WO2016130636A1 - Membranes de toiture à peler et coller dotées d'adhésifs sensibles à la pression et de graphite expansé - Google Patents

Membranes de toiture à peler et coller dotées d'adhésifs sensibles à la pression et de graphite expansé Download PDF

Info

Publication number
WO2016130636A1
WO2016130636A1 PCT/US2016/017285 US2016017285W WO2016130636A1 WO 2016130636 A1 WO2016130636 A1 WO 2016130636A1 US 2016017285 W US2016017285 W US 2016017285W WO 2016130636 A1 WO2016130636 A1 WO 2016130636A1
Authority
WO
WIPO (PCT)
Prior art keywords
adhesive
membrane
expandable graphite
coating
layer
Prior art date
Application number
PCT/US2016/017285
Other languages
English (en)
Inventor
Wensheng Zhou
Jiansheng Tang
Hao Wang
Michael J. Hubbard
Original Assignee
Firestone Building Products Co., LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Firestone Building Products Co., LLC filed Critical Firestone Building Products Co., LLC
Publication of WO2016130636A1 publication Critical patent/WO2016130636A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/04—Layered products comprising a layer of natural or synthetic rubber 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B25/00—Layered products comprising a layer of natural or synthetic rubber
    • B32B25/14—Layered products comprising a layer of natural or synthetic rubber comprising synthetic rubber copolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/16—Layered products comprising a layer of synthetic resin specially treated, e.g. irradiated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/26—Layered products comprising a layer of synthetic resin characterised by the use of special additives using curing agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/10—Interconnection of layers at least one layer having inter-reactive properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/046—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2274/00—Thermoplastic elastomer material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/542—Shear strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/748—Releasability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes

Definitions

  • Embodiments of the invention are directed toward roofing membranes that carry a cured pressure-sensitive adhesive for securing the membrane to a roof surface.
  • the membranes also include expandable graphite, which serves as flame retardant or flame barrier.
  • thermoset membranes such as those including cured EPDM (i.e., ethylene- propylene- diene terpolymer rubber) or thermoplastics such as TPO (i.e., thermoplastic olefins).
  • These membranes are typically delivered to a construction site in a bundled roll, transferred to the roof, and then unrolled and positioned.
  • the sheets are then affixed to the building structure by employing varying techniques such as mechanical fastening, ballasting, and/or adhesively adhering the membrane to the roof.
  • the roof substrate to which the membrane is secured may be one of a variety of materials depending on the installation site and structural concerns.
  • the surface may be a concrete, metal, or wood deck, it may include insulation or recover board, and/or it may include an existing membrane.
  • the individual membrane panels, together with flashing and other accessories are positioned and adjoined to achieve a waterproof barrier on the roof.
  • the edges of adjoining panels are overlapped, and these overlapping portions are adjoined to one another through a number of methods depending upon the membrane materials and exterior conditions.
  • One approach involves providing adhesives or adhesive tapes between the overlapping portions, thereby creating a water resistant seal.
  • Another mode of attachment is through the use of a pre-applied adhesive to the bottom surface of the membrane.
  • an adhesive is applied to the bottom surface of the membrane.
  • a release film or member is applied to the surface of the adhesive. During installation of the membrane, the release member is removed, thereby exposing the pressure-sensitive adhesive, and the membrane can then be secured to the roofing surface without the need for the application of additional adhesives.
  • the pre-applied adhesive can be applied to the surface of the membrane in the form of a hot-melt adhesive.
  • a hot-melt adhesive For example, U.S. Publication No. 2004/0191508, which teaches peel and stick thermoplastic membranes, employs pressure-sensitive adhesive compositions comprising styrene-ethylene-butylene-styrene (SEBS), tackifying endblock resins such as cumarone-indene resin and tackifying midblock resins such as terpene resins.
  • SEBS styrene-ethylene-butylene-styrene
  • tackifying endblock resins such as cumarone-indene resin
  • tackifying midblock resins such as terpene resins.
  • hot-melt adhesives such as butyl-based adhesives, EPDM-based adhesives, acrylic adhesives, styrene-butadiene adhesives, polyisobutylene adhesives, and ethylene vinyl acetate adhesives.
  • peel and stick membranes have inherent limitations. For example, there are temperature windows that limit the minimum temperature at which the membranes can be installed on a roof surface. Also, there are maximum temperature limits on the roof surface that the adhesive can withstand while maintaining wind-uplift integrity. With respect to the latter, where the surface temperature on the roof nears the glass transition temperature of the adhesive, the adhesive strength offered by the pressure-sensitive adhesive is not maintained. As a result, peel-and-stick membranes have not gained wide acceptance in the industry. Moreover, the use of peel-and-stick membranes has been limited to use in conjunction with white membranes (e.g., white thermoplastic membranes) because the surface temperature of these membranes remains cooler when exposed to solar energy.
  • white membranes e.g., white thermoplastic membranes
  • Embodiments of the present invention provide a membrane composite comprising a polymeric membrane panel, an adhesive layer, where the adhesive layer is a pressure-sensitive adhesive that is at least partially cured, expandable graphite, and a release member.
  • Embodiments of the present invention provide a process for forming a membrane composite, the process comprising preparing a blend of a melt-extrudable, UV-curable, pressure-sensitive adhesive and expandable graphite, heating the blend of the melt-extrudable, UV-curable, pressure-sensitive adhesive and expandable graphite allowing the blend to flow, applying the blend to a planar surface of a membrane panel to form a coating of adhesive, subjecting the coating of the adhesive to UV radiation to thereby effect crosslinking of the adhesive, applying a release member to the adhesive coating to form a composite, and winding the composite.
  • Fig. 1 is a cross-section perspective view of a membrane composite according to embodiments of the invention, wherein expandable graphite is dispersed within an adhesive layer.
  • Fig. 2 is a cross-section view of a membrane composite according to embodiments of the invention, wherein expandable graphite is located within a concentrated region of expandable graphite adjacent to the membrane.
  • FIG. 3 is a cross-section view of a membrane composite according to embodiments of the invention, wherein expandable graphite is located within a concentrated region of expandable graphite sandwiched within an adhesive layer.
  • Fig. 4 is a flow chart describing a process for making membrane composite according to embodiments of the present invention.
  • Fig. 5 is a schematic of a continuous process for making membrane composite according to embodiments of the present invention.
  • Embodiments of the invention are based, at least in part, on the discovery of roofing membranes having a pre-applied pressure-sensitive adhesive that is at least partially cured.
  • the membranes also advantageously include expandable graphite, which serves as a flame retardant or flame barrier.
  • the pre-applied adhesive is applied as a hot-melt adhesive and subsequently cured. While the prior art contemplates thermoplastic membranes that carry a pressure-sensitive adhesive applied to the membrane as a hot-melt adhesive, the hot-melt adhesives used in the present invention are advantageously cured, which provides the membranes with a higher operating temperature.
  • the adhesive can be cured without having a deleterious impact on the expandable graphite, which may be contained within or adjacent to the pressure- sensitive adhesive.
  • a release member can be applied to the pressure-sensitive adhesive, thereby allowing the membrane to be rolled, delivered to a job site, and ultimately applied to a roofing surface by using peel and stick techniques.
  • membranes that carry an adhesive for application by peel-and-stick methods are generally known as disclosed in U.S. Publication No. 2004/0191508, which is incorporated herein by reference.
  • membrane composite 11 includes polymeric panel 13, pressure-sensitive adhesive layer 15 fixedly attached to polymeric panel 13, expandable graphite 17 dispersed within pressure-sensitive adhesive layer 15, and release member 19 removably attached to layer 15.
  • the structure of adhesive layer 15 relative to the expandable graphite can be modified.
  • expandable graphite 17 is dispersed throughout adhesive layer 15 as shown in Fig. 1.
  • the dispersion of the expandable graphite 17 may be generally homogeneous. In other embodiments, the degree of dispersion may be referred to as random.
  • expandable graphite 17 may be in the form of a layer 21, which may also be referred to a concentrated region 21, within or adjacent to adhesive layer 15 and adjacent to or proximate to panel 13.
  • adhesive layer 15 includes one or more layers 21 of particles of expandable graphite 17. These particles may be held in place by a matrix of adhesive composition present within at least a portion of concentrated region 21.
