Roofing membrane composites having a pressure-sensitive adhesive layer

Abstract

A roofing membrane composite includes (a) a roofing membrane subcomponent; and (b) a double-sided adhesive subcomponent.

Description

ROOFING^MEMBRANE^COMPOSITES^HAVING^APRESSURE-SENSITIVE^ADHESIVE^LAYER FIELD^OF^THE^INVENTION

[0001] Embodiments^of^the^present^invention^are^directed^toward^roofing^membrane^composites^including^a^double-sided^adhesive^sheet. BACKGROUND^OF^THE^INVENTION

[0002] Large,^flexible^polymeric^sheets,^which^are^often^referred^to^as^membranes^or^panels,^ are^ used^ in^ the^ construction^ industry^ to^ cover^ flat^ or^ low-sloped^ roofs.^ ^ These^membranes^provide^protection^to^the^roof^from^the^environment,^particularly^in^the^form^ofa^waterproof^ barrier.^ ^ As^ is^ known^ in^ the^ art,^ commercially^popular^membranes^ include^thermoset^membranes^such^as^those^including^cured^EPDM^(i.e.,^ethylene-propylene-diene^ terpolymer^rubber)^or^thermoplastics^such^as^TPO^(i.e.,^thermoplastic^olefins).

[0003] These^membranes^are^typically^delivered^to^a^construction^site^in^a^bundled^roll,^transferred^to^the^roof,^and^then^unrolled^and^positioned.^^The^sheets^are^then^affixed^to^the^ building^structure^by^employing^varying^techniques^such^as^mechanical^fastening,^ballasting,^and / or^ adhesively^ adhering^ the^membrane^ to^ the^ roof.^ ^ The^ roof^ substrate^ to^which^ the^membrane^is^secured^may^be^one^of^a^variety^of^materials^depending^on^the^installation^site^ and^structural^concerns.^^For^example,^the^surface^may^be^a^concrete,^metal,^or^a^wood^deck,^ it^may^include^insulation^or^recover^board,^and / or^it^may^include^an^existing^membrane.

[0004] In^ addition^ to^ securing^ the^membrane^ to^ the^ roof,^ the^ individual^membrane^panels,^ together^ with^ flashing^ and^ other^ accessories,^ are^ positioned^ and^ adjoined^ (i.e.,^seamed)^together^so^as^to^achieve^a^waterproof^barrier^on^the^roof.^^Typically,^the^edges^of^ adjoining^panels^are^overlapped,^and^these^overlapping^portions^are^adjoined^(i.e.,^seamed)^ to^one^another^through^a^number^of^methods^depending^upon^the^membrane^materials^and^ exterior^conditions.^^One^approach^involves^providing^adhesives^or^adhesive^tapes^between^the^overlapping^portions,^thereby^creating^a^water-resistant seal.

[0005] WO^2017 / 165868A1^describes^ a^method^ for^ forming^a^ fully-adhered^roofing^system^by^using^peel-and-stick^techniques^whereby^a^cured^pressure-sensitive^adhesive^that^ is^disposed^on^a^roofing^membrane^is^capable^of^securing^the^membrane^to^the^roof^surface^and^is^also^capable^of^mating^the^membrane^to^an^adjacent^membrane^and^thereby^form^a^ lap^seam.^^The^surface^of^the^adjacent^membrane^to^which^the^pressure-sensitive^adhesive^is^ applied^in^forming^the^lap^seam^can^be^primed.^^The^lap^seam^can^also^be^sealed^by^employing^ complementary^lap^sealants.

[0006] Since^ the^ peel-and-stick^ techniques,^ and^ the^membranes^ giving^ rise^ to^ these^techniques,^are^very^efficient^in^the^construction^of^roof^surfaces,^there^is^a^desire^to^improve^ upon^these^methods^to^further^derive^efficiencies^while^improving^the^overall^integrity^of^the^ roof^systems. SUMMARY^OF^THE^INVENTION

[0007] Embodiments^of^the^present^invention^provide^a^roofing^membrane^composite^including^ (a)^ a^ roofing^ membrane^ subcomponent;^ and^ (b)^ a^ double-sided^ adhesive^subcomponent.

[0008] Other^embodiments^of^the^present^invention^provide^a^roof^system^including^a^roofing^membrane^composite^as^provided^above.

[0009] Still^other^embodiments^of^the^present^invention^provide^a^method^of^installing^a^ roofing^membrane^ composite^ on^ a^ roof,^ the^method^ including^ positioning^ the^ roofing^membrane^composite^on^a^roof^surface,^removing^a^release^liner,^and^securing^the^roofing^ membrane^composite^to^the^roof^through^a^pressure-sensitive^adhesive^layer^of^the^double- sided^adhesive^subcomponent. BRIEF^DESCRIPTION^OF^THE^DRAWINGS

[0010] FIG. 1^is^a^cross-sectional^view^of^a^roofing^membrane^composite^according^to^embodiments^of^the^invention.

[0011] FIG. 2^is^a^cross-sectional^view^of^a^roof^system^including^a^roofing^membrane^composite^according^to^embodiments^of^the^invention. DETAILED^DESCRIPTION^OF^ILLUSTRATIVE^EMBODIMENTS

[0012] Embodiments^ of^ the^ present^ invention^ are^ based,^ at^ least^ in^ part,^ on^ the^discovery^of^ roofing^membrane^composites^including^a^roofing^membrane^subcomponent^and^a^double-sided^adhesive^subcomponent^with^a^carrier^layer.^^The^carrier^advantageously^allows^ the^ adhesive^ to^ securely^mate^ the^ roofing^membrane^ to^ a^desired^ substrate^ even^though^ the^ substrates^ to^which^ the^ roofing^membranes^ are^ attached^may^have^ irregular^surfaces.^ ^ Thus,^ while^ the^ prior^ art^ contemplates^ roofing^ membrane^ composites^ with^pressure-sensitive^ adhesive^ layers^ for^peel-and-stick^ applications,^ it^ has^been^discovered^that^ variability^ in^ the^ surfaces^ of^ the^ substrates^ to^ which^ the^ roofing^ membranes^ are^attached,^ especially^ insulation^ boards, can^ frustrate^ the^ adhesion^offered^ by^ the layer^of^pressure-sensitive^adhesive.^^Embodiments^of^the^present^invention,^which^provide^a^carrier^layer^ adjacent^ to^ the^adhesive^ layer,^advantageously^overcome^problems^associated^with^prior^art^roofing^membrane^composites.^^Indeed,^it^has^advantageously^been^discovered^that^ these^roofing^membranes,^which^can^be^used,^for^example,^on^low-sloped^or^flat^roofs,^can^ be^secured^through^the^pressure-sensitive^adhesive^and^withstand^the^requisite^wind^uplift^forces^ at^ technologically^ useful^ high^ temperatures.^ ^ Also,^ the^ carrier^ layer^ can^ provide^additional^strength^and^durability^to^the^roofing^membrane^composites. COMPOSITE^ROOFING^MEMBRANE

[0013] Roofing^membrane^ composites^ of^ one^ or^more^ embodiments^ of^ the^ present^invention^ may^ be^ described^ with^ reference^ to^ FIG. 1,^ which^ shows^ composite^ roofing^membrane 10,^ which^ may^ simply^ be^ referred^ to^ as^ composite^ 10,^ including^ roofing^membrane subcomponent^ 13^ and^ double-sided^ adhesive^ subcomponent^ 41.^ ^ Roofing^membrane subcomponent^13,^which^may^simply^be^referred^to^as^roofing^membrane^13,polymeric^membrane^panel^13,^or^simply^panel^13 has a^ top^planar^surface^24,^a^bottom^planar^surface^23,^a^first^lateral edge^27,^and^a^second^lateral^edge^51.^^Double-sided^adhesive^subcomponent^41^is^disposed^on^and^adhesively^mated^to^planar^surface^23.^^In^one^or^more^ embodiments,^double-sided^adhesive^subcomponent^41^is^disposed^on^all^or^substantially^ all^of^surface^23,^that^is,^from^first^lateral^edge^27^to^second^lateral^edge^51.^

[0014] Double-sided^ adhesive^ subcomponent^ 41,^ which^may^ also^ be^ referred^ to^ as^double-sided^ adhesive^ sheet^ 41, adhesive^ composite^ 41, or^ adhesive^ subcomponent^ 41,includes^a^carrier^layer^47,^a^first^pressure-sensitive^adhesive^layer^43 disposed^on^a^first^planar^ surface^ of^ carrier layer^ 47,^ and^ a^ second^ pressure-sensitive^ adhesive^ layer^ 45disposed^on^a^second^planar^surface^of^carrier layer^47.^^Carrier^layer^47,^which^may^also^be^referred^to^as^middle^layer^47^or^middle^carrier^layer^47,^ may^include^a^non-rigid^foam^layer^or^a^fabric^layer.^^As^shown,^adhesive^layer^45^mates^to^surface^23^of^membrane^13.^^A^release^member^46 is^removably^attached^to^first^pressure-sensitive^layer^43 opposite^carrier layer^47.^^In^one^or^more^embodiments,^first^pressure-sensitive^adhesive^layer^43 is^disposed^on^the^ entire^ first^ planar^ surface^of^ carrier layer 47.^ ^ In^ one^ or^more^ embodiments,^ second^pressure-sensitive^ adhesive^ layer^ 45 is^ disposed^ on^ the^ entire^ second^ planar^ surface^ of^carrier layer^47.

