Method for constructing a roofing system using an adhesive transfer film for adhering building components

Abstract

1. A method of constructing a roofing system comprising: (i) applying an adhesive transfer film composite to a roofing substrate, the adhesive transfer film composite comprising an adhesive body having a first planar surface and a second planar surface, and a release member removably attached to the second planar surface of the adhesive body, the adhesive body having no carrier layer, the adhesive body comprising a crosslinked network of an acrylate-based polymer, the applying step securing the first planar surface of the adhesive body to the roofing substrate; (ii) removing the release member, thereby exposing the second planar surface of the adhesive body; and (iii) applying a building element to the second planar surface of the adhesive body, thereby adhering the building element to the substrate.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 306,699, filed February 4, 2022, which is incorporated by reference in its entirety.

[0002] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention provides an adhesive transfer film and its use in bonding building components. Certain embodiments relate to a method of constructing a roofing system that includes using the transfer film to bond one or more layers of building boards, such as insulation boards, in the roofing system. [Background technology]

[0003] Pressure sensitive adhesives have been used in the construction industry. For example, in the construction of low slope or flat roofs, polymeric single ply membranes have been used that include a layer of pressure sensitive adhesive. The pressure sensitive adhesive is used to secure the membrane to the sub-surface. The membrane provides the weatherproof layer of the roofing system. These composite membranes are advantageously installed by the so-called "peel-and-stick" method. Using the peel-and-stick method, many advantages are realized, including reduced installation time and labor, and the ability to form an adhesive system without the use of significant volatile organic compounds.

[0004] Additionally, constructing a membrane bearing a pressure-sensitive adhesive is relatively straightforward, since efficient techniques are available for applying pressure-sensitive adhesives to membranes in a factory environment, for example, the pressure-sensitive adhesive can be efficiently applied to the surface of the membrane as a hot melt composition using relatively common coating techniques.

[0005] Those skilled in the art will appreciate that many flat or low slope roof systems also include one or more layers of building boards disposed between the roof deck and the membrane. In many situations, this may include a multi-layer assembly including, for example, two or more layers of insulation board and a layer of cover board to protect the insulation board layers. The insulation boards, often referred to as board stock, may include polyisocyanurate foam, often ranging in thickness from about 2 inches to about 4 inches. These boards also typically carry opposing facers that sandwich the foam. In multi-layer roof systems, the bottom insulation layer is often mechanically fastened to the roof deck, and subsequent layers, including cover board layers, may be advantageously adhered using, for example, a low-rise foam adhesive.

[0006] Where it is desired to glue building boards in place, low foaming adhesives are commonly used, but it has also been proposed to apply a pressure-sensitive adhesive to the facers of the boards at the factory. In other words, building boards, as well as membranes carrying a pressure-sensitive adhesive layer, can be installed using a peel-and-stick installation method. However, building boards carrying a pressure-sensitive adhesive layer have several disadvantages. First, it is difficult to apply the pressure-sensitive adhesive before, for example, the construction of the foam core. In other words, attempts to apply the pressure-sensitive adhesive to the facers before bonding the facers to the foam have proven difficult due to the heat involved in the foaming process. Also, the presence of the pressure-sensitive adhesive can cause failure in the finishing of the board, including cutting and trimming the board to the desired size. As a result, building boards carrying a factory-applied pressure-sensitive adhesive layer are often constructed by applying the pressure-sensitive adhesive layer after the board is constructed, which requires a rather time-consuming process. Summary of the Invention

[0007] One or more embodiments of the present invention provide a method of constructing a roofing system comprising the steps of: (i) applying an adhesive transfer film composite to a roofing substrate, the adhesive transfer film composite comprising an adhesive body having a first planar surface and a second planar surface and a release member removably attached to the second planar surface of the adhesive body, the adhesive body being free of a carrier layer, the adhesive body comprising a crosslinked network of an acrylate-based polymer, the applying step securing the first planar surface of the adhesive body to the roofing substrate; (ii) removing the release member, thereby exposing the second planar surface of the adhesive body; and (iii) applying a building element to the second planar surface of the adhesive body, thereby adhering the building element to the substrate.

[0008] Yet another embodiment of the present invention provides a process for constructing a roofing system, the process comprising: (i) preparing a roofing system comprising a first layer of insulation board mechanically secured to a roof deck, the first layer of insulation board comprising an exposed surface; (ii) applying a transfer film composite to a portion of the exposed surface of the first layer of insulation board, the transfer film composite comprising an adhesive body having a first planar surface and a second planar surface and an optional release member removably attached to the second planar surface of the adhesive body, the applying step comprising bonding the first planar surface of the adhesive body to a portion of the exposed surface of the layer of insulation board; (iii) optionally removing the optional release member, thereby exposing the second planar surface of the adhesive body; and (iv) applying a building board to the second planar surface of the adhesive body, thereby adhering the building board to the portion of the layer of building board. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a perspective view of an adhesive composite for use in the present invention. [Diagram 2] FIG. 1 is a perspective view of an adhesive composite for use in the present invention. [Diagram 3] 1 is a flow chart outlining a process in accordance with the present invention; [Figure 4] FIG. 1 is a cross-sectional view of a roof system constructed in accordance with an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present invention is based, at least in part, on the discovery of an adhesive transfer film and its use in the construction of buildings, particularly in the construction of roofing systems for flat or low-slope roofs. The adhesive transfer film comprises a layer of pressure-sensitive adhesive. Although the prior art contemplates adhesive tapes that include a substrate, sometimes referred to as a backing layer or carrier layer, used in the construction industry, it has been unexpectedly discovered that the adhesive film of the present invention, which does not include a substrate, i.e., a backing layer, provides technical advantages, particularly in the fastening of building elements to roof surfaces. Without wishing to be bound by any particular theory, it is believed that the absence of a combination of a backing layer and an adhesive composition provides an advantage over the prior art. As a result, the present invention also provides a method of installing building elements, such as elements of a roofing system, using the adhesive transfer film of the present invention. Furthermore, the present invention relates to the discovery that the adhesive transfer film of the present invention is useful for fastening building boards to a roof deck or sub-layer of a roofing system. Although the prior art contemplates the use of building boards having a factory-applied pressure-sensitive adhesive layer, the use of a transfer film during on-site construction of the roof system overcomes the disadvantages associated with the use of building boards bearing a factory-applied pressure-sensitive adhesive layer.

[0011] Transfer Film Composite As mentioned above, an adhesive transfer film is used in the practice of the present invention. In one or more embodiments, the adhesive transfer film comprises an adhesive body that may be provided in a composite comprising an adhesive body and a release member. In this regard, reference may be made to FIG. 1, which shows a composite 11 comprising an adhesive body 13 and a release member 23. The adhesive body 13 may generally be in the form of a sheet comprising a first planar surface 15 and an opposing second planar surface 17. The release member 23 comprises a first contact surface 25 and an opposing second surface 27. The first contact surface 25 of the release member 23 is removably attached to the second planar surface 17 of the adhesive body 13. In one or more embodiments, the release member 23 contacts at least substantially all of the second planar surface 17 of the adhesive body 13 via the contact surface 25.

