CONSTRUCTION BOARDS HAVING A PRESSURE-SENSITIVE ADHESIVE LAYER
A construction board comprising a foam layer, an pressure-sensitive adhesive layer that is at least partially cured, and a release liner.
1 . A construction board comprising:
(a) a foam layer;
(b) an pressure-sensitive adhesive layer that is at least partially cured; and
(c) a release liner.
2 . The construction board of claim 1 , wherein said foam layer comprises a polyurethane, phenolic or polyisocyanurate cellular structure.
3 . The construction board of claim 1 , wherein said adhesive layer is an silane terminated hot melt pressure sensitive adhesive or acrylic-based hot-melt pressure sensitive adhesive.
4 . The construction board of claim 1 , wherein said adhesive layer includes a UV-cured acrylic pressure sensitive adhesive.
5 . The construction board of claim 1 , wherein said adhesive layer has a thickness of from about 51 to about 381 μm.
6 . The construction board of claim 1 , wherein said foam layer includes a density of less than 2.5 pounds per cubic foot and an ISO index of at least 120.
7 . The construction board of claim 1 , wherein said foam layer includes a density greater than 2.5 pounds per cubic foot and an ISO index of at least 270.
8 . The construction board of claim 1 , where the construction board includes a facer disposed on said foam layer, and said adhesive layer is disposed on said facer.
9 . The construction board of claim 1 , wherein the release liner is a polymeric film or a polymeric-coated paper.
10 . The construction board of claim 1 , where the adhesive layer has a Tg of less than 0° C.
11 . A method for forming a construction board having an at least partially cured, pressure-sensitive adhesive, the method comprising:
(a) extruding a curable hot-melt adhesive onto a facer;
(b) at least partially curing said adhesive using UV radiation;
(c) applying a release film to said adhesive layer; and
(d) mating the facer to a foam or rising foam.
12 . The method of any of claim 11 , where the curable hot-melt adhesive is a silane-terminated hot-melt pressure-sensitive adhesive or an acrylic-based hot-melt pressure-sensitive adhesive.
13 . The method of claim 11 , where said step of extruding applies an adhesive layer having a thickness of from about 51 to about 381 μm.
14 . The method of claim 11 , where said foam has a density of less than 2.5 pounds per cubic foot and an ISO index of at least 120.
15 . The method of claim 11 , where the foam has a density that is greater than 2.5 pounds per cubic foot and an ISO index of at least 270.
16 . The method of claim 11 , where the adhesive has a Tg of less than 0° C.
17 . A roof system comprising:
(a) a roof deck;
(b) an insulation board or cover board over said roof deck; and
(c) a membrane over said insulation board or cover board, where said insulation board or cover board is fully secured to an underlying substrate through an at least partially-cured pressure-sensitive adhesive.