[0015] In^one^or^more^embodiments,^roofing^membrane^composite^10^can^optionally^include^a^primer^layer.^^That^is,^in^embodiments^where^the^roofing^membrane^composite^10^ is^pre-primed^(i.e.^a^primer^layer^is^applied^prior^to^delivery^to^the^location^of^installation),as^shown^in FIG. 1,^a primer^layer^63^may^be^disposed^on^planar^surface^24^of^panel^13.^^In^one^or^more^embodiments,^primer^layer^63^is^disposed^on^only^a^portion^of^surface^24.^^For^example,^and^as^specifically^shown^in^FIG.1,^primer^layer^63^is^disposed^on^a^lap^portion^65,^which^may^also^be^referred^to^a^lap^area^65,^on^first^planar^surface^24.^^An^optional^release^ member^67^may^be^removably^attached^to^primer^layer^63^on^surface^68^of^primer^layer^63,^ which^surface^68^is^opposite^to^where^primer^layer^63^contacts^planar^surface^24^of^panel^13.^ ^ In^ one^ or^more^ embodiments,^ primer^ layer^ 63^ is^ tack^ free^ and^ therefore^ a^ release^member^is^not^required.^^In^one^or^more^embodiments,^roofing^membrane^composite^10^will^ be^field^primed^such^that^a^primer^layer^is^not^applied^prior^to^delivery^to^the^location^of^ installation.^^Other^aspects^of^a^primer^layer,^such^as^suitable^compositions^thereof,^will^be^ generally^known^to^the^skilled^person.^

[0016] Aspects^of^the^invention^can^be^described^with^reference^to^FIG. 2,^which^shows^a^roof^assembly^11^according^to^aspects^of^the^invention.^^As^shown,^assembly^11^includes^a^ first^membrane^panel^13^adhesively^mated^to^a^second^membrane^panel^15^in^a^lap^area^17^ where^panel^13^overlaps^panel^15.^^The^membrane^panels^13,15^are^mated,^via^a^top^surface^26^of^ panel^ 15,^ through^a^ first^double-sided^adhesive^sheet^41^ that^extends^across^ lower^planar^surface^23^of^panel^13.^^Double-sided^adhesive^sheet^41^also^secures^panel^13^to^roof^ substrate^21.^^The^skilled^person^appreciates^that^in^order^to^install^composites^13,15^to^deck^ 21,^any^release^member^removably^secured^to^composite^13,15^require^removal.^^Similarly,^ a^second^double-sided^adhesive^sheet^41',^which^includes^a^carrier^layer^47',^a^first^pressure-sensitive^ adhesive^ layer^ 43',^ and^ a^ second^ pressure-sensitive^ adhesive^ layer^ 45',^ extends^across^lower^planar^surface^25^of^panel^15^and^secures^panel^15^to^roof^substrate^21.^^Roof^substrate^21^may^include^ the^roof^deck,^or^ in^other^embodiments,^ roof^substrate^21^may^include^ an^ intervening^ construction^ layer^ disposed^ above^ the^ roof^ deck.^ ^ As^ the^ skilled^person^ will^ appreciate,^ these^ intervening^ layers^ may^ include,^ but^ are^ not^ limited^ to,^insulation^boards,^cover^boards,^underlayment,^and^existing^membranes. ROOFING^MEMBRANE

[0017] Practice^of^the^present^invention^is^not^necessarily^limited^by^the^selection^of^a^particular^roofing^membrane (e.g.^membrane^panel^13).^^As^is^known^in^the^art,^numerous^roofing^membranes^have^ been^ proposed^ and^ several^ are^used^ commercially. In^ these^or^other^ embodiments,^ the^ membrane^ may^ be^ flexible^ and^ capable^ of^ being^ rolled^ up^ for^shipment.^In^these^or^other^embodiments,^the^membrane^may^include^fiber^reinforcement,^ such^as^a^scrim.

[0018] In^one^or^more^embodiments,^the^membrane^may^be^a^thermoset^material.^^In^other^embodiments, the^membrane^may^be^a^thermoformable or^thermoplastic material.^^In^one^ or^ more^ embodiments,^ the^ membrane^ may^ be^ an^ EPDM-based membrane^ (i.e.^ a^membrane^ based^ on^ ethylene-propylene-diene^ rubber).^ In^ other^ embodiments,^ the^membrane^ may^ be^ a^ thermoplastic^ olefin-based^ (i.e.^ TPO^ based)^ membrane.^ ^ In^ other^embodiments,^the^membrane^may^be^a^polyvinyl^chloride-based^(i.e.^PVC^based)^membrane.^^In^one^or^more^ embodiments,^ the^membrane^ includes^EPDM^membranes^ including^ those^that^meet^the^specifications^of^the^ASTM^D-4637-21.^^In^other^embodiments,^the^membrane^includes^ thermoplastic olefin^membranes^ including^ those^ that^meet^ the^ specifications^ of^ASTM^ D-6878-03.^ ^ In^ other^ embodiments,^ the^ membrane^ includes^ a^ polyvinyl^ chloride^membrane^ including^ those^ that^meet^ the^ specifications^ of^ ASTM^ D-4434-21.^ ^ Still^ other^membranes^may^include^TPV,^CSPE,^and^asphalt-based^membranes.

[0019] Commercially^ available^ thermoplastic^ roofing^ membranes^ may^ include^polyvinyl^ chloride,^ or^ polyolefin^ copolymers.^ ^ ^ For^ example,^ thermoplastic^ olefin^ (TPO)^membranes^are^available^under^the^ trade^names^UltraPlyTM,^and^ReflexEONTM (ELEVATE)^and^SureWeldTM(Carlisle^SynTec).^^Commercially^available^thermoset^roofing^membranes^ may^include^elastomeric^copolymers^such^as^ethylene-propylene-diene^copolymer^(EPDM)^rubber^ and^ functionalized^ olefins^ such^ as^ chlorosulfonated^ polyethylene^ (CSPE).^ ^ For^example,^EPDM^membranes^are^available^under^the^trade^name^RubberGardTM,^RubberGard^PlatinumTM,^ RubberGard^EcoWhiteTM,^ and^ RubberGard^MAXTM (ELEVATE).^ ^ Useful^ EPDM^membrane^is^disclosed^in,^ for^example,^U.S.^Patent^Nos^7,175,732;^^6,502,360;^^6,120,869;^^5,849,133;^ ^ 5,389,715;^ ^ 4,810,565;^ ^ 4,778,852;^ 4,732,925;^ and^ 4,657,958,^ which^ are^incorporated^herein^ by^ reference.^ ^ EPDM^membranes^ are^ commercially^ available^ from^ a^number^ of^ sources;^ examples^ include^ those^ available^ under^ the^ tradenames^RubberGard^(ELEVATE)^and^SURE-SEAL^(Carlisle^SynTec).

[0020] Where^ the^ roofing^ membrane^ subcomponent^ includes^ a^ roofing^ membrane^including^a^plasticizer^(e.g.^PVC^membrane),^it^has^advantageously^been^discovered^that^the^ carrier^layer^can^be^made^of^a^material^which^is^adapted^to^resist^or^block^migration^of^the^plasticizer^ from^ the^roofing^membrane.^ ^ Certain^ conventional^roofing^membranes^utilize^ a^plasticizer^to^make^the^membrane^more^flexible^and^easier^to^process.^^Plasticizers,^which^are^chemicals^that^generally^ increase^ flexibility^of^a^polymer^by^reducing^intermolecular^forcesbetween^polymer^chains,^can^migrate^from^a^conventional^roofing^membrane^and^come^into^ contact^with^an^adhesive,^which^can^interfere^with^the^adhesion^bond^between^the^membrane^and^ the^substrate^ to^which^ the^membrane^ is^ attached.^ ^ The^ carrier^ layers^of^one^or^more^embodiments^ of^ the^ present^ invention^ have^ been^ advantageously^ found^ to^ sufficiently^prevent^migration^of^a^plasticizer^from^a^corresponding^roofing^membrane.^^These^carrier^layers^ can therefore^ serve^ to^ improve^ overall^ adhesion^ of^ roofing^ systems^ that^ employ^membranes^including^plasticizers.^^Still^further,^it^has^been^unexpectedly^found^that^double-sided^ adhesive^ subcomponents^ disclosed^ herein,^ particularly^ the^ pressure-sensitive^adhesive^layers^thereof,^offer^improved^adhesion^to^the^roofing^membrane,^even^for^roofing^membranes which^are^polyvinyl^chloride^based^and^which^include^plasticizer,^which^may^be^referred^to^as^monomeric^plasticizer.^ ^Particular^carrier^layers^which^have^been^ found^to^achieve^these^one^or^more^functions^include those^made^of^polyethylene^terephthalate^(e.g.^polyethylene^terephthalate^foam),^polyolefins,^and^fleece.^