[0012] In one or more embodiments, the composite is provided in the form of a roll at the installation location (e.g., at the roof site). Those skilled in the art will appreciate that for a roll to be useful, it must be possible to unroll it and place it in place within the roof system. Thus, the nature of the release member is important. For example, as shown in FIG. 1, when the composite comprises a single release member, both sides of the release member are adapted to be peeled from the adhesive body. In other words, as will be appreciated by those skilled in the art, in order to roll up the composite 11, the first planar surface 15 of the adhesive body 13 contacts the top surface 27 of the release member 23 during rolling up.

[0013] In other embodiments, the composite comprises two opposing release members. In this regard, see FIG. 2, which illustrates a composite 11′ comprising an adhesive body 13, a first release member 23, and a second release member 33. The first release member 23 includes a contact surface 25 and a facing surface 27. The second release member 33 includes a contact surface 37 and a facing surface 35. The contact surface 25 of the release member 23 is removably attached to the first side 17 of the adhesive body 13. Similarly, the contact surface 37 of the release member 33 is removably attached to the first side 15 of the adhesive body 13.

[0014] Adhesive Body In one or more embodiments, the adhesive body 13, sometimes referred to as adhesive layer 13, comprises a pressure sensitive adhesive. In one or more embodiments, the adhesive body is substantially a pressure sensitive adhesive, for example, the adhesive body may comprise a uniform (or substantially uniform) mass of pressure sensitive adhesive. Reference may also be made to a 100% adhesive body. In one or more embodiments, the adhesive body does not have a backing substrate, such as a woven backing, that typically serves as a substrate or carrier layer in many tapes.

[0015] In terms of composition, the adhesive body may include a single chemical component, or in other embodiments, the adhesive body may be a mixture of chemical components that act together to form a pressure sensitive adhesive.

[0016] In one or more embodiments, the adhesive body includes, as a major polymeric component, a rubber, such as ethylene-propylene-diene rubber, ethylene-propylene rubber, polychloroprene, and / or butyl rubber. Exemplary rubber-based pressure-sensitive adhesive compositions are disclosed in U.S. Patent Nos. 9,296,927, 9,068,038, 8,347,932, and 5,859,114, which are incorporated herein by reference.

[0017] In another embodiment, the adhesive body comprises a hot melt pressure sensitive adhesive composition. Exemplary hot melt pressure sensitive adhesive compositions that can be used in the practice of the present invention include compositions based on acrylic polymers, butyl rubber, ethylene vinyl acetate, natural rubber, nitrile rubber, silicone rubber, styrene block copolymers, ethylene-propylene-diene rubber, atactic polyalphaolefins and / or vinyl ether polymers. In combination with these base polymers, the pressure sensitive adhesive compositions can include various supplemental components, such as, but not limited to, tackifying resins, waxes, antioxidants and plasticizers. Pressure sensitive adhesives useful in the practice of the present invention are known in the art, for example, as described in U.S. Pat. No. 8,968,853, which is incorporated herein by reference.

[0018] In certain embodiments, the adhesive body is a cured hot melt pressure sensitive adhesive. Cured pressure sensitive adhesives useful in the practice of the present invention are known in the art, for example, as described in WO 2015 / 042258, which is incorporated herein by reference.

[0019] In one or more embodiments, the curable hot melt adhesive that can be used to form the cured pressure sensitive adhesive layer can be an acrylic hot melt adhesive. In one or more embodiments, the acrylic hot melt adhesive is a polyacrylate, sometimes referred to as an acrylate-based polymer or polyacrylate elastomer. In one or more embodiments, the acrylic hot melt adhesive can include two or more chemically distinct polyacrylates. In one or more embodiments, a useful polyacrylate can be represented by the formula: [ka] (In the formula, each R 1 are individually hydrogen or a hydrocarbyl group, and each R 2 In the case of a homopolymer, each R 1 and R 2 are the same for each unit. In the case of copolymers, there are at least two different R 1 and / or two different R 2 is present in the polymer chain.

[0020] In one or more embodiments, hydrocarbyl groups include, for example, alkyl, cycloalkyl, substituted cycloalkyl, alkenyl, cycloalkenyl, substituted cycloalkenyl, aryl, substituted aryl, aralkyl, alkaryl, aryl, and alkynyl groups, each of which contains from 1 carbon atom, the minimum number of carbon atoms suitable for forming the group, up to about 20 carbon atoms. These hydrocarbyl groups may contain heteroatoms, including, but not limited to, nitrogen, oxygen, boron, silicon, sulfur, and phosphorus atoms. In certain embodiments, each R 2 is an alkyl group having at least 4 carbon atoms. In certain embodiments, R 1 is hydrogen, and R 2 is selected from the group consisting of butyl, 2-ethylhexyl, and mixtures thereof.

[0021] In one or more embodiments, polyacrylates useful for forming the adhesive body in the practice of the invention may be characterized by a glass transition temperature (Tg) of less than 0° C., in other embodiments less than −20° C., and in other embodiments less than −30° C. In these or other embodiments, useful polyacrylates may be characterized by a Tg of from about −70° C. to about 0° C., in other embodiments from about −50° C. to about −10° C., and in other embodiments from about −40° C. to about −20° C.

[0022] In one or more embodiments, polyacrylates useful as adhesives in the practice of this invention can be characterized by a number average molecular weight of from about 100 kg / mol to about 350 kg / mol, in other embodiments from about 150 kg / mol to about 270 kg / mol, and in other embodiments from about 180 kg / mol to about 250 kg / mol.

[0023] In one or more embodiments, the polyacrylates useful as adhesives in the practice of the present invention may be characterized by a Brookfield viscosity at 150° C. of from about 20,000 cps to about 70,000 cps, in other embodiments from about 30,000 cps to about 60,000 cps, and in other embodiments from about 40,000 cps to about 50,000 cps.

[0024] Specific examples of polyacrylates useful as adhesives in the practice of the present invention include poly(butyl acrylate) and poly(2-ethylhexyl acrylate). These polyacrylates can be formulated with photoinitiators, solvents, plasticizers, and resins, such as natural resins and hydrocarbon resins. Those skilled in the art can easily formulate the desired coating composition. Useful coating compositions are disclosed, for example, in U.S. Patent Nos. 6,720,399, 6,753,079, 6,831,114, 6,881,442, and 6,887,917, which are incorporated herein by reference.

[0025] In other embodiments, the polyacrylate may contain polymerized units that act as photoinitiators. These units may be derived from copolymerizable photoinitiators, including acetophenone or benzophenone derivatives. These polyacrylate elastomers and coating compositions formed therefrom are known, as disclosed in U.S. Pat. Nos. 7,304,119 and 7,358,319, which are incorporated herein by reference.

