Method for constructing a roof system using adhesive transfer films adhering construction components

Abstract

A method for constructing a roof system, the method comprising (i) applying an adhesive transfer film composite to a roof substrate, where the adhesive transfer film composite includes an adhesive body having first and second planar surfaces and a release member removably attached to the second planar surface of the adhesive body, where the adhesive body is devoid of a carrier layer, and where the adhesive body includes a crosslinked network of acrylate-based polymers, whereby said step of applying secures the first planar surface of the adhesive body to the roof substrate; (ii) removing the release member to thereby expose the second planar surface of the adhesive body; and (iii) applying a construction element to the second planar surface of the adhesive body to thereby adhere the construction element to the substrate.

1 . A method for constructing a roof system, the method comprising:
 (i) applying an adhesive transfer film composite to a roof substrate, where the adhesive transfer film composite includes an adhesive body having first and second planar surfaces and a release member removably attached to the second planar surface of the adhesive body, where the adhesive body is devoid of a carrier layer, and where the adhesive body includes a crosslinked network of acrylate-based polymers, whereby said step of applying secures the first planar surface of the adhesive body to the roof substrate;   (ii) removing the release member to thereby expose the second planar surface of the adhesive body; and   (iii) applying a construction element to the second planar surface of the adhesive body to thereby adhere the construction element to the substrate.   
     
     
         2 . The method of  claim 1 , where said step of applying an adhesive transfer film composite includes providing the adhesive transfer film composite in the form of a roll, unrolling the roll of adhesive transfer film composite, and mating the first planar surface of the adhesive body to the substrate. 
     
     
         3 . The method of  claim 1 , where the substrate is selected from the group consisting of a roof deck, an insulation board, a coverboard, and an existing membrane. 
     
     
         4 . The method of  claim 1 , where the substrate is a first layer of construction boards. 
     
     
         5 . The method of  claim 4 , where the first layer of construction boards is mechanically fastened into place. 
     
     
         6 . The method of  claim 1 , where the construction element is selected from the group consisting of a coverboard, an insulation board, and a membrane panel. 
     
     
         7 . The method of  claim 1 , where the substrate is a roof deck and the roof deck is selected from the group consisting of a concrete deck, a corrugated metal deck, and a wood deck. 
     
     
         8 . The method of  claim 1 , where the adhesive body includes a UV-cured polyacrylate adhesive, and where the adhesive body is characterized by a degree of cure where less than 5% of the adhesive body is soluble in xylene at 25° C. after 24 hours. 
     
     
         9 . (canceled) 
     
     
         10 . The method of  claim 1 , where the adhesive body has a thickness of from about 25 μm to about 2,000 μm, and where the adhesive body is compositionally homogeneous. 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . The method of  claim 1 , where said adhesive body is UV-cured by subjecting the first planar surface of the body to UV radiation, and where the cure characteristics of the first planar surface of the adhesive body are distinct from the cure characteristics of the second planar surface of the adhesive body. 
     
     
         14 . (canceled) 
     
     
         15 . The method of  claim 1 , where the adhesive body is foamed. 
     
     
         16 . A process of constructing a roof system, the process comprising:
 (i) providing a roof system including a first layer of insulation boards mechanically secured to a roof deck, said first layer of insulation boards including an exposed surface;   (ii) applying a transfer film composite to a portion of the exposed surface of the first layer of insulation boards, where the transfer film composite includes an adhesive body having first and second planar surfaces and an optional release member removably attached to the second planar surface of the adhesive body, where said step of applying includes mating the first planar surface of the adhesive body to a portion of the exposed surface of the layer of insulation boards;   (iii) optionally removing the optional release member to thereby expose the second planar surface of the adhesive body; and   (iv) applying a construction board to the second planar surface of the adhesive body to thereby adhere the construction board to a portion of the layer of construction boards.   
     
     
         17 . The process of  claim 16 , wherein said step of applying a construction board to the second planar surface of the adhesive body forms a second layer of construction boards having an upper planar surface, the process further comprising:
 (v) applying a transfer film composite to a portion of the second layer of construction boards having an upper planar surface, where the transfer film composite includes an adhesive body having first and second planar surfaces and an optional release member removably attached to the second planar surface of the adhesive body, where the transfer film composite is devoid of a carrier layer, where said step of applying includes mating the first planar surface of the adhesive body to a portion of the second layer of construction boards having an upper planar surface;   (vi) optionally removing the optional release member to thereby expose the second planar surface of the adhesive body; and   (vii) applying a construction board to the second planar surface of the adhesive body to thereby adhere the construction board to a portion of the second layer of construction boards, and thereby form a third layer of construction boards.   
     
     
         18 . The process of  claim 17 , further comprising the step of applying a membrane system over said second layer of construction boards or said third layer of construction boards. 
     
     
         19 . The process of  claim 16 , where said step of applying a transfer film includes providing the adhesive transfer film composite in the form of a roll, unrolling the roll of adhesive transfer film composite, and mating the first planar surface of the adhesive planar body to the substrate. 
     
     
         20 . The process of  claim 17 , where the construction board employed to make the third layer of construction boards is a coverboard. 
     
     
         21 . The process of  claim 17 , where the construction board employed to make the second layer of construction boards is an insulation board. 
     
     
         22 . The process of  claim 17 , where the construction board employed to make the second layer of construction boards is a coverboard. 
     
     
         23 . The process of  claim 16 , where the adhesive body includes a UV-cured polyacrylate adhesive, and where the adhesive body is characterized by a degree of cure where less than 5% of the adhesive body is soluble in xylene at 25° C. after 24 hours. 
     
     
         24 . (canceled) 
     
     
         25 . The process of  claim 16 , where the adhesive body has a thickness of from about 25 μm to about 890 μm, and where the adhesive body is compositionally homogeneous. 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . The process of  claim 16 , where said adhesive body is UV-cured by subjecting the first planar surface of the body to UV radiation. 
     
     
         29 . The process of  claim 16 , where the cure characteristics of the first planar surface of the adhesive body are distinct from the cure characteristics of the second planar surface of the adhesive body. 
     
     
         30 . The process of  claim 16 , where the adhesive body is foamed.