[0021] In^one^or^more^embodiments,^the^roofing^membrane^panels^are^characterized^by^ conventional^dimensions.^ ^ For^ example,^ in^ one^or^more^ embodiments,^ the^membrane^panels^may^have^a^thickness^of^from^about^500^µm^to^about^3^mm,^in^other^embodiments^ from^about^1,000^µm^to^about^2.5^mm,^and^in^other^embodiments^from^about^1,500^µm^to^about^2^mm.^^In^these^or^other^embodiments,^the^membrane^panels^of^the^present^invention^ are^characterized^by^a^width^of^about^1^m^to^about^20^m,^in^other^embodiments^from^about^ 2^m^to^about^18^m,^and^in^other^embodiments^from^about^3^m^to^about^15^m. PRESSURE^SENSITIVE^ADHESIVELAYER

[0022] The^ adhesive^ subcomponent^ includes^ first^ and^ second^ pressure-sensitive^adhesive^layers^disposed^on^opposite^sides^the^non-rigid^foam^carrier^layer.^^In^one^or^more^ embodiments,^the^respective^pressure-sensitive^adhesive^layers^may^have^one^or^more^of^the^same^properties.^ ^For^example,^the^respective^pressure-sensitive^adhesive^layers^may^have^the^same^thickness^and / or^may^be^compositionally^the^same.^^In^other^embodiments,^ the^respective^pressure-sensitive^adhesive^layers^may^have^distinct^characteristics.

[0023] In^ one^ or^ more^ embodiments,^ the^ pressure-sensitive^ adhesive^ layers^ of^ the^adhesive^ sheet^ may^ be^ characterized^ by^ a^ thickness^ that^ is^ greater^ than^ 25,^ in^ other^embodiments^greater^than^50,^in^other^embodiments^greater^than^75,^in^other^embodiments^ greater^than^90,^in^other^embodiments^greater^than^100,^in^other^embodiments^greater^than^ 110,^in^other^embodiments^greater^than^125,^and^in^other^embodiments^greater^than^150^ µm.^In^these^or^other^embodiments,^the^thickness^of^the^pressure-sensitive^adhesive^layers^of^ the^ adhesive^ sheet^ is^ less^ than^ 500,^ in^ other^ embodiments^ less^ than^ 400,^ in^ other^embodiments^less^than^300,^in^other^embodiments^less^than^200,^and^in^other^embodiments^less^ than^150^ µm.^ ^ In^ one^or^more^ embodiments,^ the^ thickness^of^ the^ pressure-sensitive^adhesive^ layers^ of^ the^ adhesive^ sheet^may^ be^ from^ about^ 25^ to^ about^ 500^ µm,^ in^ other^embodiments^from^about^50^to^about^400^µm,^and^in^other^embodiments^from^about^100^to^ about^300^µm.

[0024] In^one^or^more^ embodiments,^ the^pressure-sensitive^ adhesive^ layers^may^be^characterized^by^their^glass^transition^temperature^(Tg).^^As^a^skilled^person^appreciates,^the^Tg^of^the^adhesive^can^be^determined^using^standard^ techniques^ for^differential^scanning^calorimetry^(DSC)^such^as^those^outlined^in^ASTM^D-7426-24.^^In^one^or^more^embodiments,^ the^adhesive^layers^are^characterized^by^a^Tg^of^less^than^-10^°C,^in^other^embodiments^less^ than^-20^°C,^in^other^embodiments^less^than^-30^°C,^and^in^other^embodiments^less^than^-40^°C.^ ^ In^ these^or^other^embodiments,^ the^adhesive^ layers^may^be^characterized^by^ a^Tg^of^greater^than^-70^°C,^in^other^embodiments^greater^than^-60^°C,^and^in^other^embodiments^ greater^than^-50^°C.

[0025] In^one^or^more^ embodiments,^ the^pressure-sensitive^ adhesive^ layers^may^be^characterized^ by^ their^ modulus.^ ^ As^ the^ skilled^ person^ appreciates,^ the^ modulus^ of^ the^adhesive^ can^ be^ determined^ by^ dynamic^ mechanical^ analysis^ (DMA)^ using^ procedures^analogous^ to^ ASTM^ D-4065-20.^ ^ In^ one^ or^ more^ embodiments,^ the^ pressure-sensitive^adhesive^of^the^pressure-sensitive^layers^has^a^modulus,^at^25^°C^and^1^Hz,^of^less^than^1,000^ kPa,^in^other^embodiments^less^than^500^kPa,^in^other^embodiments^less^than^300^kPa,^and^ in^other^embodiments^less^than^100^kPa.

[0026] In^one^or^more^embodiments,^the^pressure-sensitive^adhesive^layers^include,^as^major^polymeric^component,^a^rubber^such^as^ethylene-propylene-diene^rubber,^ethylene-propylene^ rubber,^ polychloroprene,^ and / or^ butyl^ rubber.^ ^ In^ other^ embodiments,^ the^pressure-sensitive^ adhesive^ layers^ include,^ as^ a^ major^ component,^ an^ acrylic^ resin^ or^polyacrylate^polymer.^^In^these^or^other^embodiments,^the^pressure-sensitive^adhesive^may^include^copolymers^that^ include^acrylic^and / or^acrylate^units^and^optionally^one^or^morefunctional^units^that^can,^upon^a^stimulus^such^as^heat,^crosslink^the^polymers.^^Exemplary^ pressure-sensitive^adhesive^compositions^based^upon^rubbers^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.

[0027] In^ one^ or^ more^ embodiments,^ the^ pressure-sensitive^ adhesive^ layer^may^ be^formed^from^a^solvent-borne^or^water-borne^composition^that^can^be^applied^to^the^surface^ of^the^foam^carrier^layer^or^to^a^transfer^film.^^As^the^skilled^person^appreciates,^evaporation^ or^removal^of^the^solvent^or^water^provides^the^adhesive^layer.^^In^one^or^more^embodiments,^heat^ or^ other^ energy^ is^ imparted^ to^ the^ adhesive^ layer^ during^ or^ after^ the^ evaporation^process^to^thereby^initiate^crosslinking^of^the^polymers^within^the^adhesive^layer.

[0028] In^other^embodiments,^the^pressure-sensitive^adhesive^layers^are^formed^from^a^ hot-melt^ pressure-sensitive^ adhesive^ composition^ that^ can^ be^ melt-extruded^ onto^ the^surface^of^ the^ foam^carrier^ or^ a^ transfer^ film.^ ^ Exemplary^melt-extrudable^ (i.e.^ hot-melt)^pressure-sensitive^ adhesives^ include^ compositions^ based^ upon^ acrylic^ polymers,^polyacrylates,^butyl^rubber,^ethylene^vinyl^ acetate,^natural^ rubber,^nitrile^rubber,^silicone^rubber,^ styrene^ block^ copolymers,^ ethylene-propylene-diene^ rubber,^ atactic^ polyalpha^olefins,^and / or^vinyl^ether^polymers.^In^combination^with^these^base^polymers,^the^pressure- sensitive^adhesive^compositions^may^include^a^variety^of^complementary^constituents^such^as,^ but^ not^ limited^ to,^ tackifying^ resins,^waxes,^ antioxidants,^ and^ plasticizers.^ ^ Pressure-sensitive^adhesives^that^are^useful^in^practicing^the^present^invention^are^known^in^the^art^as^ described,^ for^ example,^ in^ U.S.^ Patent^ No.^ 8,968,853,^ which^ is^ incorporated^ herein^ by^reference.

[0029] In^ one^ or^ more^ embodiments,^ the^ pressure-sensitive^ adhesive^ is^ non-crosslinked.^ ^ In^ other^ embodiments,^ the^ pressure-sensitive^ adhesive^ is^ crosslinked.^ ^ In^particular^ embodiments,^ the^ adhesive^ layers^ include^ a^ cured,^ hot-melt^ pressure-sensitive^adhesives.^ ^ Cured^ pressure-sensitive^ adhesives^ that^ are^ useful^ in^ practicing^ the^ present^invention^ are^ known^ in^ the^ art^ as^ described,^ for^ example,^ in^WIPO^ Publication^ No.^WO^2015 / 042258,^ WO^ 2017 / 165868,^ WO^ 2017 / 165870,^ and^ WO^ 2017 / 165871^ which^ are^incorporated^herein^by^reference.