[0026] Useful adhesive compositions are commercially available in the art. For example, useful adhesives include those available under the trade name acResin (BASF), those available under the trade name AroCure (Ashland Chemical), Loctite Duro-Tak (Henkel) and NovaMelt RC (NovaMelt). In one or more embodiments, these hot melt adhesives can be cured (i.e., crosslinked) by UV light.

[0027] In one or more embodiments, the adhesive body comprises substantially cured polyacrylate. In other words, the adhesive body is substantially free of other components such as plasticizers. In one or more embodiments, the adhesive body comprises greater than 90 wt%, in other embodiments greater than 95 wt%, and in other embodiments greater than 99 wt% cured polyacrylate based on the total weight of the adhesive body.

[0028] In one or more embodiments, the curable adhesive is at least partially cured after application to the release member, as discussed in more detail below. In one or more embodiments, the adhesive is cured to an extent that it is not heat processable to its pre-cured form. In these or other embodiments, the cured adhesive is characterized by a crosslinked infinite polymer network. While at least partially cured, the adhesive layer of one or more embodiments is essentially free of curable residues, such as sulfur or sulfur bridges, and / or phenolic compounds or phenolic residue bridges. In one or more embodiments, the adhesive body is characterized by a degree of cure that can be quantified based on gel content. As will be appreciated by those skilled in the art, gel content can be determined based on the level of insoluble material after solvent extraction, which for purposes of this specification refers to solvent extraction with THF at its boiling point after 4 hours of extraction. These extraction techniques can be performed, for example, using a Soxhlet extraction apparatus. In one or more embodiments, the gel content of the cured adhesive layer is greater than 50% by weight, in other embodiments greater than 55% by weight, and in other embodiments greater than 60% by weight, based on THF extraction at the boiling point of THF after 4 hours. In these or other embodiments, the gel content is less than 95%, in other embodiments less than 90%, in other embodiments less than 85%, and in other embodiments less than 80%. In one or more embodiments, the gel content is from about 50% to about 95% by weight, in other embodiments from about 55% to about 90% by weight, and in other embodiments from about 60% to about 85% by weight.

[0029] In one or more embodiments, the adhesive body can be cured using one or more curing techniques, including, but not limited to, UV curing, electron beam curing, and thermal curing. In certain embodiments, UV curing is used, and in this regard, reference can be made to U.S. Patent Application Publication Nos. 2016 / 0230392, 2017 / 0015083, 2017 / 0114543, 2019 / 0071872, 2019 / 0316359, and 2020 / 0299965, which are incorporated herein by reference.

[0030] In one or more embodiments, the cure characteristics of the adhesive body are substantially uniform throughout the thickness of the adhesive body. In other words, the degree of cure at any given point along the thickness of the adhesive body does not vary significantly, which refers to a deviation that is smaller than would otherwise significantly affect the practice of the invention. In other embodiments, the degree of cure varies such that there is a cure continuum from one plane to the other through the thickness of the film. In these embodiments, the degree of cure at one plane is significantly greater than the degree of cure at the opposing plane, and the adhesive properties differ significantly at the opposing surfaces to an extent that alters the practice and results of the invention.

[0031] In one or more embodiments, the adhesive body is characterized as a solid adhesive mass. In other embodiments, the adhesive body is cellular, e.g., the adhesive body is foamed. When the adhesive body is foamed, the adhesive body has a viscosity of 0.3 g / cm 3 and in other embodiments, 0.5 g / cm 3 and in other embodiments 0.7 g / cm 3 In these or other embodiments, the adhesive body may be characterized by a density of greater than 1.06 g / cm 3 in other embodiments less than 1.03 g / cm 3 in other embodiments less than 1.0 g / cm 3 In one or more embodiments, the adhesive body may be characterized by a density of less than about 0.3 g / cm 3 ~Approx. 1.06g / cm 3and in other embodiments, about 0.5 g / cm 3 ~Approx. 1.03g / cm 3 and in other embodiments, about 0.7 g / cm 3 ~Approx. 1.0g / cm 3 The density of the material may be characterized as:

[0032] Adhesive Body Dimensions In one or more embodiments, the adhesive body (e.g., body 13) has a thickness greater than 25 μm, in other embodiments greater than 50 μm, in other embodiments greater than 75 μm, and in other embodiments greater than 100 μm. In these or other embodiments, the adhesive body may have a thickness less than 2000 μm, in other embodiments less than 1750 μm, in other embodiments less than 1500 μm, in other embodiments less than 1250 μm, and in other embodiments less than 1000 μm. In one or more embodiments, the adhesive body has a thickness of about 25 μm to about 2000 μm, in other embodiments about 50 μm to about 1750 μm, in other embodiments about 75 μm to about 1500 μm, and in other embodiments about 100 μm to about 1250 μm. In one or more embodiments, the thickness of the adhesive body is substantially constant across the width of the adhesive body. For example, in one or more embodiments, the thickness varies by less than 5%, in other embodiments less than 3%, and in other embodiments less than 1.5%.

[0033] In one or more embodiments, the adhesive body (e.g., body 13) has a width greater than 30 cm, in other embodiments greater than 45 cm, in other embodiments greater than 60 cm, and in other embodiments greater than 75 cm. In these or other embodiments, the adhesive body can have a width less than 15 m, in other embodiments less than 12 m, in other embodiments less than 9 m, and in other embodiments less than 6 m. In one or more embodiments, the adhesive body has a width of about 30 cm to about 15 m, in other embodiments about 45 cm to about 12 m, in other embodiments about 60 cm to about 9 m, and in other embodiments about 75 cm to about 6 m.

[0034] In one or more embodiments, the composite is provided in the form of a roll, and thus the adhesive body (e.g., body 13) can have a wide range of lengths. In one or more embodiments, the adhesive body has a length of more than 30 cm, in other embodiments more than 6 m, in other embodiments more than 10 m, and in other embodiments more than 50 m. In these or other embodiments, the adhesive body can have a length of less than 900 m, in other embodiments less than 750 m, in other embodiments less than 600 m, in other embodiments less than 300 m, and in other embodiments less than 100 m. In one or more embodiments, the adhesive body has a length of about 30 cm to about 900 m, in other embodiments about 6 m to about 750 m, in other embodiments about 10 m to about 600 m, and in other embodiments about 20 m to about 300 m.

[0035] Peeling material In one or more embodiments, the release liner, sometimes referred to as the release member (e.g., liner 23 and liner 33), comprises a polymeric film or extrudate. The polymeric film or extrudate may comprise a single polymeric layer or may comprise two or more polymeric layers laminated or coextruded together. In other embodiments, the release liner comprises a cellulosic substrate having a polymeric film or coating applied thereon, sometimes referred to as the polymeric layer.