  • expandable graphite 17 is held in place by being adhered to the surface 14 of sheet or panel 13.
  • adhesive layer 15 may also include expandable graphite 17 dispersed therein.
  • composite 11 can include both a layer 21 having a high concentration of expandable graphite 17, and expandable graphite 17 that is dispersed throughout the matrix of the adhesive layer 15.
  • expandable graphite 17 may be in the form of a layer 21, which may also be referred to a concentrated region 21, sandwiched within adhesive layer 15.
  • adhesive layer 15 includes one or more layers 21 of particles of expandable graphite 17 sandwiched between first adhesive sublayer 15' and second adhesive sublayer 15". As with previous embodiments, these particles may be held in place by a matrix of adhesive composition present within at least a portion of concentrated region 21.
  • adhesive layer 15 may also include expandable graphite 17 dispersed therein.
  • composite 11 includes both a layer 21 having a high concentration of expandable graphite, and it also includes expandable graphite dispersed throughout the matrix of the adhesive layer 15.
  • the adhesive layer 15 can include multiple discreet regions of the expandable graphite, such as may exist in a pattern where the expandable graphite is applied on the top of the asphaltic sheet in rows or strips in the machine direction of the sheet.
  • the thickness of adhesive layer 15 may be at least 2 ⁇ , in other embodiments at least 5 ⁇ , in other embodiments at least 20 ⁇ , in other embodiments at least 50 ⁇ , in other embodiments at least 75 ⁇ , and in other embodiments at least 100 ⁇ . In these or other embodiments, the thickness of adhesive layer 15 may be at most 1 mm, in other embodiments at most 0.85 mm, in other embodiments at most 0.7 mm, in other embodiments at most 0.6 mm, in other embodiments at most 0.5 mm, in other embodiments at most 0.25 mm, in other embodiments at most 0.1 mm, and in other embodiments at most 0.050 mm.
  • the thickness of adhesive layer 15 may be from about 1 ⁇ to about 3 mm, in other embodiments from about 2 ⁇ to about 0.5 mm, in other embodiments from about 2 ⁇ to about 1.0 mm, in other embodiments from about 5 ⁇ to about 0.4 mm, and in other embodiments from about 5 ⁇ to about 0.050 mm.
  • the pressure-sensitive adhesive layer may have a thickness of at least 25 ⁇ (1 mil), in other embodiments at least 51 ⁇ (2 mil), in other embodiments at least 102 ⁇ (4 mil), in other embodiments at least 127 ⁇ (5 mil), and in other embodiments at least 152 ⁇ (6 mil). In these or other embodiments, the pressure-sensitive adhesive layer has a thickness of at most 381 ⁇ (15 mil), in other embodiments at most 305 ⁇ (12 mil), in other embodiments at most 254 ⁇ (10 mil), in other embodiments at most 204 ⁇ (8 mil), and in other embodiments at most 153 ⁇ (6 mil).
  • the adhesive layer has a thickness of from about 25 to about 381 ⁇ (about 1 to about 15 mil), in other embodiments from about 25 to about 305 ⁇ (about 2 to about 12 mil), in other embodiments from about 102 to about 255 ⁇ (about 4 to about 10 mil), and in other embodiments from about 77 to about 153 ⁇ (about 3 to about 6 mil).
  • the layer of expandable graphite particles may be covered by a layer of adhesive. Stated another way, the layer or region of concentrated expandable graphite may be sandwiched within the adhesive material.
  • the layer of expandable graphite e.g. layer 21
  • the layer of expandable graphite is located approximately within the middle of adhesive layer 15 (i.e. there is approximately an equal thickness of adhesive between region 21 and panel 13 and between region 21 and member 19.
  • layer of expandable graphite 21 is offset closer in proximity to panel 13, and therefore the thickness of adhesive between region 21 and panel 13 is smaller than the thickness of adhesive between region 21 and member 19.
  • adhesive layer 15 may include a planar region that includes a higher concentration of expandable graphite relative to any other region of the article.
  • layer 15 may include a continuous layer of expandable graphite having a variable or relatively constant thickness across the membrane.
  • the expandable graphite may be discontinuous throughout a region so long as the concentration of expandable graphite within the region is higher than in other areas or regions of the layer.
  • the discontinuity of the expandable graphite within the layer 15 may result from the adhesive composition which may form a matrix in which the expandable graphite is at least partially dispersed within this region or layer.
  • the expandable graphite may be dispersed uniformly within the adhesive layer, it should also be appreciated that the concentration of the expandable graphite may not be constant within this layer. Indeed, as will be appreciated from the description of how to fabricate the articles of the embodiments herein, a concentration gradient may exist whereby the concentration of the expandable graphite moves from a region of maximum concentration to a region of decreased concentration.
  • the concentration of expandable graphite 17 proximate to surface 14 of membrane 13 is the highest, which corresponds to the lowest concentration of adhesive within layer 15.
  • the concentration of expandable graphite 17 proximate to release layer 19 is the lowest, which corresponds to the highest concentration of adhesive within layer 15.
  • the concentration of expandable graphite 17 within layer 15 may be at least 0.5 %, in other embodiments at least 1 %, in other embodiments at least 3%, and in other embodiments at least 5 % based upon the total weight of the layer. In these or other embodiments, where expandable graphite 17 is dispersed within adhesive layer 15, the concentration of expandable graphite 17 within layer 15 may be at most 80 %, in other embodiments at most 60 %, and in other embodiments at most 40 % based upon the total weight of the layer.
  • the concentration of expandable graphite 17 within layer 15 may be from about 1 to about 60 %, in other embodiments from about 3 to about 40 %, and in other embodiments from about 5 to about 20 % based upon the total weight of the layer.
  • the membrane may be a thermoset material. In other embodiments the membrane may be a thermoformable material. In one or more embodiments, the membrane may be EPDM based. In other embodiments, the membrane may be TPO based. In these or other embodiments, the membrane may be flexible and capable of being rolled up for shipment. In these or other embodiments, the membrane may include fiber reinforcement, such as a scrim. In one or more embodiments, the membrane includes EPDM membranes including those that meet the specifications of the ASTM D-4637. In other embodiments, the membrane includes thermoplastic membranes including those that meet the specifications of ASTM D-6878- 03. Still other membranes may include PVC, TPV, CSPE, and asphalt-based membranes.
  • the roofing membrane panels are characterized by conventional dimensions.
  • the membrane panels may have a thickness of from about 500 ⁇ to about 3 mm, in other embodiments from about 1,000 ⁇ to about 2.5 mm, and in other embodiments from about 1,500 ⁇ to about 2 mm.
  • the membrane panels of the present invention are characterized by a width of about 1 m to about 20 m, in other embodiments from about 2 m to about 18 m, and in other embodiments from about 3 m to about 15 m.
  • the curable hot-melt adhesive that may be used for forming the cured pressure-sensitive adhesive layer may be an acrylic-based hot-melt adhesive.
  • the adhesive is a polyacrylate such as a polyacrylate elastomer.
  • useful polyacrylates include one or more units defined by the formula:
  • each R1 is individually hydrogen or a hydrocarbyl group and each R ⁇ is individually a hydrocarbyl group.
  • each R.1 and R.2, respectively, throughout the polymer are same in each unit.
  • at least two different R.1 and/or two different R2 are present in the polymer chain.
  • hydrocarbyl groups include, for example, alkyl, cycloalkyl, substituted cycloalkyl, alkenyl, cycloalkenyl, substituted cycloalkenyl, aryl, substituted aryl, aralkyl, alkaryl, allyl, and alkynyl groups, with each group containing in the range of from 1 carbon atom, or the appropriate minimum number of carbon atoms to form the group, up to about 20 carbon atoms.
  • These hydrocarbyl groups may contain heteroatoms including, but not limited to, nitrogen, oxygen, boron, silicon, sulfur, and phosphorus atoms.
  • each R.2 is an alkyl group having at least
  • R.1 is hydrogen and R.2 is selected from the group consisting of butyl, 2-ethylhexyl, and mixtures thereof.
  • the polyacrylate elastomers that are useful as adhesives in the practice of this invention may be characterized by a glass transition temperature (Tg) of less than 0 °C, in other embodiments less than -20 °C, in other embodiments less than -30 °C.
  • useful polyacrylates may be characterized by a Tg of from about -70 to about 0 °C, in other embodiments from about -50 to about -10 °C, and in other embodiments from about -40 to about -20 °C.
  • the polyacrylate elastomers that are useful as adhesives in the practice of this invention may be characterized by a number average molecular weight of from about 9 to about 80 kg/mole, in other embodiments from about 12 to about 50 kg/mole, in other embodiments from about 15 to about 30 kg/mole, in other embodiments from about 100 to about 350 kg/mole, in other embodiments from about 150 to about 270 kg/mole, and in other embodiments from about 180 to about 250 kg/mole.
  • the polyacrylate elastomers that are useful as adhesives in the practice of this invention may be characterized by a Brookfield viscosity at 150 °C of from about 10,000 to about 200,000 cps, in other embodiments from about 20,000 to about 170,000 cps, in other embodiments from about 25,000 to about 150,000 cps, in other embodiments from about 20,000 to about 70,000 cps, in other embodiments from about 30,000 to about 60,000 cps, and in other embodiments from about 40,000 to about 50,000 cps.
  • the polyacrylate elastomers may include polymerized units that serve as photoinitiators. These units may derive from copolymerizable photoinitiators including acetophenone or benzophenone derivatives. These polyacrylate elastomers and the coating compositions formed therefrom are known as disclosed in U.S. Patent Nos 7,304,119 and 7,358,319, which are incorporated herein by reference.
  • Useful adhesive compositions are commercially available in the art.
  • useful adhesives include those available under the tradename acResin (BASF), those available under the tradename AroCure (Ashland Chemical), and NovaMeltRC (NovaMelt) .
  • these hot-melt adhesives may be cured (i.e., crosslinked) by UV light.
  • the hot-melt adhesive is at least partially cured after being applied to the membrane, as will be discussed in greater detail below.
  • the adhesive is cured to an extent that it is not thermally processable in the form it was prior to cure.
  • the cured adhesive is characterized by a cross-linked infinite polymer network. While at least partially cured, the adhesive layer of one or more embodiments is essentially free of curative residue such as sulfur or sulfur crosslinks and/or phenolic compounds or phenolic-residue crosslinks.
  • expandable graphite which may also be referred to as expandable flake graphite, intumescent flake graphite, or expandable flake, includes intercalated graphite in which an intercallant material is included between the graphite layers of graphite crystal or particle.
  • intercallant materials include halogens, alkali metals, sulfates, nitrates, various organic acids, aluminum chlorides, ferric chlorides, other metal halides, arsenic sulfides, and thallium sulfides.
  • the expandable graphite includes non-halogenated intercallant materials.
  • the expandable graphite includes sulfate intercallants, also referred to as graphite bisulfate.
  • sulfate intercallants also referred to as graphite bisulfate.
  • bisulfate intercalation is achieved by treating highly crystalline natural flake graphite with a mixture of sulfuric acid and other oxidizing agents which act to catalyze the sulfate intercalation.
  • expandable graphite examples include HPMS Expandable Graphite (HP Materials Solutions, Inc., Woodland Hills, CA ) and Expandable Graphite Grades 1721 (Asbury Carbons, Asbury, NJ).
  • HPMS Expandable Graphite HP Materials Solutions, Inc., Woodland Hills, CA
  • Expandable Graphite Grades 1721 (Asbury Carbons, Asbury, NJ).
  • Other commercial grades contemplated as useful in the present invention include 1722, 3393, 3577, 3626, and 1722HT (Asbury Carbons, Asbury, NJ).
  • the expandable graphite may be characterized as having a mean or average size in the range from about 30 ⁇ to about 1.5 mm, in other embodiments from about 50 ⁇ to about 1.0 mm, and in other embodiments from about 180 to about 850 ⁇ . In certain embodiments, the expandable graphite may be characterized as having a mean or average size of at least 30 ⁇ , in other embodiments at least 44 ⁇ , in other embodiments at least 180 ⁇ , and in other embodiments at least 300 ⁇ .
  • expandable graphite may be characterized as having a mean or average size of at most 1.5 mm, in other embodiments at most 1.0 mm, in other embodiments at most 850 ⁇ , in other embodiments at most 600 ⁇ , in yet other embodiments at most 500 ⁇ , and in still other embodiments at most 400 ⁇ .
  • Useful expandable graphite includes Graphite Grade #1721 (Asbury Carbons), which has a nominal size of greater than 300 ⁇ .
  • the expandable graphite may be characterized as having a nominal particle size of 20x50 (US sieve). US sieve 20 has an opening equivalent to 0.841 mm and US sieve 50 has an opening equivalent to 0.297 mm. Therefore, a nominal particle size of 20x50 indicates the graphite particles are at least 0.297 mm and at most 0.841 mm.
  • the expandable graphite may be characterized as having a carbon content in the range from about 75% to about 99%. In certain embodiments, the expandable graphite may be characterized as having a carbon content of at least 80%, in other embodiments at least 85%, in other embodiments at least 90%, in yet other embodiments at least 95%, in other embodiments at least 98%, and in still other embodiments at least 99% carbon.
  • the expandable graphite may be characterized as having a sulfur content in the range from about 0% to about 8%, in other embodiments from about 2.6% to about 5.0%, and in other embodiments from about 3.0% to about 3.5%.
  • the expandable graphite may be characterized as having a sulfur content of at least 0%, in other embodiments at least 2.6%, in other embodiments at least 2.9%, in other embodiments at least 3.2%, and in other embodiments 3.5%.
  • the expandable graphite may be characterized as having a sulfur content of at most 8%, in other embodiments at most 5%, in other embodiments at most 3.5%.
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) in the range from about 10:1 to about 500:1, in other embodiments at least 20:1 to about 450:1, in other embodiments at least 30:1 to about 400:1, in other embodiments from about 50:1 to about 350:1.
  • cc/g expansion ratio