[0030] In^one^or^more^embodiments,^the^curable^hot-melt^adhesive^that^may^be^used^for^forming^the^cured^pressure-sensitive^adhesive^layer^may^be^an^acrylic-based^hot-melt^ adhesive.^In^one^or^more^embodiments,^the^acrylic-based^holt-melt^adhesive^is^a^polyacrylatesuch^ as^ a^ polyacrylate^ elastomer.^ ^ The^ polyacrylates,^ which^may^ also^ be^ referred^ to^ as^acrylate-based^polymers,^may^include^two^or^more^chemically^distinct^polyacrylates.^^In^one^or^ more^ embodiments,^ useful^ polyacrylates^ include^ one^ or^ more^ units^ defined^ by^ the^formula:where^each^R1is^individually^hydrogen^or^a^hydrocarbyl^group^and^each^R2is^individually^a^ hydrocarbyl^group.^In^the^case^of^a^homopolymer,^each^R1and^R2,^respectively,^throughout^the^polymer^are^same^ in^each^unit.^ ^ In^ the^ case^of^a^copolymer,^at^ least^ two^different^R1and / or^two^different^R2are^present^in^the^polymer^chain.

[0031] In^one^or^more^embodiments,^hydrocarbyl^groups^include,^ for^example,^alkyl,^cycloalkyl,^ substituted^ cycloalkyl,^ alkenyl,^ cycloalkenyl,^ substituted^ cycloalkenyl,^ aryl,^substituted^aryl,^aralkyl,^alkaryl,^allyl,^and^alkynyl^groups,^with^each^group^containing^in^the^ range^of^from^1^carbon^atom,^or^the^appropriate^minimum^number^of^carbon^atoms^to^form^ 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^particular^embodiments,^ each^R2 is^an^ alkyl^group^having^at^ least^ 4^carbon^atoms.^ ^ In^particular^ embodiments,^R1 is^ hydrogen^ and^R2 is^ selected^ from^ the^ group^ consisting^of^butyl,^2-ethylhexyl,^and^mixtures^thereof.

[0032] In^ one^ or^more^ embodiments,^ the^ polyacrylate^ elastomers^ that^ are^ useful^ in^preparing^the^adhesive^layers^may^be^characterized^by^a^glass^transition^temperature^(Tg)^ of^less^than^0^°C,^in^other^embodiments^less^than^-20^°C,^in^other^embodiments^less^than^-30^ °C.^^In^these^or^other^embodiments,^useful^polyacrylates^may^be^characterized^by^a^Tg^of^from^ about^-70^to^about^0^°C,^in^other^embodiments^from^about^-50^to^about^-10^°C,^and^in^other^ embodiments^from^about^-40^to^about^-20^°C.^^In^the^context^of^the^present^invention,^glass^transition^ temperatures^ are^ determined^ according^ to^ ASTM^ E1356-08^ by^ differential^scanning^calorimetry^(DSC).

[0033] In^ one^ or^more^ embodiments,^ the^ polyacrylate^ elastomers^ that^ are^ useful^ in^preparing^the^adhesive^layers^may^be^characterized^by^a^number^average^molecular^weight^ of^from^about^100^to^about^350^kg / mole,^in^other^embodiments^from^about^150^to^about^270^ kg / mole,^and^in^other^embodiments^from^about^180^to^about^250^kg / mole.

[0034] In^ one^ or^more^ embodiments,^ the^ polyacrylate^ elastomers^ that^ are^ useful^ in^preparing^the^adhesive^layers^may^be^characterized^by^a^Brookfield^viscosity^at^150^°C^of^ from^about^20,000^to^about^70,000^cps,^in^other^embodiments^from^about^30,000^to^about^ 60,000^cps,^and^in^other^embodiments^from^about^40,000^to^about^50,000^cps.

[0035] Specific^examples^of^ polyacrylate^elastomers^ that^ are^useful^ in^preparing^ the^adhesive^ layers^ include^ poly(butylacrylate),^ and^ poly(2-ethylhexylacryalte).^ ^ These^polyacrylate^elastomers^may^be^formulated^with^photoinitiators,^solvents,^plasticizers,^and^resins^such^as^natural^and^hydrocarbon^resins.^^The^skilled^person^can^readily^formulate^a^ desirable^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.

[0036] In^other^ embodiments,^ the^polyacrylate^elastomers^may^ include^polymerized^units^ that^ serve^ as^ photoinitiators.^ ^ These^ units^ may^ derive^ from^ copolymerizable^photoinitiators^ including^acetophenone^or^benzophenone^derivatives.^ ^These^polyacrylate^elastomers^and^the^coating^compositions^formed^therefrom^are^known^as^disclosed^in^U.S.^ Patent^Nos.^7,304,119^and^7,358,319,^which^are^incorporated^herein^by^reference.

[0037] Useful^ adhesive^ compositions^ are^ commercially^ available^ in^ the^ art.^ ^ For^example,^ useful^ adhesives^ include^ those^ available^ under^ the^ tradename^ acResin^ (BASF),^those^ available^ under^ the^ tradename^ AroCure^ (Ashland^ Chemical),^ and^ NovaMeltRC^(NovaMelt).^ ^ In^ one^ or^more^ embodiments,^ these^ hot-melt^ adhesives^may^ be^ cured^ (i.e.,^crosslinked)^by^UV^light.

[0038] In^one^or^more^embodiments,^the^adhesive^layers^substantially^include^a^cured^polyacrylate^elastomer.^ In^other^words,^the^adhesive^layers^are^substantially^devoid^of^other^constituents^such^as^plasticizers^and^the^like.^^ In^one^or^more^embodiments,^the^adhesive^layers^include^greater^than^80^wt^%,^in^other^embodiments^greater^than^85^wt^%,^in^other^ embodiments^greater^than^90^wt^%,^in^other^embodiments^greater^than^95^wt^%,^and^in^ other^embodiments^greater^than^99^wt^%^of^the^cured^polyacrylate^elastomer,^based^upon^ the^total^weight^of^the^adhesive^layers.

[0039] In^one^or^more^ embodiments,^ the^ adhesive^ layers^ (e.g.^polyacrylate^hot-melt^adhesive)^are^at^least^partially^cured^after^being^applied^to^the^foamed^carrier^layer,^as^will^ be^discussed^in^greater^detail^below.^^In^one^or^more^embodiments,^the^adhesive^is^cured^to^an^extent^that^ it^is^not^thermally^processable^in^the^form^it^was^prior^to^cure.^ ^In^these^or^other^embodiments,^the^cured^adhesive^is^characterized^by^a^cross-linked^infinite^polymer^ network.^^While^at^least^partially^cured,^the^adhesive^layer^of^one^or^more^embodiments^is^essentially^ free^ of^ curative^ residue^ such^ as^ sulfur^ or^ sulfur^ crosslinks^ and / or^ phenolic^compounds^ or^ phenolic-residue^ crosslinks.^ ^ In^ one^ or^ more^ embodiments,^ the^ adhesive^layers^are^characterized^by^a^degree^of^cure^that^can^be quantified^based^upon^gel^content.^^As^ the^skilled^person^appreciates,^ gel^ content^can^be^determined^based^upon^ the^ level^of^insoluble^ material^ following^ solvent^ extraction,^ which^ for^ purposes^ of^ this^ specification^refers^to^solvent^extraction^using^THF^at^its^boiling^point^following^four^hours^of^extraction.^^ These^extraction^techniques^can^be^performed,^for^example,^using^Soxhlet^extraction^devices.^^ In^one^or^more^embodiments,^the^gel^content^of^the^cured^adhesive^layer,^based^upon^a^THF^extraction^ at^ the^ boiling^ point^ of^ THF^ after^ four^ hours,^ is^ greater^ than^ 20%,^ in^ other^embodiments^ greater^ than^ 30%,^ in^ other^ embodiments^ greater^ than^ 40%,^ in^ other^embodiments^ greater^ than^ 50%,^ in^ other^ embodiments^ greater^ than^ 55%,^ and^ in^ other^embodiments^greater^than^60%^by^weight.^^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^20%^to^about^99%,^in^other^embodiments^from^about^50%^to^about^95%,^in^other^ embodiments^from^about^55%^to^about^90%,^and^in^other^embodiments^from^about^60%^to^ about^80%^by^weight.

[0040] In^one^or^more^embodiments,^the^adhesive^layers^may^be^cured^by^employing^one^or^more^curing^techniques^including,^but^not^limited^to,^UV^curing,^electron^beam^curing,^ and^thermal^curing.^In^particular^embodiments,^UV^curing^is^employed,^and^in^this^respect,^reference^ can^ be^ made^ to^ U.S.^ Publication^ Nos.^ 2016 / 0230392,^ ^ 2017 / 0015083,^2017 / 0114543,^^2019 / 0071872,^^2019 / 0316359,^and^^2020 / 0299965.

