Peel-and-stick roofing membranes and methods for forming fully-adhered roofing systems

Abstract

A method of installing a roof system, the method comprising (i) providing a first membrane composite including a polymeric planar body having first and second planar surfaces, a UV-cured pressure-sensitive adhesive layer disposed on the second planar surface, a release member removably secured to the pressure-sensitive adhesive layer opposite the planar body; and a primer layer disposed along a lap area on the first planar surface; (ii) adhesively securing the first membrane composite to a roof surface through the UV-cured pressure-sensitive adhesive layer; (iii) providing a second membrane composite including a polymeric planar body having first and second planar surfaces, a UV-cured pressure-sensitive adhesive layer disposed on the second planar surface, a release member removably secured to the pressure-sensitive adhesive layer opposite the planar body; and optionally including a primer layer disposed along a lap area on the first planar surface; (iv) adhesively securing the second membrane composite to the roof surface through the UV-cured pressure-sensitive adhesive layer, where the second membrane composite is positioned adjacent to and partially overlapping the lap area of the first membrane composite; and (v) adhesively securing the second membrane composite to the first planar surface of the first membrane composite along the primer layer through the UV-cured pressure-sensitive adhesive layer disposed on the second membrane composite.

What is claimed is: 
     
         1 . A method of installing a roof system, the method comprising:
 (i) providing a first membrane composite including a polymeric planar body having first and second planar surfaces, a UV-cured pressure-sensitive adhesive layer disposed on the second planar surface, a release member removably secured to the pressure-sensitive adhesive layer opposite the planar body; and a primer layer disposed along a lap area on the first planar surface;   (ii) adhesively securing the first membrane composite to a roof surface through the UV-cured pressure-sensitive adhesive layer;   (iii) providing a second membrane composite including a polymeric planar body having first and second planar surfaces, a UV-cured pressure-sensitive adhesive layer disposed on the second planar surface, a release member removably secured to the pressure-sensitive adhesive layer opposite the planar body; and optionally including a primer layer disposed along a lap area on the first planar surface;   (iv) adhesively securing the second membrane composite to the roof surface through the UV-cured pressure-sensitive adhesive layer, where the second membrane composite is positioned adjacent to and partially overlapping the lap area of the first membrane composite; and   (v) adhesively securing the second membrane composite to the first planar surface of the first membrane composite along the primer layer through the UV-cured pressure-sensitive adhesive layer disposed on the second membrane composite.   
     
     
         2 . The method of  claim 1 , further comprising removing a release member that is removably secured to the pre-applied primer layer. 
     
     
         3 . The method of  claim 1 , wherein the lap area extends along a lateral edge of the roofing membrane. 
     
     
         4 . The method of  claim 1 , wherein the primer layer includes a primer composition including polyvinylacrylates, polyvinylmethacrylates, polyisoprene, polyisobutylenes, polystyrene-methacrylate copolymer, polystyrene-acrylate copolymer, polyvinylchloride, polyvinylidenedichloride, polyvinylidenedichloride-ethylene copolymer, polyvinylchloride-ethylene copolymer, polyvinylacetate, polyvinylacetate-ethylene copolymer, polystyrene, polystyrene-ethylene copolymer, polystyrene-isoprene copolymer, polystyrene-butylene copolymer, or polystyrene-butadiene copolymer. 
     
     
         5 . The method of  claim 1 , wherein the primer layer includes a copolymer of esters of methacrylic acid and acrylic acid or combinations thereof. 
     
     
         6 . The method of  claim 1 , wherein the primer layer derives from a solvent-based primer composition, and wherein the solvent-based primer composition includes from 2 to weight percent of a solvent selected from the group consisting of acetone, butyl acetate, and combinations thereof. 
     
     
         7 . The method of  claim 1 , where the pressure-sensitive adhesive layer includes a UV-cured acrylic resin. 
     
     
         8 . The method of  claim 1 , where the polymeric membrane is a thermoplastic membrane. 
     
     
         9 . The method of  claim 1 , where the polymeric membrane is a cured rubber membrane. 
     
     
         10 . The method of  claim 1 , where the pressure-sensitive adhesive layer has a thickness of from about 102 to about 381 μm and a Tg of less than 0° C. 
     
     
         11 . The method of  claim 1 , where the pressure-sensitive adhesive includes one or more units deriving from butyl acrylate or 2-ethylhexyl acrylate. 
     
     
         12 . The method of  claim 1 , where said step of providing a second membrane composite includes providing a second membrane composite in the form of a roll, and where the process includes unrolling the second membrane composite. 
     
     
         13 . A membrane composite comprising:
 (i) a polymeric membrane panel having a first planar surface and a second planar surface;   (ii) a pressure-sensitive adhesive layer disposed on said second planar surface;   (iii) a release member removably secured to said pressure-sensitive adhesive layer; and   (iv) a primer layer applied along a lap area on said second planar surface.   
     
     
         14 . The membrane composite of  claim 13 , further including a release member removably secured to said primer layer. 
     
     
         15 . The membrane composite of  claim 13 , where said membrane composite is in the form of a roll. 
     
     
         16 . A process for forming a membrane composite, the process comprising:
 (i) heating a melt-extrudable, UV-curable pressure-sensitive adhesive to allow the adhesive to flow;   (ii) applying the adhesive to a second planar surface of a membrane panel to form a coating of adhesive;   (iii) subjecting the coating of the adhesive to UV radiation to thereby effect crosslinking of the adhesive;   (iv) applying a release member to the adhesive coating;   (v) applying a primer composition along a lap area of a first planar surface of the membrane panel;   (vi) allowing the primer composition to dry to form a pre-applied primer layer to form a composite; and   (vii) winding the composite.   
     
     
         17 . The process of  claim 16 , where said step of providing a first membrane composite includes providing a first membrane composite in the form of a roll, and where the process includes unrolling the first membrane composite.