PEEL-AND-STICK ROOFING MEMBRANES AND METHODS FOR FORMING FULLY-ADHERED ROOFING SYSTEMS

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.