[0041] In^one^or^more^embodiments,^the^cure^characteristics^of^the^adhesive^layer^are^substantially^homogeneous^through^the^thickness^of^the^adhesive^layer.^^In^other^words,^the^ degree^of^cure^at^any^given^point^along^the^thickness^of^the^adhesive^layer^does^not^change^appreciably,^ which^ refers^ to^ deviations^ that^ are^ less^ than^ would^ otherwise^ have^ an^appreciable^impact^on^the^practice^of^the^invention.^ ^In^other^embodiments,^the^degree^of^cure^varies^such^that^a^cure^continuum^exists^from^one^planar^surface^to^the other^planar^surface^through^the^thickness^of^the^adhesive^layer.^ ^ In^these^embodiments,^the^degree^of^cure^at^one^planar^surface^of^the^adhesive^layer^is^appreciably^greater^than^the^degree^of^cure^at^the^opposed^planar^surface^of^the^adhesive^layer^such that^the^adhesive^characteristics^will^be^appreciably^different^at^the^opposed^surfaces.Carrier^Layer NON-RIGID^FOAM^LAYER

[0042] In^one^or^more^embodiments,^the^carrier^layer^of^the^adhesive^subcomponent^includes^a^non-rigid^foam^layer,^which^may^also^be^referred^to^as^a^foam^or^foamed^carrier^ layer.^^As^is^generally^understood^in^the^art,^a^foam^is^a^cellular^structure^that^may^include^an^ interconnected^network^of^solid^struts^or^plates^(also^referred^to^as^matrix)^that^form^the^ edges^and^faces^of^cells.^^These^cellular^structures^may,^in^one^or^more^embodiments,^also^be^ defined^by^a^“relative^density”^that^is^less^than^0.8,^in^other^embodiments^less^than^0.5,^and^in^other^ embodiments^ less^ than^0.3.^ ^As^ those^ skilled^ in^ the^art^will^ appreciate,^ “relative^density”^refers^to^the^density^of^the^cellular^material^divided^by^that^of^the^solid^from^which^ the^cell^walls^are^made.^^As^the^relative^density^increases,^the^cell^walls^thicken,^and^the^pore^ space^shrinks^such^that^at^some^point^there^is^a^transition^from^a^cellular^structure^to^one^ that^is^better^defied^as^a^solid^containing^isolated^pores.^^In^one^or^more^embodiments,^the^foam^is an^open-cell^foam.^^In^other^embodiments,^the^foam^is^a^closed-cell^foam.

[0043] In^one^or^more^embodiments,^the^matrix^of^the^non-rigid^foam^layer^may^include^a^ thermoplastic^ resin.^ ^ Exemplary^ thermoplastic^ resins^ include,^ but^ are^ not^ limited^ to,^polyolefin^resins,^polyvinylchloride^resins,^acrylic^resins,^and^ethylene-vinyl^acetate^(EVA),^ acrylonitrile-butadiene-styrene^resin^(ABS),^and^polyethylene^terephthalate^resin^(PET).^^In^other^ embodiments,^ the^ matrix^ of^ the^ foamed^ carrier^ layer^ includes^ a^ thermoplastic^elastomer.^ ^Exemplary^ thermoplastic^elastomers^ include,^but^are^not^ limited^ to,^ ethylene^vinyl^ acetate,^ acrylic^ resins,^ and^ polymer^ blends^ including^ thermoplastic^ vulcanizates^or^EPDM,^SBR^and^neoprene^blends.^^In^other^embodiments,^the^matrix^of^the^foamed^carrier^ layer^is^a^thermoset^material.^Exemplary^thermoset^materials^include,^but^are^not^limited^to,^polyurethane,^ cured^ EPDM,^ cured^ blends^ of^ neoprene,^ EPDM,^ and^ SBR,^ cured^ blends^ of^neoprene^and^EPDM,^ and^ crosslinked^ polyolefins.^ ^ For^ example,^ the^ foam^may^ include^ a^polyethylene^or^polyethylene^copolymer^matrix^that^is^e-beam^crosslinked.

[0044] In^one^or^more^embodiments,^the^non-rigid^foam^layer^is^fabricated^from^a^resin^that^ inhibits^ migration^ of^ plasticizers^ conventionally^ used^ in^ PVC^ membranes^ including^phthalate^esters,^acrylates,^and^cellulose-based^compounds^such^as^cellulose^acetate.^^In one^or^ more^ embodiments,^ the^ non-rigid^ foam^ is^ fabricated^ from^ polyester^ resins^ such^ as^polyethylene^terephthalate^resins.

[0045] Aspects^of^the^invention^rely^on^the^selection^of^a^non-rigid^foam^layer,^and^more^particularly^ the^selection^of^a^non-rigid^ foam^layer^with^certain^characteristics.^ ^ It^will^be^appreciated^that^the^characteristics^of^the^non-rigid^foam^layer^are^best^quantified^prior^to^application^of^ the^pressure-sensitive^adhesive^ layers^to^ the^non-rigid^foam^layer^and^also^prior^to^incorporating^the^non-rigid^foam^layer^into^the^composites^of^the^present^invention.

[0046] The^non-rigid^foam^layer^may^be^characterized^by^the^density^of^the^foam^layer,^which^may^be^referred^to^as^foam^density,^prior^to^being^mated^to^the^adhesive^layers.^^As^a^ skilled^person^appreciates,^the^density^of^the^foam^layer^can^be^determined^by^ASTMD1056-20^for^rubber^ foams^and^ASTM^D3575-20^for^polyolefin^ (thermoplastic)^ foams.^In^one^or^more^embodiments,^the^density^of^the^foamed^carrier^layer^is^greater^than^0.8^(12.81^kg / m3),^ in^other^embodiments^greater^than^1.0^(16.02^kg / m3),^in^other^embodiments^greater^than^1.2^ (19.22^ kg / m3),^ in^ other^ embodiments^ greater^ than^ 1.4^ (22.43^ kg / m3),^ in^ other^embodiments^greater^than^1.6^(25.63^kg / m3),^in^other^embodiments^greater^than^1.8^(28.83^kg / m3),^and^in^other^embodiments^greater^than^2.0^pounds^per^cubic^foot^(lbs / ft3) (32.03^kg / m3).^^In^these^or^other^embodiments,^the^density^of^the^foamed^carrier^layer^is^less^than^ 10^(160.19^kg / m3),^in^other^embodiments^less^than^8^(128.15^kg / m3),^in^other^embodiments^ less^than^6^(96.11^kg / m3),^in^other^embodiments^less^than^4^(64.08^kg / m3),^and^in^other^embodiments^less^than^3^lbs / ft3 (48.06^kg / m3).^ In^one^or^more^embodiments,^the^density^of^the^foamed^carrier^layer^may^be^from^about^0.8^to^about^10^lbs / ft3 (12.81^– 160.19^kg / m3),^in^other^embodiments^ from^about^1.0^to^about^8^lbs / ft3 (16.02^– 128.15^kg / m3),^ in^other^embodiments^ from^about^1.0^ to^about^6^lbs / ft3,^ in^other^embodiments^from^about^1.0^to^about^4^lbs / ft3 (16.02^– 64.08^kg / m3),^and^in^other^embodiments^from^about^1.2^to^about^3^lbs / ft3 (19.22^– 48.06^kg / m3).

[0047] The^non-rigid^ foam^ layer^may^ be^ characterized^ by^ the^ firmness^of^ the^ foam,^which^is^determined^by^ASTM^D1056-20^prior^to^being^mated^to^the^adhesive^layers.^^In^one^ or^more^embodiments,^the^firmness^of^the^foamed^carrier^layer^may^be^greater^than^0.1^psi^(0.689^ kPa),^ in^ other^ embodiments^ may^ be^ greater^ than^ 0.25^ psi^ (1.72^ kPa),^ in^ other^embodiments^may^be^greater^than^0.5^psi^(3.45^kPa),^in^other^embodiments^may^be^greater^than^1^psi^ (6.89^kPa),^ in^other^embodiments^greater^ than^3^psi^ (20.67^kPa),^and^ in^other^embodiments^greater^than^5^psi^(34.45^kPa).^^In^these^or^other^embodiments,^the^firmness^ of^the^foamed^carrier^layer^may^be^less^than^15^psi^(103.35^kPa),^in^other^embodiments^less^than^ 12^ psi^ (82.68^ kPa),^ in^ other^ embodiments^ less^ than^ 10^ psi^ (68.90^ kPa),^ in^ other^embodiments^less^than^8^psi^(55.12^kPa),^in^other^embodiments^less^than^6^psi^(41.34^kPa),^and^in^other^embodiments^less^than^4^psi^(27.56^kPa).^ ^ In^one^or^more^embodiments,^the^foamed^carrier^layer^may^have^a^firmness^of^from^about^0.1^to^about^15^psi^(0.689^- 103.35^kPa),^in^other^embodiments^from^about^0.5^to^about^15^psi^(3.45^kPa^- 103.35^kPa),^in^other^embodiments^from^about^2^to^about^12^psi^(13.78^- 82.68^kPa),^in^other^embodiments^from^about^1^to^about^10^psi^(6.89^kPa^- 68.90^kPa),^in^other^embodiments^from^about^1^to^about^12^psi^(6.89^- 68.90^kPa),^and^in^other^embodiments^from^about^3^to^about^10^psi^(20.67^-68.90^kPa).