[0036] Since the transfer film composite used in the present invention is typically provided to the installation site in the form of a roll, the nature and configuration of the release member facilitates this type of transportation, storage and distribution. For example, when the transfer film composite comprises a single release member, both planar surfaces of the release member are adapted to be removably adhered or attached to the adhesive body, as generally described above with reference to FIG. 1. In other words, both planar surfaces of the release member are adapted to be peeled from the adhesive body.

[0037] Materials suitable for forming the release liner, which is a polymer film or extrusion, include polypropylene, polyester, high density polyethylene, medium density polyethylene, low density polyethylene, polystyrene or high impact polystyrene. Materials suitable for forming the polymer layer on the cellulosic release liner include siloxane-based materials, butadiene-based materials, organic materials (e.g., styrene-butadiene rubber latex), and those polymer materials used to form the above-mentioned films or extrusions. These polymer materials can provide a number of advantageous properties, including high moisture resistance, good resistance to temperature fluctuations during processing and storage, and increased tear and wrinkle resistance. The above-mentioned films and materials may be coated with a release agent (e.g., silicone).

[0038] In one or more embodiments, the release member is characterized by a thickness of about 15 μm to about 80 μm, in other embodiments about 15 μm to about 150 μm, in other embodiments about 18 μm to about 75 μm, in other embodiments about 18 μm to about 100 μm, and in other embodiments about 20 μm to about 50 μm.

[0039] How to Build a Roof System As proposed above, the methods of the present invention use an adhesive transfer film to secure one or more building articles, such as building boards, to a roofing system. These methods generally include contacting a planar surface of an adhesive body to a roofing substrate, removing a release member to expose a top planar surface of the adhesive body, and contacting a building article to the top surface of the adhesive body. In this way, the building article is adhered to the roofing substrate.

[0040] The method of one or more embodiments of the present invention can be described in more detail with reference to FIG. 3. According to one or more embodiments, the installation process 101 includes step 103 of preparing a roll of adhesive transfer film composite and step 105 of positioning the roll on the surface of the roof, sometimes referred to as the substrate. The process further includes step 107 of unfolding the roll, sometimes referred to as unrolling the roll. If the composite includes an upper release member and a lower release member, the process may include step 109 of removing the lower release member so that the surface of the adhesive body can be contacted with the roof substrate. If the composite includes a single release member, it will be understood by those skilled in the art that the release member can be removably adhered to the upper surface of the adhesive body, and thus the act of unrolling the composite can bring the adhesive body into direct contact with the substrate without the need to remove the release member. Once the lower surface of the adhesive body is exposed, the process includes step 111 of contacting the lower surface of the adhesive body with the substrate at the location where installation of the adhesive (and thus the building board to be installed) is desired. It will be understood by those skilled in the art that the act of spreading the composite may occur together (i.e., simultaneously) with contacting the adhesive body with the substrate. With the adhesive body in contact with the substrate at the desired location, the process continues with optional step 113 of applying a force to the top release member, thereby enhancing adhesion between the adhesive body and the substrate. The process continues with step 115 of removing the top release member, thereby exposing the top planar surface of the adhesive body and allowing step 117 of contacting a building board with the top surface of the adhesive body. After contacting the building board with the adhesive body, step 119 of applying a force (e.g., pressure) to the building board can enhance the adhesion between the board and the adhesive body and between the adhesive body and the substrate.

[0041] As will be appreciated by those skilled in the art, the nature of the composite may affect the order in which the various steps of the installation process are performed. For example, if the composite includes a single release member (i.e., only a top release member), the process may include the spreading step 109 and the contacting step 111 of the adhesive to the substrate simultaneously (e.g., the adhesive is contacted during the spreading step). The applying pressure step 113 may likewise be performed together with the spreading and contacting steps. In other words, the composite roll may be unrolled and once the exposed portion of the adhesive body is in contact with the substrate, the composite roll may be unrolled and a force applied by a roller or the like at a location downstream of where it contacts the substrate.

[0042] Roofing system The use of adhesive transfer film in conjunction with the method of the present invention provides a unique roofing system. An exemplary roofing system according to the present invention can be described with reference to FIG. 4, which shows a roofing system 201 constructed on a roof deck 203. A first layer of insulation boards 205 is disposed on the roof deck 203. As will be appreciated by those skilled in the art, the first layer of insulation boards 205 may comprise a plurality of insulation boards (sometimes referred to as board stock) arranged in a pattern that may be conventionally used in the art, such as a staggered pattern. As specifically shown in FIG. 4, the layer 205 includes a first board 205A and a second board 205B. The first layer of insulation boards 205 may be secured to the roof deck 203, optionally via mechanical fasteners 221, 221′.

[0043] A layer of adhesive film 231 applied to layer 205 according to the invention is placed on top (against deck 203) and adhered to the first layer 205. An optional second layer 209 of insulation boards is placed on top (against deck 203) and adhered to the adhesive film 231. Like layer 205, layer 209 includes a plurality of insulation boards arranged in a pattern that may be conventionally used in the art (e.g., horizontally offset with respect to other boards in the layer and vertically offset with respect to boards of the first layer 205). As specifically shown in FIG. 4, layer 209 includes a first board 209A, a second board 209B, and a third board 209C. It will be understood that according to the invention, two or more boards in a single layer of boards are secured to a substrate (i.e., an underlying layer) via a common film adhesive. As specifically shown in FIG. 4, for the second insulation layer 209, boards 209A, 209B and 209C can be adhered to the substrate (i.e., the first layer 205 of the insulation board) via a common adhesive film 231.

[0044] A layer of adhesive film 233 applied to layer 209 according to the present invention is disposed over and adhered to second layer 209. Optional cover board layer 213 is disposed over and adhered to adhesive film 233. Similar to layers 205 and 209, layer 213 includes multiple cover boards arranged in a pattern that may be conventionally used in the art (e.g., horizontally offset relative to other boards in the layer and vertically offset relative to boards of second layer 209). As specifically shown in FIG. 4, layer 213 includes a first cover board 213A and a second cover board 213B. Similar to second layer 209 and adhesive film 231, the present invention provides that two or more of the cover boards of layer 213 are adhered to layer 209 via a common adhesive film 233.

[0045] A membrane layer 217 is disposed over the coverboard layer 213 (relative to the deck 203). Those skilled in the art will appreciate that the membrane layer 217 may be formed from multiple membrane panels laminated together to form a water impermeable layer to protect the building structure. The membrane layer 217 may be secured to the roof deck, either directly or indirectly, using various techniques known in the art. For example, the membrane layer 217, and in particular the individual membrane panels of layer 217, may be mechanically attached to the roof deck 203. Alternatively, the membrane panels of membrane layer 217 may be bonded to an underlying substrate, such as the coverboard layer 213. For example, the various panels of layer 217 may carry a pressure sensitive layer.