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) of at least 10:1, in other embodiments at least 20:1, in other embodiments at least 30:1, in other embodiments at least 40:1, in other embodiments at least 50:1, in other embodiments at least 60:1, in other embodiments at least 90:1, in other embodiments at least 160:1, in other embodiments at least 210:1, in other embodiments at least 220:1, in other embodiments at least 230:1, in other embodiments at least 270:1, in other embodiments at least 290:1, and in yet other embodiments at least 300:1.
  • the expandable graphite may be characterized as having an expansion ratio (cc/g) of at most 350:1, and in yet other embodiments at most 300:1.
  • the expandable graphite as it exists with the thermoplastic component of the thermoplastic membrane of the present invention, may be partially expanded.
  • the expandable graphite is not expanded, however, to a deleterious degree, which includes that amount or more of expansion that will deleteriously impact the ability to form the sheet product and/or the ability of the graphite to serve as flame retardant at desirable levels, which include those levels that allow proper formation of the sheet.
  • the expandable graphite is expanded to at most 60%, in other embodiments at most 50%, in other embodiments at most 40%, in other embodiments at most 30%, in other embodiments at most 20%, and in other embodiments at most 10% beyond its original unexpanded size.
  • the expandable graphite may be characterized as having a pH in the range from about 1 to about 12; in other embodiments from about 1 to about 6; and in yet other embodiments from about 5 to about 10. In certain embodiments, the expandable graphite may be characterized as having a pH in the range from about 4 to about 7. In one or more embodiments, the expandable graphite may be characterized as having a pH of at least 1, in other embodiments at least 4, and in other embodiments at least 5. In certain embodiments, the expandable graphite may be characterized as having a pH of at most 10, in other embodiments at most 7, and in other embodiments at most 6.
  • the expandable graphite may be characterized by an onset temperature ranging from about 100 °C to about 250 °C; in other embodiments from about 160 °C to about 225 °C; and in other embodiments from about 180 °C to about 200 °C. In one or more embodiments, the expandable graphite may be characterized by an onset temperature of at least 100 °C, in other embodiments at least 130 °C, in other embodiments at least 160 °C, and in other embodiments at least 180 °C.
  • the expandable graphite may be characterized by an onset temperature of at most 250 °C, in other embodiments at most 225 °C, and in other embodiments at most 200 °C.
  • Onset temperature may also be interchangeably referred to as expansion temperature; and may also be referred to as the temperature at which expansion of the graphite starts.
  • the expandable graphite may be disposed on the fabric substrate in conjunction with a complementary flame retardant.
  • complementary flame retardants may include any compound that increases the burn resistivity, particularly flame spread such as tested by UL 94 and/ or UL 790, in the polymeric compositions of the present invention.
  • useful flame retardants include those that operate by forming a char-layer across the surface of a specimen when exposed to a flame.
  • Other flame retardants include those that operate by releasing water upon thermal decomposition of the flame retardant compound.
  • Useful flame retardants may also be categorized as halogenated flame retardants or non-halogenated flame retardants.
  • Exemplary non-halogenated flame retardants include magnesium hydroxide, aluminum trihydrate, zinc borate, ammonium polyphosphate, melamine polyphosphate, and antimony oxide (Sb203).
  • Magnesium hydroxide (Mg(OH)2) is commercially available under the tradename VertexTM 60
  • ammonium polyphosphate is commercially available under the tradename ExoliteTM AP 760 (Clarian)
  • melamine polyphosphate is available under the tradename BuditTM 3141 (Budenheim)
  • antimony oxide (Sb203) is commercially available under the tradename FireshieldTM.
  • the complementary flame retardant includes colemanite, which is a borate mineral that is believed to include about 50-80% calcium borate.
  • release member 17 may include a polymeric film or extrudate, or in other embodiments it may include a cellulosic substrate. Where the polymeric film and/or cellulosic substrate cannot be readily removed after being attached to the asphaltic component, the polymeric film and/or cellulosic substrate can carry a coating or layer that allows the polymeric film and/ or cellulosic substrate to be readily removed from the asphaltic component after attachment.
  • This polymeric film or extrudate may include a single polymeric layer or may include two or more polymeric layers laminated or coextruded to one another.
  • Suitable materials for forming a release member that is a polymeric film or extrudate include polypropylene, polyester, high-density polyethylene, medium-density polyethylene, low-density polyethylene, polystyrene or high-impact polystyrene.
  • the coating or layer applied to the film and/or cellulosic substrate may include a silicon- containing or fluorine-containing coating.
  • a silicone oil or polysiloxane may be applied as a coating.
  • hydrocarbon waxes may be applied as a coating.
  • the coating which may be referred to as a release coating, can be applied to both planar surfaces of the film and/or cellulosic substrate.
  • the release coating need only be applied to the planar surface of the film and/or cellulosic substrate that is ultimately removably mated with the asphaltic component.
  • the release member is characterized by a thickness of from about 15 to about 80, in other embodiments from about 18 to about 75, and in other embodiments from about 20 to about 50 ⁇ , or in other embodiments from about 20 to about 70 ⁇ .
  • thermoplastic membrane panels may be formed by the extrusion of thermoplastic compositions into one or more layers that can be laminated into a membrane panel.
  • Thermoset membranes can be formed using known calendering and curing techniques.
  • thermoset membranes can be made by continuous process such as those disclosed in WO 2013/142562, which is incorporated herein by reference.
  • the hot-melt adhesive composition is modified by incorporating expandable graphite into the pre-cured composition.
  • the expandable graphite can be incorporated into the pre-cured pressure- sensitive adhesive compositions by melt blending.
  • the temperature of the pre-cured composition can be heated to its softening point or the temperature at which the composition will flow, which allows the composition to be mechanically mixed.
  • the expandable graphite can be added to the composition either before or after this step of heating, and then mixed into the composition to disperse the expandable graphite into the composition. This can be accomplished by employing conventional mechanical mixing devices.
  • this melt blending can take place at temperatures below the expansion temperature of the expandable graphite.
  • the expandable graphite can be incorporated into the pre-cured pressure-sensitive adhesive composition at temperatures below which deleterious expansion of the expandable graphite takes place.
  • melt blending of the expandable graphite into the pre-cured, pressure-sensitive adhesive composition takes place at temperatures of less than 200, in other embodiments less than 180, in other embodiments less than 160, and in other embodiments less than 150 °C. In one or more embodiments, blending of the expandable graphite into the pre-cured pressure-sensitive adhesive takes place at temperatures of from about 60 to about 200 °C, in other embodiments from about 80 to about 180 °C, and in other embodiments from about 100 to about 160 °C.