[0048] The^ non-rigid^ foam^ layer^ may^ be^ characterized^ by^ tensile^ strength,^ in^ the^machine^direction,^as^determined^prior^to^being^mated^to^the^adhesive^layers.^^As^a^skilled^ person^appreciates,^machine^direction^tensile^strength^of^the^foamed^carrier^layer^can^be^ determined^by^ASTM^D412-16.^^In^one^or^more^embodiments,^the^machine^direction^tensile^strength^ of^ the^ foamed^ carrier^ layer^ is^ greater^ than^ 30^ psi^ (206.70^ kPa),^ in^ other^embodiments^greater^than^40^psi^(275.6^kPa),^ in^other^embodiments^greater^ than^50^psi^(344.50^kPa),^and^in^other^embodiments^greater^than^60^psi^(413.4^kPa).^^In^these^or^other^ embodiments,^the^machine^direction^tensile^strength^of^the^foamed^carrier^layer^is^less^than^120^ psi^ (826.8^ kPa),^ in^ other^ embodiments^ less^ than^ 100^ psi^ (689^ kPa),^ in^ other^embodiments^less^than^80^psi^(551.2^kPa),^and^in^other^embodiments^less^than^50^psi^(344.5^kPa).^ ^In^one^or^more^embodiments,^the^machine^direction^tensile^strength^of^the^foamed^carrier^layer^may^be^from^about^30^to^about^100^psi^(206.7^- 689^kPa),^in^other^embodiments^from^about^40^to^about^90^psi^(275.6^- 620.1^kPa),^and^in^other^embodiments^from^about^50^to^about^80^psi^(344.5^- 551.2^kPa).^^In^one^or^more^embodiments,^the^tensile^strength^of^the^non-rigid^foam^layer^in^the^cross-machine^direction^is^at^least^70%,^in^other^embodiments^at^ least^80%,^in^other^embodiments^at^least^90%,^and^in^other^embodiments^at^least^95%^of^the^ tensile^strength^in^the^machine^direction.

[0049] The^non-rigid^foam^layer^may^be^characterized^by^its^thickness^prior^to^being^mated^to^the^adhesive^layers.^^In^one^or^more^embodiments,^the^thickness^of^the^foamed^carrier^ layer^is^greater^than^100^µm,^in^other^embodiments^greater^than^250^µm,^in^other^embodiments^ greater^than^500^µm,^in^other^embodiments^greater^than^1,000^µm,^in^other^embodiments^ greater^than^1,500^µm,^in^other^embodiments^greater^than^2,000^µm,^and^in^other^embodiments^greater^than^3,500^µm.^^In^these^or^other^embodiments,^the^thickness of^the^foamed^carrier^layer^is^less^than^10,000^µm,^in^other^embodiments^less^than^8,000^µm,^in^other^embodiments^less^than^7,000^µm,^ in^other^embodiments^ less^ than^5,000^µm^and^in^other^embodiments^less^than^4,000^µm.^^In^one^or^more^embodiments,^the^thickness^of^the^foamed^carrier^layer^may^ include^from^about^500^µm^to^about^10,000^µm,^in^other^embodiments^from^about^1,000^µm^ to^about^7,000^µm,^and^in^other^embodiments^from^about^1,500^µm^to^about^5,000^µm.

[0050] In^one^or^more^embodiments,^the^non-rigid^foam^layer^may^be^characterized^by^a^Shore^A^hardness, which^may^be^determined^by^ASTM^D2240-15,^prior^to^being^mated^with^the^adhesive^layers.^^In^one^or^more^embodiments,^the^foamed^carrier^layer^is^characterized^by^ a^ Shore^ A^ hardness^ of^ less^ than^ 10,^ in^ other^ embodiments^ less^ than^ 7,^ in^ other^embodiments^less^than^4,^in^other^embodiments^less^than^2,^and^in^other^embodiments^less^ than^1.^^In^one^or^more^embodiments,^the^foamed^carrier^layer^is^characterized^by^a^Shore^A^ hardness^of^from^about^0^to^about^10,^in^other^embodiments^from^about^1^to^about^7,^and^in^ other^embodiments^from^about^2^to^about^5.

[0051] In^one^or^more^embodiments,^the^non-rigid^foam^layer^may^be^characterized^by^the^deflection^strength of^ the^ foam,^which^can^be^determined^by^ASTM^D3575-20^at^25%^deflection,^prior^to^being^mated^to^the^adhesive^layers.^ ^ In^one^or^more^embodiments,^the^foamed^carrier^layer^may^be^characterized^by^a^deflection^strength^at^25%^deflection^of^less^than^ 15^ psi (103.42^ kPa),^ in^ other^ embodiments^ less^ than^ 12^ psi^ (82.68^ kPa),^ in^ other^embodiments^less^than^10^psi^(68.90^kPa),^in^other^embodiments^less^than^8^psi^(55.12^kPa),^in^other^ embodiments^ less^ than^6^psi^ (41.34^kPa),^ in^other^ embodiments^ less^ than^4^psi^(27.56^ kPa),^ and^ in^ other^ embodiments^ less^ than^ 2^ psi^ (13.78^ kPa).^ ^ In^ one^ or^ more^embodiments,^the^foamed^carrier^layer^may^be^characterized^by^a^deflection^strength^at^25%^deflection^of^from^about^1^to^about^30^psi^(6.89^- 206.84^kPa),^in^other^embodiments^from^about^1^to^about^25^psi^(6.89^- 172.37^kPa),^in^other^embodiments^from^about^2^to^about^20^psi^(13.78^- 137.90^kPa),^and^in^other^embodiments^from^about^3^to^about^15^psi^(20.67^-103.42^kPa).

[0052] In^one^or^more^embodiments,^the^non-rigid^foam^layer^may^be^characterized^by^elongation^in^the^machine^direction,^which^may^be^determined^by^ASTM^D^3575-20.^^In^one^ or^more^embodiments,^the^foamed^carrier^layer^may^be^characterized^by^an^elongation^of^ greater^than^100%,^in^other^embodiments^greater^than^150%,^in^other^embodiments^greater^ than^200%,^in^other^embodiments^greater^than^250%,^and^in^other^embodiments^greater^ than^300%.^^In^one^or^more^embodiments,^the^foamed^carrier^layer^may^be^characterized^by an^elongation^of^from^about^100^to^about^500%,^in^other^embodiments^from^about^150^to^ about^450%,^and^in^other^embodiments^from^about^200^to^about^400%.

[0053] In^one^or^more^embodiments,^the^non-rigid^foam^layer^may^be^characterized^by^elongation^in^the^cross-machine^direction,^which^may^be^determined^by^ASTM^D3575-20.^^In^ one^or^more^embodiments,^the^foamed^carrier^layer^may^be^characterized^by^an^elongation^of greater^ than^ 80%,^ in^ other^ embodiments^ greater^ than^ 100%,^ in^ other^ embodiments^greater^than^150%,^in^other^embodiments^greater^than^200%,^and^in^other^embodiments^greater^ than^ 220%.^ In^ one^ or^ more^ embodiments,^ the^ foamed^ carrier^ layer^ may^ be^characterized by^an^elongation^of^from^about^80^to^about^400%,^in^other^embodiments^from^about^100^to^about^350%,^and^in^other^embodiments^from^about^150^to^about^300%. FABRIC^CARRIER^LAYER

[0054] In^one^or^more^embodiments,^the^carrier^layer^is a^fabric^carrier^layer,^which^may^ also^ be^ referred^ to^ as^ a^ fleece^ carrier^ layer,^ a^ fabric,^ or^ a^ fleece.^ ^ As^ is^ generally^understood^in^the^art,^fabrics^are^those^materials^produced^from^fibers^or^filaments.^^In^one^ or^more^embodiments,^the^fabric^carrier^layer^may^include^a^synthetic^fabric^including^glass^or^polymeric^ fibers^or^ filaments.^ ^ In^particular^embodiments,^ the^ fabric^ carrier^ layer^ is^ a^fleece,^ such^ as^ a^napped^ fleece.^ ^ Also^ useful^ are^ fleece^ carrier^ layers^of^ the^ type^ that^ are^otherwise^useful^as^fabric^backing^for^roofing^membranes^are^generally^known^in^the^art^as^described^ in^U.S.^ Patent^Nos.^4,996,812;^ ^5,422,179;^ ^5,981,030; and^6,502,360^which^are^incorporated^herein^ by^ reference.^ ^ In^ particular^ embodiments,^ the^ fabric^ carrier^ layer^ is^fleece^ prepared^ from^ polyester^ filaments^ such^ as^ those^ prepared^ from^ polyethylene^terephthalate.^^In^one^or^more^embodiments,^the^fabric^carrier^layer^is^a^continuous^filament^polyester,^needle^punched,^nonwoven^fabric.^^In^other^embodiments,^the^fabric^carrier^layer^ is^a^scrim^reinforced^nonwoven^polyester^mat.^^In^yet^other^embodiments,^the^fabric^carrier^ layer^is^a^glass^fiber^mat.