[0046] Building Board As described above, roofing systems that can be constructed according to embodiments of the present invention include two or more layers of building boards. These building boards can include, but are not limited to, insulation boards (also referred to as board stock) and cover boards. Insulation boards can include board stock that includes foam with optional facers on opposing flat surfaces of the foam. Cover boards can include fiberboard, masonite board, wallboard, gypsum board, gypsum products such as DensDeck, perlite board, and high density foam board. Like insulation boards, these cover boards can carry facers on opposing flat surfaces of the board.

[0047] Foam As noted above, the building board used in the practice of the present invention may include a foam. In one or more embodiments, the foam of the building board may include an insulating foam. Examples of insulating foams that may be used include expanded polystyrene, such as expanded polystyrene, and polyurethane and / or polyisocyanurate foams. In certain embodiments, the foam is a polyisocyanurate or polyurethane foam. As will be appreciated by those skilled in the art, polyisocyanurate and / or polyurethane foams can be produced by mixing a first stream comprising an isocyanate-containing compound with a second stream comprising an isocyanate-reactive compound. Using conventional terminology, the first stream (i.e., the stream comprising the isocyanate-containing compound) may also be referred to as the A-side stream, A-side reactant stream, or simply the A-stream. Similarly, the second stream (i.e., the stream comprising the isocyanate-reactive compound) may also be referred to as the B-side stream, B-side reactant stream, or simply the B-stream. In any case, the reaction that occurs produces a foam that expands over a period of time according to one or more kinetic and / or thermodynamic properties. Thus, unless otherwise specified, the term expanding foam is understood to refer to a state in which a mixture of polyurethane reactants and / or polyisocyanurate reactants is in a pre-cure state, where the reaction mixture is substantially immobile (e.g., no longer flowable).

[0048] In one or more embodiments, either stream may carry additional components including, but not limited to, fire retardants, surfactants, blowing agents, catalysts, emulsifiers / solubilizers, fillers, fungicides, antistatic materials, and mixtures of two or more thereof.

[0049] A side stream In one or more embodiments, the A-side stream may contain only isocyanate-containing compounds. In one or more embodiments, multiple isocyanate-containing compounds may be included in the A-side. In other embodiments, the A-side stream may contain other components, such as, but not limited to, flame retardants, surfactants, blowing agents, and other non-isocyanate-reactive components. In one or more embodiments, supplemental components added to the A-side are non-isocyanate-reactive.

[0050] Suitable isocyanate-containing compounds useful in the manufacture of polyisocyanurate building boards are generally known in the art, and embodiments of the present invention are not limited by the selection of any particular isocyanate-containing compound. Useful isocyanate-containing compounds include polyisocyanates. Useful polyisocyanates include aromatic polyisocyanates such as diphenylmethane diisocyanate in the form of the 2,4'-isomer, 2,2'-isomer, and 4,4'-isomer, and mixtures thereof. Mixtures of diphenylmethane diisocyanate (MDI) and its oligomers are sometimes referred to as "crude" or polymeric MDI, and these polyisocyanates may have an isocyanate functionality of more than two. Other examples include toluene diisocyanate in the form of the 2,4'-isomer and 2,6'-isomer, and mixtures thereof, 1,5-naphthalene diisocyanate, and 1,4'-diisocyanatobenzene. Exemplary polyisocyanate compounds include polymeric Rubinate 1850 (Huntsmen Polyurethanes), polymeric Lupranate M70R (BASF), and polymeric Mondur 489N (Bayer).

[0051] B side stream In one or more embodiments, the B-side stream may include only isocyanate-reactive compounds. In one or more embodiments, multiple isocyanate-reactive compounds may be included in the B-side. In other embodiments, the B-side stream may contain other components, such as, but not limited to, flame retardants, surfactants, blowing agents, and other non-isocyanate-containing components. In certain embodiments, the B-side includes isocyanate-reactive compounds and blowing agents. In these or other embodiments, the B-side may include flame retardants, catalysts, emulsifiers / solubilizers, surfactants, fillers, fungicides, antistatic materials, water, and other ingredients commonly used in the art.

[0052] An exemplary isocyanate-reactive compound is a polyol. The term polyol or polyol compound includes diols, polyols, and glycols, which may contain water as is generally known in the art. Primary and secondary amines are suitable, as are polyether and polyester polyols. Useful polyester polyols include phthalic anhydride-based PS-2352 (Stepen), phthalic anhydride-based polyol PS-2412 (Stepen), terephthalic acid-based polyol 3522 (Kosa), and blend polyol TR 564 (Oxid). Useful polyether polyols include those based on sucrose, glycerin, and toluene diamine. Examples of glycols include diethylene glycol, dipropylene glycol, and ethylene glycol. Suitable primary and secondary amines include, but are not limited to, ethylene diamine and diethanolamine. In one or more embodiments, polyester polyols are used. In one or more embodiments, the present invention can be practiced in the absence of substantial amounts of polyether polyol. In certain embodiments, the component does not have a polyether polyol.

[0053] catalyst Catalysts may be used which are believed to initiate the polymerization reaction between isocyanates and polyols, and the trimerization reaction between free isocyanate groups if a polyisocyanurate foam is desired. Some catalysts promote both reactions, but more than one catalyst may be used to achieve both reactions. Useful catalysts include salts of alkali metals with carboxylic acids or phenols, such as potassium octanoate; condensable phenols, optionally substituted with alkyl, aryl or aralkyl groups, oxo compounds and mono- or polynuclear Mannich bases of secondary amines; tertiary amines, such as pentamethyldiethylenetriamine (PMDETA), 2,4,6-tris[(dimethylamino)methyl]phenol, triethylamine, tributylamine, N-methylmorpholine and N-ethylmorpholine; basic nitrogen compounds, such as tetraalkylammonium hydroxides, alkali metal hydroxides, alkali metal phenolates and alkali metal alcoholates; and organometallic compounds, such as tin(II) salts of carboxylic acids, tin(IV) compounds, and organolead compounds, such as lead naphthenate and lead octanoate.

[0054] Surfactants, emulsifiers and solubilizers Surfactants, emulsifiers and / or solubilizers may also be used in the production of polyurethane and polyisocyanurate foams to enhance compatibility of the blowing agent with the isocyanate and polyol components. Surfactants can serve two purposes. First, they can help emulsify / solubilize and fully react all the components. Second, they can promote cell nucleation and cell stabilization.

[0055] Exemplary surfactants include silicone copolymers or organic polymers bound to silicone polymers.Surfactants can perform both functions, but it can also be useful to ensure emulsification / solubilization by using enough emulsifier / solubilizer to maintain emulsification / solubilization, and the minimum amount of surfactant to obtain good cell nucleation and cell stabilization.Examples of surfactants include Pelron surfactant 9920, Goldschmidt surfactant B8522, and GE 6912.U.S. Patent Nos. 5,686,499 and 5,837,742 are incorporated herein by reference to show various useful surfactants.

