding adhesive and adhered roofing systems prepared using the same

• US 10,550,575 B2
• Filed: 08/02/2016
• Issued: 02/04/2020
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Holcim Technology, Ltd. (Holcim Limited)
• Original Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Inventors: Tang, Jiansheng, Carr, Joseph
• Primary Examiner(s): Moore, Margaret G
• Application Number:
  US15/226,243
• Publication Number:
  US 20160340905A1
• Time in Patent Office: 1,281 Days
• CPC Class Codes: B32B 11/044 of natural rubber or synthetic rubber
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2319/00 Synthetic rubber
• CPC Class Codes: B32B 2395/00 Bituminous material, e.g. tar, asphalt
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 25/16 comprising polydienes homopolymers or poly-halodienes homopolymers B32B25/12 takes precedence
• CPC Class Codes: B32B 37/12 characterised by using adhesives
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: C08G 65/336 containing silicon
• CPC Class Codes: C08L 57/02 Copolymers of mineral oil hydrocarbons
• CPC Class Codes: C09D 171/02 Polyalkylene oxides
• CPC Class Codes: C09J 109/00 Adhesives based on homopolymers or copolymers of conjugated diene hydrocarbons
• CPC Class Codes: C09J 171/00 Adhesives based on polyethers obtained by reactions forming an ether link in the main chain based on polyacetals C09J159/00; based on epoxy resins C09J163/00; based on polythioether-ethers C09J181/02; based on polyethersulfones C09J181/06; Adhesives based on derivatives of such polymers
• CPC Class Codes: C09J 175/04 Polyurethanes
• CPC Class Codes: C09J 201/02 characterised by the presence of specified groups , e.g. terminal or pendant functional groups
• CPC Class Codes: C09J 201/10 containing hydrolysable silane groups
• CPC Class Codes: C09J 2499/00 Presence of natural macromolecular compounds or on derivatives thereof, not provided for in groups C09J2489/00 - C09J2497/00
• CPC Class Codes: C09J 5/00 Adhesive processes in general; Adhesive processes not provided for elsewhere, e.g. relating to primers
• CPC Class Codes: E04D 11/00 Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
• CPC Class Codes: E04D 11/02 : Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: E04D 12/00 : Non-structural supports for roofing materials, e.g. battens, boards E04D11/02 and E04D13/16 take precedence; self-supporting slabs with non-structural supports for roofing materials E04B7/205
• CPC Class Codes: E04D 2015/042 : Fixing to the roof supporting structure
• CPC Class Codes: E04D 3/36 : Connecting; Fastening
• CPC Class Codes: E04D 5/08 : by making use of other materials
• CPC Class Codes: E04D 5/148 : fastening by gluing
• CPC Class Codes: E04D 7/005 : characterised by loose or embedded gravel or granules as an outer protection of the roof covering

Abstract

A bond adhesive composition comprising a polymer having a silicon-containing hydrolyzable terminal group and a hydrocarbon resin, where the composition is substantially devoid of phenolic resin.

Claims

1. An adhered membrane roof system comprising:

a roof substrate;

a polymeric membrane comprising EPDM; and

an adhesive layer disposed between the roof substrate and the polymeric membrane that is adhered directly to the polymeric membrane, where there is no fleece or other backing layer between the roof substrate and the polymeric membrane, said adhesive layer being formed from a bond adhesive composition comprising;

a polymer having a silicon-containing hydrolysable terminal group and from about 1 to about 30 wt. % of a C₉ aromatic hydrocarbon tackifying resin, where the bond adhesive composition is devoid of phenolic resin, where the hydrocarbon tackifying resin is characterized by a softening point of from 90 to about 140°

C., and a number average molecular weight of from about 300 to about 3000 g/mole.

2. The roof system of claim 1, where the adhesive layer is a substantially continuous layer.

3. The roof system of claim 1, where the roof substrate is selected from the group consisting of a roof deck, an insulation layer, a coverboard, and a roof panel.

4. The roof system of claim 1, where the roof substrate includes an insulation board.

5. The roof system of claim 1, where the roof substrate includes a coverboard.

6. The roof system of claim 1, where the roof substrate includes a polymeric roof panel.

7. The roof system of claim 6, where the polymeric roof panel includes an asphalt-based roof panel.

8. The roof system of claim 1, where the bond adhesive composition further includes an adhesion promoter.

9. The roof system of claim 1, where the bond adhesive composition further includes a catalyst.

10. The roof system of claim 1, where the bond adhesive composition further includes a moisture scavenger.

11. The roof system of claim 1, where the bond adhesive composition further includes a thixotropic compound.

12. The roof system of claim 1, where the polymer having a silicon-containing hydrolyzable terminal group is a silane-terminated polymer.

13. The roof system of claim 1, where the polymer having a silicon-containing hydrolyzable terminal group is a silane-terminated polyether or a silane-terminated polyurethane polymer.

16. The roof system of claim 1, where the hydrocarbon tackifying resin is a low-softening point tackifier resin, and where the bond adhesive composition further comprises a high-softening point hydrocarbon tackifier resin characterized by a softening point of from about 120 to about 150°

C.

17. The roof system of claim 1, where the bond adhesive composition includes at least 3 wt. % of the aromatic hydrocarbon tackifying resin.

18. The roof system of claim 1, where the weight average molecular weight of the aromatic hydrocarbon tackifying resin is from about 500 to about 6000 g/mole.

19. The roof system of claim 18, where the aromatic hydrocarbon tackifying resin is characterized by a softening point of from 95 to about 120°

C.

20. The roof system of claim 19, where the glass transition temperature of the aromatic hydrocarbon tackifying resin is from about −

40 to about 80°

C.

21. The roof system of claim 1, where the amount of polymer having a silicon-containing hydrolysable terminal group is from about 25 wt. % to about 80 wt. %.

22. The roof system of claim 1, where the bond adhesive composition further comprises a plasticizer, an adhesion promoter, a catalyst, a thixotropic compound, and an antioxidant.

14. A method for forming an adhered membrane roof system, the method comprising:

applying a bond adhesive composition to a roof substrate to form an adhesive layer, where the bond adhesive composition includes a polymer having a silicon-containing hydrolyzable terminal group and from about 1 to about 30 wt. % of a C₉ aromatic hydrocarbon tackifying resin, where the bond adhesive composition is devoid of phenolic resin, where the hydrocarbon tackifying resin is characterized by a softening point of from 90 to about 140°

C. and a number average molecular weight of from about 300 to about 3000 g/mole; and

applying a polymeric membrane comprising EPDM directly to the adhesive layer, where there is no fleece or other backing layer between the roof substrate and the polymeric membrane.

15. The method of claim 14, where the roof substrate is selected from the group consisting of a roof deck, an insulation layer, a coverboard, and a roof panel.

23. The method of claim 14, where the polymer having a silicon-containing hydrolyzable terminal group is a silane-terminated polymer.

24. The method of claim 14, where the polymer having a silicon-containing hydrolyzable terminal group is a silane-terminated polyether or a silane-terminated polyurethane polymer.

25. The method of claim 14, where the bond adhesive composition further comprises one or more components selected from the group consisting of catalysts, moisture scavengers, thixotropic compounds, plasticizers, and adhesion promoters.

26. The method of claim 14, where the hydrocarbon tackifying resin is a low-softening point tackifier resin, and where the bond adhesive composition further comprises a high-softening point hydrocarbon tackifier resin characterized by a softening point of from about 120 to about 150°

C.