[0055] In^one^or^more^embodiments,^where^the^fabric^carrier^layer^is^a^glass^fiber^mat,^the^ fabric^may^be^characterized^by^a^basis^weight^of^at^ least^50,^ in^other^embodiments^at^least^60,^and^in^other^embodiments^at^ least^70^g / m2.^ ^ In^these^or^other^embodiments,^the^glass^fiber^mat^may^be^characterized^by^a^basis^weight^of^at^most^150,^in^other^embodiments^ at^most^130,^and^in^other^embodiments^at^most^100^g / m2.^^In^one^or^more^embodiments,^the^glass^fiber^mat^may^be^characterized^by^a^basis^weight^of^from^about^50 to^about^150^g / m2,^in^other^embodiments^from^about^60^to^about^130^g / m2,^and^in^other^embodiments^from^ about^70^to^about^110^g / m2.

[0056] In^one^or^more^embodiments,^where^the^fabric^carrier^layer^is^a^glass^fiber^mat,^the^glass^mat^may^be^characterized^by^a^thickness^of^at^least^0.5^mm,^in^other^embodiments^ at^least^0.7^mm,^and^in^other^embodiments^at^least^1.0^mm.^^In^these^or^other^embodiments,^ the^glass^mat^may^be^characterized^by^a^thickness^of^at^most^2.0^mm,^in^other^embodiments^ at^most^1.5^mm,^and^in^other^embodiments^at^most^1.2^mm.^^In^one^or^more^embodiments,^ the^glass^mat^may^be^characterized^by^a^thickness^of^from^about^0.5^to^about^2.0^mm,^in^other^ embodiments^from^about^0.7^to^about^1.5^mm,^and^in^other^embodiments^from^about^1.0^to^ about^1.2^mm.

[0057] In^one^or^more^embodiments,^where^the^fabric^carrier^layer^is^a^polyester^fleece,^the^ fabric^may^be^characterized^by^a^basis^weight^of^at^ least^70,^ in^other^embodiments^at^least^85,^and^in^other^embodiments^at^least^100^g / m2.^^In^these^or^other^embodiments,^the^polyester^ fleece^ may^ be^ characterized^ by^ a^ basis^ weight^ of^ at^ most^ 400,^ in^ other^embodiments^at^most^300,^and^in^other^embodiments^at^most^280^g / m2.^ ^ In^one^or^more^embodiments,^the^polyester^fleece^may^be^characterized^by^a^basis^weight^of^from^about^70^ to^about^400^g / m2,^in^other^embodiments^from^about^85^to^about^300^g / m2,^and^in^other^ embodiments^from^about^100^to^about^280^g / m2.

[0058] In^one^or^more^embodiments,^where^the^fabric^carrier^layer^is^a^polyester^fleece,^the^glass^mat^may^be^characterized^by^a^thickness^of^at^least^0.5^mm,^in^other^embodiments^ at^least^0.7^mm,^and^in^other^embodiments^at^least^1.0^mm.^^In^these^or^other^embodiments,^the^ polyester^ fleece^ may^ be^ characterized^ by^ a^ thickness^ of^ at^ most^ 4.0^ mm,^ in^ other^embodiments^at^most^2.0^mm,^and^in^other^embodiments^at^most^1.5^mm.^^In^one^or^more^ embodiments,^the^polyester^fleece^may^be^characterized^by^a^thickness^of^from^about^0.5^to^about^ 4.0^ mm,^ in^ other^ embodiments^ from^ about^ 0.7^ to^ about^ 2.0^ mm,^ and^ in^ other^embodiments^from^about^1.0^to^about^1.5^mm.

[0059] The^fabric^carrier^employed^in^the^present^invention^may^be^characterized^by^tensile^strength,^in^the^machine^direction,^as^determined^prior^to^being^mated^to^the^adhesive^layers.^ ^ As^ a^ skilled^ person^ appreciates,^machine^ direction^ tensile^ strength^ of^ the^ fabric^carrier^ layer^ can^ be^ determined^ by^ ASTM^ D412-16.^ ^ In^ one^ or^more^ embodiments,^ the^machine^ direction^ tensile^ strength^of^ the^ fabric^ carrier^ layer^ is^ greater^ than^ 30,^ in^other^embodiments^ greater^ than^ 40,^ in^ other^ embodiments^ greater^ than^ 50,^ and^ in^ other^embodiments^greater^than^55^daN.^^In^these^or^other^embodiments,^the^machine^direction^ tensile^strength^of^the^fabric^carrier^layer^is^less^than^120,^in^other^embodiments^less^than^ 100,^in^other^embodiments^less^than^80,^and^in^other^embodiments^less^than^70^daN.^^In^one^ or^more^embodiments,^the^machine^direction^tensile^strength^of^the^fabric^carrier^layer^may^ be^from^about^30^to^about^100^daN,^in^other^embodiments^from^about^40^to^about^90^daN,^ and^in^other^embodiments^from^about^50^to^about^80^daN. INTUMESCENT^MATERIAL

[0060] In^one^or^more^embodiments,^the^carrier^layer^includes^intumescent^material.^^Useful^intumescent^materials^include^those^that^act^as^a^fire^resistant^material.^^A^preferred^ intumescent^material^for^embodiments^of^the^invention^is^expandable^graphite.^^Expandable^ graphite^may^also^be^referred^to^as^expandable^flake^graphite,^intumescent^flake^graphite,^or^ expandable^flake;^and,^for^the^purposes^herein,^these^terms^may^be^used^interchangeably.^

[0061] In^ one^ or^ more^ embodiments,^ expandable^ graphite^ includes^ intercalated^graphite^in^which^an^intercallant^material^is^included^between^the^graphite^layers^of^graphite^crystal^ or^ particle.^ ^ Examples^ of^ intercallant^ materials^ include^ halogens,^ alkali^ metals,^sulfates,^ nitrates,^ various^organic^acids,^ aluminum^chlorides,^ ferric^ chlorides,^ other^metal^halides,^arsenic^sulfides,^and^thallium^sulfides.^^In^one^or^more^embodiments^of^the^present^ invention,^the^expandable^graphite^includes^non-halogenated^intercallant^materials.^^In^one^ or^more^embodiments,^the^expandable^graphite^includes^sulfate^intercallants,^also^referred^to^as^graphite^bisulfate.^^As^is^known^in^the^art,^bisulfate^intercalation^is^achieved^by^treating^ highly^crystalline^natural^flake^graphite^with^a^mixture^of^sulfuric^acid^and^other^oxidizing^ agents^which^act^to^catalyze^the^sulfate^intercalation.

[0062] Commercially^ available^ examples^ of^ expandable^ graphite^ include^ HPMS^Expandable^ Graphite^ (HP^ Materials^ Solutions,^ Inc.,^ Woodland^ Hills,^ CA)^ and^ Expandable^Graphite^Grades^1721^(Asbury^Carbons,^Asbury,^NJ).^^Other^commercial^grades^contemplated^as^useful^ in^ the^present^ invention^ include^1722,^3393,^ 3577,^ 3626,^and^1722HT^ (Asbury^Carbons,^Asbury,^NJ).

[0063] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^ a^mean^or^average^size^ in^ the^range^ from^about^30^µm^to^ about^1.5^mm,^ in^other^embodiments^from^about^50^µm^to^about^1.0^mm,^and^in^other^embodiments^from^about^180^to^ about 850^ µm.^ ^ In^ one^ or^ more^ embodiments,^ the^ expandable^ graphite^ may^ be^characterized^as^having^a^mean^or^average^size^of^at^least^30^µm,^in^other^embodiments^at^ least^44^µm,^in^other^embodiments^at^least^180^µm,^and^in^other^embodiments^at^least^300^µm.^ ^In^one^or^more^embodiments,^expandable^graphite^may^be^characterized^as^having^a^mean^or^average^size^of^at^most^1.5^mm,^ in^other^embodiments^at^most^1.0^mm,^ in^other^embodiments^ at^ most^ 850^ µm,^ in^ other^ embodiments^ at^ most^ 600^ µm,^ in^ yet^ other^embodiments^ at most^ 500^ µm,^ and^ in^ still^ other^ embodiments^ at^ most^ 400^ µm.^ ^ Useful^expandable^graphite^includes^Graphite^Grade^#1721^(Asbury^Carbons),^which^has^a^nominal^ size^of^greater^than^300^µm.