[0056] Suitable emulsifiers / solubilizers include DABCO Ketene 20AS (Air Products) and Tergitol NP-9 (nonylphenol plus 9 moles of ethylene oxide).

[0057] Flame retardants Flame retardants can be used in the production of polyurethane and polyisocyanurate foams, especially when the foam contains a flammable blowing agent such as pentane isomers. Useful flame retardants include tri(monochloropropyl)phosphate (also known as tris(chloropropyl)phosphate), tri-2-chloroethylphosphate (also known as tris(chloroethyl)phosphate), phosphonic acid, methyl ester, dimethyl ester, and diethyl ester. U.S. Patent No. 5,182,309 is incorporated herein by reference to show useful blowing agents.

[0058] Foaming Agent Useful blowing agents include isopentane, n-pentane, cyclopentane, alkanes, (cyclo)alkanes, hydrofluorocarbons, hydrochlorofluorocarbons, fluorocarbons, fluorinated ethers, alkenes, alkynes, carbon dioxide, hydrofluoroolefins (HFOs) and the noble gases.

[0059] Amount of reactants Isocyanurates are the trimerization reaction products of three isocyanates forming a six-membered ring. The equivalent ratio of NCO groups (supplied from the isocyanate-containing compound or A-side) to isocyanate-reactive groups (supplied from the isocyanate-containing compound or B-side) is sometimes referred to as the index or ISO index. When the NCO equivalents and isocyanate-reactive group equivalents are equal, the index is 1.00, which is referred to as an index of 100, and the mixture is said to be stoichiometrically equivalent. As the ratio of NCO equivalents to isocyanate-reactive group equivalents increases, the index increases. When the index is above about 150, the material is generally known as a polyisocyanurate foam, even if many polyurethane linkages remain untrimerized. When the index is below about 150, the foam is generally known as a polyurethane foam, even if some isocyanurate linkages are present. For purposes of this specification, references to polyisocyanurates and polyurethanes are used interchangeably unless a specific ISO index is mentioned.

[0060] In one or more embodiments, the concentration of isocyanate-containing compounds relative to isocyanate-reactive compounds in each of the A side stream and B side stream is adjusted to provide a foam product having an ISO Index of greater than 150, in other embodiments greater than 170, in other embodiments greater than 190, in other embodiments greater than 210, in other embodiments greater than 220, and in other embodiments greater than 250. In these or other embodiments, the concentration of isocyanate-containing compounds relative to isocyanate-reactive compounds in each of the A side stream and B side stream is adjusted to provide a foam product having an ISO Index of less than 400, in other embodiments less than 350, and in other embodiments less than 300. In one or more embodiments, the concentration of isocyanate-containing compounds relative to isocyanate-reactive compounds in each of the A side stream and B side stream is adjusted to provide a foam product having an ISO Index of about 150 to about 400, in other embodiments about 170 to about 350, in other embodiments about 190 to about 330, and in other embodiments about 220 to about 280.

[0061] In one or more embodiments in which an alkane blowing agent is used, the amount of alkane blowing agent (e.g., pentane) used in the preparation of a polyisocyanurate foam building board according to the present invention may be described with reference to the amount of isocyanate-reactive compound (e.g., polyol) used. For example, in one or more embodiments, more than 12 parts by weight (pbw), in other embodiments more than 14 pbw, and in other embodiments more than 18 pbw of alkane blowing agent per 100 pbw of polyol may be used. In these or other embodiments, less than 40 pbw, in other embodiments less than 36 pbw, and in other embodiments less than 33 pbw of alkane blowing agent per 100 pbw of polyol may be used. In one or more embodiments, from about 12 pbw to about 40 pbw, in other embodiments from about 14 pbw to about 36 pbw, and in other embodiments from about 18 pbw to about 33 pbw of alkane blowing agent per 100 parts by weight of polyol may be used.

[0062] In one or more embodiments in which a hydrofluoroolefin blowing agent is used, the amount of hydrofluoroolefin blowing agent used in the preparation of the polyisocyanurate foam building board according to the present invention can be described with reference to the amount of isocyanate-reactive compound (e.g., polyol) used. For example, in one or more embodiments, more than 15 parts by weight (pbw), in other embodiments more than 18 pbw, and in other embodiments more than 20 pbw of hydrofluoroolefin blowing agent per 100 pbw of polyol can be used. In these or other embodiments, less than 50 pbw, in other embodiments less than 45 pbw, and in other embodiments less than 40 pbw of hydrofluoroolefin blowing agent per 100 pbw of polyol can be used. In one or more embodiments, from about 15 pbw to about 50 pbw, in other embodiments from about 18 pbw to about 45 pbw, and in other embodiments from about 20 pbw to about 40 pbw of hydrofluoroolefin blowing agent per 100 parts by weight of polyol can be used.

[0063] In one or more embodiments, the amount of surfactant (e.g., silicone copolymer) used in the preparation of polyisocyanurate foam building boards according to the present invention may be described with reference to the amount of isocyanate-reactive compound (e.g., polyol) used. For example, in one or more embodiments, more than 1.0 parts by weight (pbw) of surfactant per 100 pbw of polyol may be used, in other embodiments more than 1.5 pbw, and in other embodiments more than 2.0 pbw. In these or other embodiments, less than 5.0 pbw, in other embodiments less than 4.0 pbw, and in other embodiments less than 3.0 pbw of surfactant per 100 pbw of polyol may be used. In one or more embodiments, from about 1.0 pbw to about 5.0 pbw, in other embodiments from about 1.5 pbw to about 4.0 pbw, and in other embodiments from about 2.0 pbw to about 3.0 pbw of surfactant per 100 parts by weight of polyol may be used.

[0064] In one or more embodiments, the amount of flame retardant (e.g., liquid phosphate) used in the manufacture of polyisocyanurate foam building boards according to the present invention may be described with reference to the amount of isocyanate-reactive compound (e.g., polyol) used. For example, in one or more embodiments, more than 5 parts by weight (pbw) of flame retardant per 100 pbw of polyol may be used, in other embodiments more than 10 pbw, and in other embodiments more than 12 pbw. In these or other embodiments, less than 30 pbw, in other embodiments less than 25 pbw, and in other embodiments less than 20 pbw of flame retardant per 100 pbw of polyol may be used. In one or more embodiments, from about 5 pbw to about 30 pbw, in other embodiments from about 10 pbw to about 25 pbw, and in other embodiments from about 12 pbw to about 20 pbw of flame retardant per 100 parts by weight of polyol may be used.

[0065] In one or more embodiments, the amount of catalyst(s) used in the practice of the present invention can be readily determined by one of ordinary skill in the art without undue experimentation or calculation. Indeed, one of ordinary skill in the art will recognize various process parameters that affect the amount of catalyst desired. Additionally, the amount of catalyst used can be varied to achieve various desired properties, such as a desired index.