  • the expandable graphite is incorporated into the membrane composites of the present invention by first applying the expandable graphite to a planar surface of the membrane. In one or more embodiments, the expandable graphite is applied directly to the planar surface of the membrane.
  • an adhesive (such as the pressure-sensitive adhesive described herein) is first applied to the planar surface of the membrane, and then the expandable graphite is subsequently applied to the surface of the membrane carrying a layer of adhesive.
  • one method for applying may include dropping the expandable graphite onto the planar surface of the membrane.
  • the expandable graphite particles may be dropped at a rate and amount to create at least a partial layer of expandable graphite particles on the surface of the membrane or on the adhesive layer applied to the membrane.
  • the act of dropping the expandable graphite particles onto the membrane may at least partially imbed some of the graphite particles into an adhesive that is pre- applied to the membrane.
  • the expandable graphite particles can be at least temporarily secured to the surface of the membrane through other forces such as static or electromagnetic forces.
  • the step of dropping the expandable graphite onto the surface of the membrane creates a concentration gradient of the expandable graphite on the surface of the membrane.
  • the curable hot-melt adhesive can be extruded onto the membrane by using known apparatus such as adhesive coaters.
  • the adhesive can then subsequently be cured by using, for example, UV radiation.
  • the release film can be applied to the adhesive layer, and the membrane can then be subsequently rolled for storage and/ or shipment.
  • the process can be supplemented with continuous techniques for applying and curing the adhesive coatings according to embodiments of the present invention to thereby prepare usable membrane composites within a single continuous process.
  • a process 30 for preparing a composite membrane according to the present invention generally begins with a step of heating 32, wherein a pressure-sensitive adhesive is heated to a sufficient temperature to allow the adhesive to be applied as a coating within a coating step 34.
  • the adhesive composition may include expandable graphite dispersed therein. In other embodiments, the adhesive composition is devoid of expandable graphite.
  • the adhesive is applied to the membrane to form a coating layer.
  • this step coating step may take place by directly applying the adhesive including the expandable graphite to the surface of the membrane.
  • this coating step 34 is preceded by an expandable graphite applying step 33 wherein expandable graphite particles are applied to the surface of the membrane to form a layer or concentrate region of expandable graphite adjacent to the surface of the membrane.
  • this step of applying expandable graphite may take place by dropping expandable graphite onto the surface of the membrane prior to application of an adhesive.
  • a layer of adhesive material which may include the pre-cured pressure sensitive material described herein, and which adhesive may optionally include expandable graphite, is first applied to the membrane in a first coating step 31.
  • This first coating step 31 may then be followed by step 33 of applying a layer of expandable graphite to the layer of adhesive formed in step 31.
  • coating step 34 applies a layer of curable pressure-sensitive adhesive to cover the layer or partial layer of expandable graphite formed in step 33.
  • the coating is subjected to a UV-curing step 36 where sufficient UV energy is applied to the coating to thereby effect a desirable curing or crosslinking of the adhesive.
  • a release member can be applied to the cured coating in a member application step 38.
  • the composite is wound into a roll at winding step 40.
  • heating step 32 heats the adhesive to a temperature of from about 120 to about 160 °C, in other embodiments from about 125 to about 155 °C, and in other embodiments from about 130 to about 150 °C.
  • the step of applying the curable hot-melt adhesive which may optionally include expandable graphite dispersed therein, takes place at a temperature below the expansion temperature of the expandable graphite. In these or other embodiments, the step of applying the expandable graphite takes place at a temperature below which the expandable graphite is deleteriously expanded.
  • coating step 34 applies an adhesive to the surface of a membrane to form a coating layer of adhesive that has a thickness of at least 2 ⁇ , in other embodiments at least 5 ⁇ , in other embodiments at least 10 ⁇ , in other embodiments at least 20 ⁇ , in other embodiments at least 51 ⁇ (2 mil), in other embodiments at least 102 ⁇ (4 mil), in other embodiments at least 127 ⁇ (5 mil), and in other embodiments at least 152 ⁇ (6 mil).
  • coating step 34 applies an adhesive to the surface of a membrane to form a coating layer of adhesive that has a thickness of from about 51 to about 381 ⁇ (about 2 to about 15 mil), in other embodiments from about 2 to about 381 ⁇ , in other embodiments from about 5 to about 305 ⁇ , in other embodiments from about 10 to about 254 ⁇ , in other embodiments from about 102 to about 305 ⁇ (about 4 to about 12 mil), and in other embodiments from about 127 to about 254 ⁇ (about 5 to about 10 mil).
  • the coating has a uniform thickness such that the thickness of the coating at any given point on the surface of the membrane does not vary by more than 51 ⁇ (2 mil), in other embodiments by more than 38 ⁇ (1.5 mil), and in other embodiments by more than 25 ⁇ (1 mil).
  • this first coating layer may have a thickness of at least 2 ⁇ , in other embodiments at least 5 ⁇ , in other embodiments at least 10 ⁇ , in other embodiments at least 20 ⁇ , in other embodiments at least 51 ⁇ (2 mil), in other embodiments at least 102 ⁇ (4 mil), in other embodiments at least 127 ⁇ (5 mil), and in other embodiments at least 152 ⁇ (6 mil).
  • coating step 31 applies an adhesive to the surface of a membrane to form a first coating layer of adhesive that has a thickness of from about 51 to about 381 ⁇ (about 2 to about 15 mil), in other embodiments from about 2 to about 381 ⁇ , in other embodiments from about 5 to about 305 ⁇ , in other embodiments from about 10 to about 254 ⁇ , in other embodiments from about 102 to about 305 ⁇ (about 4 to about 12 mil), and in other embodiments from about 127 to about 254 ⁇ (about 5 to about 10 mil).
  • the coating has a uniform thickness such that the thickness of the coating at any given point on the surface of the membrane does not vary by more than 51 ⁇ (2 mil), in other embodiments by more than 38 ⁇ (1.5 mil), and in other embodiments by more than 25 ⁇ (1 mil).
  • UV curing step 36 subjects the adhesive coating to a UV dosage of from about 30 to about 380 millijoule/cm ⁇ , in other embodiments from about 35 to about 300 millijoule/cm ⁇ , in other embodiments from about 40 to about 280 millijoule/cm ⁇ , in other embodiments from about 45 to about 240 millijoule/cm2, and in other embodiments from about 48 to about 235 millijoule/cm ⁇ .
  • the required dosage of energy can be exceeded without having a deleterious impact on the adhesives of the present invention. For example, up to ten times, in other embodiments up to five times, and in other embodiments up to three times the required dosage can be applied to the coating composition without having a deleterious impact on the coating composition and/or its use in the present invention.
  • UV curing step 36 subjects the adhesive coating to a UV intensity, which may also be referred to as UV irradiance, of at least 150, in other embodiments at least 200, and in other embodiments at least 250 milliWatts/cm ⁇ .
