Composite roof structures prepared using one-part moisture curing polyurethane foaming adhesive compositions containing a reversibly blocked catalyst

Abstract

The present invention relates to composite roof structures and their preparation. The composite roof structure is prepared by applying a one-part, moisture curable, foaming, polyurethane adhesive composition to the roof deck, placing the roofing material in contact with the adhesive composition, and allowing the adhesive mixture to foam, fill, and cure. If multiple layer of the roofing material are used to form the composite roof structure, then the above procedure may be used to adhere each of the roofing material layers.

1. A method of adhering roofing material to a roof deck, comprising;
 A. applying a one-part, moisture curable, foaming, polyurethane adhesive composition, consisting essentially of; 
 i. an isocyanate terminated prepolymer prepared from at least one organic polyisocyanate and at least one composition containing at least two isocyanate reactive moieties, and  
 ii. a reversibly blocked catalyst, consisting essentially of; the addition product of a sulfonyl isocyanate and a tertiary amine and/or a tin (II) or tin (IV) carboxylate composition; to a roof deck;  
 
 B. positioning the roofing material on the deck with sufficient pressure to seat the roofing material in the polyurethane adhesive composition; and  
 C. allowing the polyurethane composition to foam, fill and cure.  
 
     
     
       2. The method of adhering roofing material as claimed in  claim 1 , where prior to applying the polyurethane adhesive composition to the roof deck, the roof deck is misted with water. 
     
     
       3. The method of adhering roofing material as claimed in  claim 1 , where prior to applying the polyurethane adhesive composition to the roof deck, the roof deck is misted with an acidic, aqueous solution. 
     
     
       4. The method of adhering roofing material as claimed in  claim 1 , where the organic polyisocyanate is diphenylmethane diisocyanate. 
     
     
       5. The method of adhering roofing material as claimed in  claim 1 , where the composition containing at least two isocyanate reactive moieties is a polyether polyol free of nitrogen. 
     
     
       6. The method of adhering roofing material as claimed in  claim 1 , where the reversibly blocked catalyst is the reaction product of a sulfonyl isocyanate, a tertiary amine, and a tin(II) or tin(IV) carboxylate composition. 
     
     
       7. A method of adhering roofing material to a roof deck comprising:
   applying to said roof deck a one part moisture curable foaming polyurethane adhesive composition consisting essentially of:        an isocyanic terminated pre - polymer prepared from at least one organic polyisocyanate and at least one composition containing at least two isocyanate reactive moieties; and        a reversibly blocked catalyst consisting essentially of the addition product of a sulfonyl isocyanate and at least one of the group consisting of a tertiary amine, a tin  ( II )  structural unit and a tin  ( IV )  structural unit;        positioning roofing material on the deck with sufficient pressure to seat the roofing material in the polyurethane adhesive composition; and        allowing the polyurethane composition to foam, fill and cure.     
     
     
       8. The method of adhering roofing materials claimed in  claim 7  wherein prior to applying the polyurethane adhesive composition to the roof deck, the roof deck is misted with water. 
     
     
       9. The method of adhering the roofing materials claimed in  claim 7  wherein prior to applying the polyurethane adhesive composition to the roof deck the roof deck is misted with an acidic aqueous solution. 
     
     
       10. The method of adhering the roofing material as claimed in  claim 7  wherein the organic polyisocyanate is diphenyl- methane diisocyanate.   
     
     
       11. The method of adhering roofing materials claimed in  claim 7  wherein a composition containing at least two isocyanate moieties is a polyetherpolyol free of nitrogen. 
     
     
       12. The method claimed in  claim 7  wherein said reversibly blocked catalyst consists essentially of the addition product of a sulfonyl isocyanate and at least two of the group consisting of a tertiary amine, a tin ( II )  structural unit and a tin  ( IV )  structural unit.   
     
     
       13. The method claimed in  claim 7  wherein said reversibly blocked catalyst consists essentially of the addition product of a sulfonyl isocyanate and a tertiary amine and a tin ( II )  structural unit and a tin  ( IV )  structural unit.