[0066] Foam properties As indicated above, the foam may include polyurethane foam and / or polyisocyanurate foam. As is generally understood in the art, foams are cellular structures that may include an interconnected network of solid struts or plates that form the ends and faces of the cells. These cellular structures may also be defined by a "relative density" that in one or more embodiments is less than 0.8, in other embodiments less than 0.5, and in other embodiments less than 0.3. As will be understood by those skilled in the art, "relative density" refers to the density of the cellular material divided by the density of the solid from which the cell walls are made. As the relative density increases, the cell walls thicken and the pore space shrinks, at some point transitioning from a cellular structure to one that is better defined as a solid containing isolated pores.

[0067] In one or more embodiments, the foam is characterized by a relatively low density. In one or more embodiments, the foam has a density of 2.5 pounds per cubic foot (12 kg / m 2 ) in other embodiments, less than 2.0 pounds per cubic foot (9.8 kg / m 2 ) in other embodiments, less than 1.9 pounds per cubic foot (9.3 kg / m 2 ) and in yet other embodiments less than 1.8 pounds per cubic foot (8.8 kg / m 2 In one or more embodiments, the foam may have a density, as defined in accordance with ASTM C303, of less than 1.50 pounds per cubic foot (7.32 kg / m 2 ) or optionally 1.55 lb / ft3 (7.57 kg / m 2 ) or greater.

[0068] In other embodiments, the foam is characterized by a relatively high density. In one or more embodiments, the foam has a density of 2.5 pounds per cubic foot (12.2 kg / m), as determined according to ASTM C303. 2 ) as defined by ASTM C303, and in other embodiments, the density is 2.8 pounds per cubic foot (13.7 kg / m 2 ) in other embodiments, 3.0 pounds per cubic foot (14.6 kg / m 2 ) and in yet other embodiments greater than 3.5 pounds per cubic foot (17.1 kg / m 2 In one or more embodiments, the density is greater than 20 pounds per cubic foot (97.6 kg / m 2 ) in other embodiments, less than 10 pounds per cubic foot (48.8 kg / m 2 ) in other embodiments, less than 6 pounds per cubic foot (29.3 kg / m 2 ) in other embodiments, less than 5.9 pounds per cubic foot (28.8 kg / m 2 ) in other embodiments, less than 5.8 pounds per cubic foot (28.3 kg / m 2 ) in other embodiments, less than 5.7 pounds per cubic foot (27.8 kg / m 2 ) in other embodiments, less than 5.6 pounds per cubic foot (27.3 kg / m 2 ) in yet another embodiment, less than 5.5 pounds per cubic foot (26.9 kg / m 2 ) may be less than

[0069] In one or more embodiments, the foam is characterized by a desired ISO index. As will be appreciated by those skilled in the art, the ISO index correlates to the PIR / PUR ratio and can be determined by IR spectroscopy using a standard foam of known index greater than 150, in other embodiments greater than 180, in other embodiments greater than 200, in other embodiments greater than 220, in other embodiments greater than 240, in other embodiments greater than 260, in other embodiments greater than 270, in other embodiments greater than 285, in other embodiments greater than 300, in other embodiments greater than 315, and in other embodiments greater than 325 (note that a PIR / PUR ratio of 3 would result in an ISO index of 300). In these or other embodiments, the foam can be characterized by an ISO index less than 350, in other embodiments less than 300, in other embodiments less than 275, in other embodiments less than 250, in other embodiments less than 225, and in other embodiments less than 200.

[0070] Building board facer The facers of the building boards may be the same or different. In one or more embodiments, the facers may comprise a variety of materials or compositions, many of which are known or commonly used in the art. Useful facers include those comprising aluminum foil, cellulosic fibers, reinforced cellulosic fibers, kraft paper, coated fiberglass mat, uncoated fiberglass mat, chopped glass, and combinations thereof. Useful facer materials are known, as described in U.S. Patent Nos. 6,774,071, 6,355,701, RE36674, 6,044,604, and 5,891,563, which are incorporated herein by reference.

[0071] The thickness of the facer material may vary, for example, from about 0.01 inches to about 1.00 inches (0.025 cm to 2.54 cm) thick, or in other embodiments from about 0.015 inches to about 0.050 inches (0.04 cm to 0.13 cm) thick, or in other embodiments from about 0.015 inches to about 0.030 inches (0.04 cm to 0.07 cm) thick. The facer material may also include more robust or rigid materials such as fiberboard, perlite board, or gypsum board. The thickness of rigid facers may vary, for example, the thickness of rigid facers may be from about 0.2 inches to about 1.5 inches (0.51 cm to 3.8 cm), or in other embodiments from about 0.25 inches to about 1.0 inches (0.64 cm to 2.54 cm).

[0072] In one or more embodiments, the facer is optional. Thus, in one or more embodiments, the building board may be facerless. It is known that facerless building boards can be produced, as described in U.S. Patent No. 6,117,375, which is incorporated herein by reference.

[0073] In other embodiments, the facer can be a generally solid material such as wood board, particle board, or fiberboard. In one or more embodiments, the facer is a wood board such as plywood, luan board, or oriented strand board (OSB). In other embodiments, the facer board is a particle board or fiberboard, such as fiberboard, masonite board, wallboard, gypsum board, gypsum products such as DensDeck, perlite board, and high density foam board.

[0074] Other roof system components The practice of the present invention is not limited by the selection of any particular roof deck. Thus, the roofing system of the present invention may include a variety of roof decks. Exemplary roof decks include concrete pads, steel decks, wood beams, and foam concrete decks.

[0075] The practice of the present invention is also not limited by the selection of any waterproof layer or membrane. As known in the art, several membranes can be used to protect roofing systems from environmental exposure (e.g., weathering membranes), especially environmental moisture in the form of rain or snow. Useful membranes include those known as single-ply roofing membranes. Useful protective membranes include polymeric membranes. Useful polymeric membranes include both thermoplastic and thermosetting materials. For example, membranes made of poly(ethylene-co-propylene-co-diene) terpolymer rubber or poly(ethylene-co-propylene) copolymer rubber can be used, as known in the art. Roofing membranes made from these materials are known in the art, as described in U.S. Patent Nos. 6,632,509, 6,615,892, 5,700,538, 5,703,154, 5,804,661, 5,854,327, 5,093,206 and 5,468,550, which are incorporated herein by reference. Other useful polymeric membranes include those made from various thermoplastic polymers or polymer composites. For example, thermoplastic olefins (i.e., TPO), thermoplastic vulcanizates (i.e., TPV) or polyvinyl chloride (PVC) materials can be used.