  • UV curing step 36 subjects the adhesive coating to a UV intensity of from about 150 to about 500 milliWatts/cm ⁇ , in other embodiments from about 200 to about 400 milliWatts/cm ⁇ , and in other embodiments from about 250 to about 350 milliWatts/cm ⁇ .
  • the energy supplied to the coating layer within UV radiation step 36 is in the form of UV-C electromagnetic radiation, which can be characterized by a wave length of from about 250 to about 260 nm.
  • the UV dosage applied during UV curing step 36 is regulated based upon a UV measuring and control system that operates in conjunction with UV curing step 36. According to this system, UV measurements are taken proximate to the surface of the adhesive coating layer using known equipment such as a UV radiometer. The data from these measurements can be automatically inputted into a central processing system that can process the information relative to desired dosage and/or cure states and automatically send signal to various variable-control systems that can manipulate one or more process parameters.
  • the power supplied to the UV lamps and/or the height at which the UV lamps are positioned above the coating layer can be manipulated automatically based upon electronic signal from the central processing unit.
  • the UV intensity, and therefore the UV dosage can be adjusted in real time during the manufacturing process.
  • the step of curing the curable hot-melt adhesive composition takes place at a temperature of less than 200, in other embodiments less than 180, and in other embodiments less than 160 °C. In these or other embodiments, the step of curing takes place at a temperature of from about 20 to about 180, in other embodiments from about 30 to about 160, in other embodiments from about 40 to about 150, in other embodiments from about 30 to about 150, and in other embodiments from about 40 to about 120 °C. In one or more embodiments, the step of curing the curable hot-melt adhesive takes place at a temperature below which the expandable graphite expands. In these or other embodiments, the step of curing takes place at a temperature below which the expandable graphite undergoes deleterious expansion.
  • Continuous process 50 includes a heating step 52 where UV curable hot-melt adhesive 51 is heated to a desired temperature within a heated tank 53.
  • expandable graphite 17' may be blended in the adhesive 51 within tank 53.
  • Adhesive 51, with or without expandable graphite is fed into an extrusion device, such as a coater 55, which may include a pump, such as a gear pump 57, and a slot die 59.
  • coater 55 extrudes adhesive 51, which is in its molten, liquid or flowable state, and deposits a coating layer 61 of adhesive 51 onto a planar surface 63 of membrane 65.
  • coating step 54 can include a roll-coating operation, where adhesive 51 is applied to membrane 65 while membrane 65 is at least partially wound around a coating mandrel 67.
  • preceding coating step 54 an optional step 48 of applying expandable graphite takes place. As indicated above, this step 48 forms a layer of expandable graphite to which the adhesive is subsequently applied.
  • two separate coating steps are positioned in sequence, where first coating step 54 forms a first adhesive layer, and a second coating step 47 forms a second adhesive layer. Between first coating step 54 and second coating step 47, a step 48' of applying expandable graphite applies a layer of expandable graphite onto the first adhesive coating, and then the second coating step 47 applies a layer of adhesive onto the expandable graphite.
  • Membrane 65 carrying coating layer 61 is fed to a crosslinking step 56, where coating layer 61 of adhesive 51 is subjected to a desired dosage of UV radiation 69, which may be supplied by one or more UV lamps 71.
  • UV lamps 71 may include, for example, mercury- type UV lamps or LED UV lamps.
  • the desired dosage of UV energy can be supplied to coating 61 by adjusting the UV intensity and exposure time. The intensity can be manipulated by the power supplied to the respective lamps and the height (H) that the lamps are placed above the surface of coating 61 of adhesive 51. Exposure time can be manipulated based upon the line speed (i.e., the speed at which membrane 65 carrying coating layer 61 is passed through UV curing step 56).
  • release paper 73 may be applied to upper surface 75 of coating layer 61 within release paper application step 58. As shown in Fig. 5, release paper 73 may be supplied from a mandrel 77 and removably mated to upper surface 75 through pressure supplied by nip rolls 79. After application of release paper 73, the composite product may be wound within winding step 60 to provide wound rolls 81 of composite products 83.
  • the layer of crosslinked pressure-sensitive adhesive disposed on a surface of the membrane according to the present invention may be characterized by an advantageous peel strength.
  • the peel strength of the layer of crosslinked pressure-sensitive adhesive disposed on the membranes of the present invention may be characterized by a peel strength, as determined according to Pressure Sensitive Tape Council (PSTC) 101, of at least 3.0, in other embodiments at least 3.5, and in other embodiments at least 4.0.
  • PSTC Pressure Sensitive Tape Council
  • the peel strength may be from about 3.0 to about 25 in other embodiments from about 3.5 to about 20, and in other embodiments from about 4.0 to about 18 psi.
  • the layer of crosslinked pressure-sensitive adhesive disposed on a surface of the membrane according to the present invention may be characterized by an advantageous dead load shear.
  • the dead load shear of the layer of crosslinked pressure-sensitive adhesive disposed on the membranes of the present invention may be characterized by a dead load shear, as determined according to PSTC 107, of at least 0.5 hour (time of failure), in other embodiments at least 1.0 hour, and in other embodiments at least 1.5. In these or other embodiments, the dead load shear may be from about 2.0 to about 2.5 hours.
  • the membrane composites of the present invention can advantageously be applied to a roof surface (also known as roof substrate) by using standard peel and stick techniques.
  • the membrane can be unrolled on a roof surface and placed into position. Portions of the membrane are then typically folded back and portions of the release member are removed.
  • the membrane can then subsequently be adhered to the roof surface by using various techniques including the use of rollers and the like to mate the adhesive to the substrate.
  • the seams can be secured by using conventional techniques.
  • thermoplastic membranes can be wielded together at the seam.
  • thermoset membranes either liquid adhesives or tapes can be used to form a seam.
  • the pressure-sensitive adhesive layer employed in the membranes of the present invention allows the membranes to be adhered to a variety of roofing surfaces. These include, but are not limited to, wood decks, concrete decks, steel decks, faced construction boards, and existing membrane surfaces.
  • the membranes of the present invention are adhered, through the cured adhesive layer disclosed herein, to a faced construction board such as, but not limited to, polyisocyanurate insulation boards or cover boards that include facers prepared from polar materials.
  • the adhesives of the present invention provide advantageous adhesion to facers that contain cellulosic materials and/or glass materials.
  • embodiments of the present invention are directed toward a roof deck including a construction board having a cellulosic or glass facer and a membrane secured to the construction board through an at least partially cured polyacrylate adhesive layer in contact with a glass or cellulosic facer of the construction board.