[0076] The use of these materials in roofing membranes is known in the art, such as described in U.S. Patent Nos. 6,502,360, 6,743,864, 6,543,199, 5,725,711, 5,516,829, 5,512,118, and 5,486,249, which are incorporated herein by reference. In one or more embodiments, the membranes include those defined by ASTM D4637-03 and / or ASTM D6878-03.

[0077] In yet other embodiments, the protective membrane may include a bitumen or asphalt membrane. In one embodiment, these asphalt membranes are obtained from asphalt sheets applied to the roof. These asphalt roofing membranes are known in the art, such as those described in U.S. Patent Nos. 6,579,921, 6,110,846, and 6,764,733, which are incorporated herein by reference. In other embodiments, the protective membrane may be obtained by application of hot asphalt to the roof.

[0078] Other layers or elements of the roofing system are not excluded by the practice of the present invention. For example, another layer of material can be applied over the protective membrane, as known in the art. Often these materials are applied to protect the protective membrane from exposure to electromagnetic radiation, especially radiation in the form of UV light. In some cases, a ballast material is applied over the protective membrane. Often this ballast material simply comprises aggregate in the form of rocks, stones or gravel; U.S. Patent No. 6,487,830 is incorporated herein by reference in this regard.

[0079] Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art, and this invention is not to be duly limited to the illustrative embodiments set forth herein.

Claims

1. 1. A method of constructing a roof system, the method comprising: (i) applying an adhesive transfer film composite to a roofing substrate, the adhesive transfer film composite comprising an adhesive body having a first planar surface and a second planar surface, and a release member removably attached to the second planar surface of the adhesive body, the adhesive body being free of a carrier layer, the adhesive body comprising a crosslinked network of an acrylate-based polymer, the applying step securing the first planar surface of the adhesive body to the roofing substrate; (ii) removing the release member, thereby exposing a second planar surface of the adhesive body; (iii) applying a construction element to a second planar surface of the adhesive body, thereby adhering the construction element to the substrate; A method comprising:

2. 10. The method of claim 1 , wherein the step of applying the adhesive transfer film composite comprises: providing the adhesive transfer film composite in the form of a roll; unrolling the roll of adhesive transfer film composite; and bonding a first planar surface of the adhesive plane to the substrate.

3. 3. The method of claim 1 or 2, wherein the substrate is selected from the group consisting of roof decks, insulation boards, cover boards, and existing membranes.

4. The method of any one of claims 1 to 3, wherein the substrate is a first layer of a building board.

5. The method of claim 4 wherein the first layer of building board is mechanically fastened in place.

6. The method according to any one of claims 1 to 5, wherein the construction element is selected from the group consisting of cover boards, insulation boards and membrane panels.

7. The method of any one of claims 1 to 6, wherein the substrate is a roof deck, the roof deck being selected from the group consisting of a concrete deck, a corrugated metal deck, and a wood deck.

8. The method of any one of claims 1 to 7, wherein the adhesive body comprises a UV cured polyacrylate adhesive.

9. 9. The method of any one of claims 1 to 8, wherein the adhesive body is characterized by a degree of cure whereby less than 5% of the adhesive body is soluble in xylene after 24 hours at 25°C.

10. The method of any one of claims 1 to 9, wherein the adhesive body has a thickness of about 25 μm to about 2000 μm.

11. The method of any one of claims 1 to 10, wherein the adhesive body has a width of from about 30 cm to about 15 m.

12. The method of any one of claims 1 to 11, wherein the adhesive body is compositionally homogeneous.

13. The method of any one of claims 1 to 12, wherein the adhesive body is UV cured by subjecting a first planar surface of the body to UV radiation.

14. The method of any one of claims 1 to 13, wherein a cure characteristic of a first planar surface of the adhesive body is different from a cure characteristic of a second planar surface of the adhesive body.

15. The method of any one of claims 1 to 14, wherein the adhesive body is foamed.

16. 1. A process for constructing a roof system, the process comprising: (i) providing a roof system comprising a first layer of insulation board mechanically secured to a roof deck, the first layer of insulation board including an exposed surface; (ii) applying a transfer film composite to a portion of an exposed surface of a first layer of the insulation board, the transfer film composite comprising an adhesive body having a first planar surface and a second planar surface, and an optional release member removably attached to the second planar surface of the adhesive body, the applying step including bonding the first planar surface of the adhesive body to the portion of the exposed surface of the layer of insulation board; (iii) optionally removing the optional release member, thereby exposing a second planar surface of the adhesive body; (iv) applying a building board to a second planar surface of the adhesive body, thereby adhering the building board to a portion of the layer of the building board; The process includes:

17. applying a building board to the second planar surface of the adhesive body to form a second layer of building board having a top planar surface; (v) applying a transfer film composite to a portion of a second layer of the building board having a planar upper surface, the transfer film composite comprising an adhesive body having a first planar surface and a second planar surface, and an optional release member removably attached to the second planar surface of the adhesive body, the transfer film composite having no carrier layer, the applying step including bonding the first planar surface of the adhesive body to a portion of the second layer of the building board having a planar upper surface; (vi) optionally removing the optional release member, thereby exposing a second planar surface of the adhesive body; (vii) applying a building board to a second planar surface of the adhesive body, thereby adhering the building board to a portion of the second layer of building board, thereby forming a third layer of building board; 20. The process of claim 16, further comprising:

18. 18. The process of claim 16 or 17, further comprising applying a membrane system onto the second layer of the building board or onto the third layer of the building board.

19. 19. The process of any one of claims 16-18, wherein the applying step comprises providing the adhesive transfer film composite in the form of a roll, unrolling the roll of adhesive transfer film composite, and bonding a first planar surface of the adhesive plane to the substrate.

20. The process according to any one of claims 16 to 19, wherein the building board used to make the third layer of the building board is a cover board.

21. The process according to any one of claims 16 to 20, wherein the building board used to make the second layer of the building board is an insulating board.

22. The process according to any one of claims 16 to 20, wherein the building board used to make the second layer of the building board is a cover board.

23. The process of any one of claims 16 to 22, wherein the adhesive body comprises a UV cured polyacrylate adhesive.

24. 24. The process of any one of claims 16 to 23, wherein the adhesive body is characterized by a degree of cure where less than 5% of the adhesive body is soluble in xylene after 24 hours at 25°C.

25. The process of any one of claims 16 to 24, wherein the adhesive body has a thickness of from about 25 μm to about 890 μm.

26. The process of any one of claims 16 to 25, wherein the adhesive body has a width of from about 30 cm to about 15 m.

27. The process of any one of claims 16 to 26, wherein the adhesive body is compositionally homogeneous.

28. The process of any one of claims 16 to 27, wherein the adhesive body is UV cured by subjecting a first planar surface of the body to UV radiation.

29. The process of any one of claims 16 to 28, wherein the cure characteristics of a first planar surface of the adhesive body are different from the cure characteristics of a second planar surface of the adhesive body.

30. The process of any one of claims 16 to 29, wherein the adhesive body is foamed.

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