Landscapes

  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne une membrane composite comprenant un panneau formant membrane polymère, une couche adhésive, ladite couche adhésive étant un adhésif sensible à la pression durci au moins en partie, du graphite expansé et un élément de libération
PCT/US2016/017285 2015-02-10 2016-02-10 Membranes de toiture à peler et coller dotées d'adhésifs sensibles à la pression et de graphite expansé WO2016130636A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201562114140P 2015-02-10 2015-02-10
US62/114,140 2015-02-10

Publications (1)

Publication Number Publication Date
WO2016130636A1 true WO2016130636A1 (fr) 2016-08-18

Family

ID=55745797

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2016/017285 WO2016130636A1 (fr) 2015-02-10 2016-02-10 Membranes de toiture à peler et coller dotées d'adhésifs sensibles à la pression et de graphite expansé

Country Status (1)

Country Link
WO (1) WO2016130636A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017049280A1 (fr) * 2015-09-18 2017-03-23 Firestone Building Products Co., LLC Procédé pour préparer des articles de construction avec des adhésifs sensibles à la pression durcis
WO2018127698A1 (fr) * 2017-01-09 2018-07-12 Trade Fabrication Systems Ltd Procédé de fabrication d'un panneau de construction protégé
US20220411669A1 (en) * 2019-09-13 2022-12-29 Firestone Building Products Company, Llc Fully-adhered roofing systems utilizing a primer having a silicon-terminated polymer
US11624189B2 (en) 2016-03-25 2023-04-11 Holcim Technology Ltd Fully-adhered roof system adhered and seamed with a common adhesive

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040191508A1 (en) 2003-02-11 2004-09-30 Hubbard Michael J. Peel-and-stick installation method for thermoplastic-type covering systems
US20140013693A1 (en) * 2012-07-12 2014-01-16 Firestone Building Products Co., LLC Asphaltic sheet materials including expandable graphite
US20140141672A1 (en) * 2012-11-16 2014-05-22 Firestone Building Products Co., LLC Thermoplastic membranes containing expandable graphite
US20140373467A1 (en) * 2011-12-29 2014-12-25 Firestone Building Products Co, Llc Roofing membranes with expandable graphite as flame retardant
US20160002929A1 (en) * 2014-07-03 2016-01-07 Firestone Building Products Co, Llc Epdm roofing membranes with expandable graphite as flame retardant

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20040191508A1 (en) 2003-02-11 2004-09-30 Hubbard Michael J. Peel-and-stick installation method for thermoplastic-type covering systems
US20140373467A1 (en) * 2011-12-29 2014-12-25 Firestone Building Products Co, Llc Roofing membranes with expandable graphite as flame retardant
US20140013693A1 (en) * 2012-07-12 2014-01-16 Firestone Building Products Co., LLC Asphaltic sheet materials including expandable graphite
US20140141672A1 (en) * 2012-11-16 2014-05-22 Firestone Building Products Co., LLC Thermoplastic membranes containing expandable graphite
US20160002929A1 (en) * 2014-07-03 2016-01-07 Firestone Building Products Co, Llc Epdm roofing membranes with expandable graphite as flame retardant

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2017049280A1 (fr) * 2015-09-18 2017-03-23 Firestone Building Products Co., LLC Procédé pour préparer des articles de construction avec des adhésifs sensibles à la pression durcis
US10688730B2 (en) 2015-09-18 2020-06-23 Firestone Building Products Company, Llc Process for preparing construction articles with cured pressure-sensitive adhesives
US11400658B2 (en) 2015-09-18 2022-08-02 Holcim Technology Ltd Process for preparing construction articles with cured pressure-sensitive adhesives
US11787124B2 (en) 2015-09-18 2023-10-17 Holcim Technology Ltd Process for preparing construction articles with cured pressure-sensitive adhesives
US11624189B2 (en) 2016-03-25 2023-04-11 Holcim Technology Ltd Fully-adhered roof system adhered and seamed with a common adhesive
WO2018127698A1 (fr) * 2017-01-09 2018-07-12 Trade Fabrication Systems Ltd Procédé de fabrication d'un panneau de construction protégé
US20220411669A1 (en) * 2019-09-13 2022-12-29 Firestone Building Products Company, Llc Fully-adhered roofing systems utilizing a primer having a silicon-terminated polymer

Similar Documents

Publication Publication Date Title
US10519663B2 (en) Peel and stick roofing membranes with cured pressure-sensitive adhesives
US11624189B2 (en) Fully-adhered roof system adhered and seamed with a common adhesive
US20200324511A1 (en) Construction boards having a pressure-sensitive adhesive layer
US20240060306A1 (en) Fabric-backed roofing membrane composite
US20230272619A1 (en) Method of reroofing
US11400658B2 (en) Process for preparing construction articles with cured pressure-sensitive adhesives
WO2016130636A1 (fr) Membranes de toiture à peler et coller dotées d'adhésifs sensibles à la pression et de graphite expansé
WO2024102281A1 (fr) Membranes de toiture comprenant un adhésif durci thermiquement

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 16715924

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 16715924

Country of ref document: EP

Kind code of ref document: A1