[0064] In^one^or^more^embodiments^of^the^present^invention,^the^expandable^graphite^may^be^characterized^as^having^a^nominal^particle^size^of^20x50^(US^sieve).^^US^sieve^20^has^ an^opening^equivalent^to^0.841^mm^and^US^sieve^50^has^an^opening^equivalent^to^0.297^mm.^^ Therefore,^a^nominal^particle^size^of^20x50^indicates^the^graphite^particles^are^at^least^0.297^ mm^and^at^most^0.841^mm.

[0065] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^ a^ carbon^ content^ in^ the^ range^ from^ about^ 70%^ to^ about^ 99%.^ ^ In^ one^ or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^a^carbon^content^of^ at^least^80%,^in^other^embodiments^at^least^85%,^in^other^embodiments^at^least^90%,^in^yet^other^ embodiments^ at^ least^ 95%,^ in^ other^ embodiments^ at^ least^ 98%,^ and^ in^ still^ other^embodiments^at^least^99%^carbon.

[0066] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^a^sulfur^content^in^the^range^from^about^0%^to^about^8%,^in^other^embodiments^from^ about^2.6%^to^about^5.0%,^and^in^other^embodiments^from^about^3.0%^to^about^3.5%.^In^one^or^more^ embodiments,^ the^ expandable^ graphite^may^ be^ characterized^ as^ having^ a^ sulfur^content^of^at^least^0%,^in^other^embodiments^at^least^2.6%,^in^other^embodiments^at^least^ 2.9%,^in^other^embodiments^at^least^3.2%,^and^in^other^embodiments^3.5%.^^In^one^or^more^ embodiments,^the^expandable^graphite^may^be^characterized^as^having^a^sulfur^content^of^at^ most^8%,^in^other^embodiments^at^most^5%,^in^other^embodiments^at^most^3.5%.

[0067] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^ an^ expansion^ ratio^ (cc / g)^ in^ the^ range^ from^ about^ 10:1^ to^ about^ 500:1,^ in^ other^embodiments^at^least^20:1^to^about^450:1,^in^other^embodiments^at^least^30:1^to^about^400:1,^ in^other^embodiments^from^about^50:1^to^about^350:1.^^In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^an^expansion^ratio^ (cc / g)^of^at^ least^10:1,^ in^ other^ embodiments^ at^ least^ 20:1,^ in^ other^ embodiments^ at^ least^ 30:1,^ in^ other^embodiments^at^ least^40:1,^ in^other^embodiments^at^ least^50:1,^ in^other^embodiments^at^least^60:1,^in^other^embodiments^at^least^90:1,^in^other^embodiments^at^least^160:1,^in^other^ embodiments^at^least^210:1,^^in^other^embodiments^at^least^220:1,^in^other^embodiments^at^ least^230:1,^in^other^embodiments^at^least^270:1,^in^other^embodiments^at^least^290:1,^and^in^ yet^ other^ embodiments^ at^ least^ 300:1.^ ^ In^one^ or^more^ embodiments,^ the^ expandable^graphite^may^be^characterized^as^having^an^expansion^ratio^(cc / g)^of^at^most^350:1,^and^in^ yet^other^embodiments^at^most^300:1.

[0068] In^one^or^more^embodiments,^the^expandable^graphite,^as^ it^exists^within^ the^adhesive^sheet^of^the^present^invention,^is^partially^expanded.^^In^one^or^more^embodiments,^ the^expandable^graphite^is^not^expanded,^however,^to^a^deleterious^degree,^which^includes^ that^amount^or^more^of^expansion^that^will^deleteriously^the^ability^to^form^the^sheet^product^ and^the^ability^of^the^graphite^to^serve^as^flame^retardant^at^desirable^levels,^which^include^ those^levels^that^allow^proper^formation^of^the^adhesive^sheet.^^In^one^or^more^embodiments,^ the^expandable^graphite^is^expanded^to^at^most^100%,^in^other^embodiments^at^most^50%,^in^ other^ embodiments^ at^ most^ 40%,^ in^ other^ embodiments^ at^ most^ 30%,^ in^ other^embodiments^ at^most^ 20%,^ and^ in^ other^ embodiments^ at^ most^ 10%^beyond^ its^ original^unexpanded^size.

[0069] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^as^having^a^pH^in^the^range^from^about^1^to^about^10;^in^other^embodiments^from^about^1^to^about^ 6;^ and^ in^ yet^ other^ embodiments^ from^ about^ 5^ to^ about^ 10.^ ^ In^ one^ or^ more^embodiments, the^expandable^graphite^may^be^characterized^as^having^a^pH^ in^ the^range^from^about^4^ to^about^7.^ ^ In^one^or^more^embodiments,^ the^ expandable^ graphite^may^be^characterized^as^having^ a^pH^of^ at^ least^1,^ in^other^ embodiments^at^ least^ 4,^and^ in^other^embodiments^ at^ least^ 5.^ ^ In^ one^or^more^ embodiments,^ the^ expandable^ graphite^may^be^characterized^ as^ having^ a^ pH^ of^ at^ most^ 10,^ in^ other^ embodiments^ at^ most^ 7,^ in^ other^embodiments^at^most^6.5,^ in^other^embodiments^at^most^6,^and^in^other^embodiments^at^most^5.

[0070] In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^by^an^onset^ temperature^ranging^from^about^100^°C^ to^about^280^°C;^ in^other^embodiments^from^about^160^°C^to^about^225^°C;^and^in^other^embodiments^from^about^180^°C^to^about^200^°C.^ In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^by^an^onset^ temperature^ of^ at^ least^ 100^ °C,^ in^ other^ embodiments^ at^ least^ 130^ °C,^ in^ other^embodiments^at^least^160^°C,^in^other^embodiments^at^least^170^°C,^in^other^embodiments^ at^least^180^°C,^in^other^embodiments^at^least^190^°C,^and^in^other^embodiments^at^least^200^ °C.^^In^one^or^more^embodiments,^the^expandable^graphite^may^be^characterized^by^an^onset^temperature^ of^ at^ most^ 250^ °C,^ in^ other^ embodiments^ at^ most^ 225^ °C,^ and^ in^ other^embodiments^at^most^200^°C.^^Onset^temperature^may^also^be^interchangeably^referred^to^ as^expansion^temperature;^it^may^also^be^referred^to^as^the^temperature^at^which^expansion^ of^the^graphite^starts.

[0071] Practice^of^this^invention^is^not^limited^by^the^selection^of^any^particular^method^for^ adding^ the^ intumescent^ material^ to^ the^ middle^ carrier^ layer.^ ^ In^ one^ or^ more^embodiments,^the^intumescent^material^can^be^included^when^the^material^of^the^middle^carrier^ layer^ is^ produced.^ ^ Adding^ the^ intumescent^ material^ during^ manufacture^ of^ the^middle^ carrier^ layer^ could^ include^ accounting^ for^ suitable^ temperature^ at^ which^ the^manufacturing^occurs.^ ^That^ is,^ onset^ temperature of^ the^ intumescent^material should^be^considered.^^For^example,^adding^the^intumescent^material^during^manufacture^of^the^middle^ carrier^layer^could^include^employing^a^low^temperature^foam^as^the^middle^carrier^layer.^^ In^one^or^more^embodiments,^particularly^where^the^middle^carrier^layer^is^a^foamed^carrier^ layer^made^of^open^cell^foam,^the^intumescent^material^may^be^added^at^or^near^the^surface^ of^the^middle^carrier^layer.^^For^example,^the^intumescent^material^may^be^added^into^the^ open^cells^of^open^cell^foam,^such^as^by^sprinkling^the^intumescent^material.^^Exemplary^open^cell^ foam^for^the^middle^carrier^includes^a^ foam^which^ is^cut^to^a^desired^ thickness.^ ^The^addition^of^the^ intumescent^material,^whether^by^sprinkling^or^another^technique,^should^include^ not^ interfering^ with^ the^ adhesive^ properties^ of^ the^ middle^ carrier^ layer^ to^ a^deleterious^degree.^ ^ In^ one^or^more^ embodiments,^ particularly^where^ the^middle^ carrier^layer^is^a^fabric^carrier^layer,^the^intumescent^material^may^be^applied^by^coating^the^middle^carrier^ layer^ with^ a^ coating^ including^ the^ intumescent material.^ ^ Application^ of^ the^intumescent^ material^ by^ coating^ may^ be^ a^ dip^ coating^ technique.^ ^ Application^ of^ the^intumescent^material^by^coating^may^include^employing^a^suspension^with^a^binder,^where^ the^suspension^includes^the^intumescent^material.^^Exemplary^suspensions^and^binders^will^ generally^be^known^to^the^skilled^person,^and^may^include^latex^and^acrylic^suspensions.^^In^ one^or^more^embodiments,^conventional^methods^for^coating^fabrics^may^be^employed^in^the^ practice^ of^ this^ invention.^ ^ As^ an^ example,^ U.S.^ Patent No.^ 5,112,678^ is^ incorporated^herein^by^reference.

[0072] In^one^or^more^embodiments,^the^middle^carrier^layer^includes^at^least^1%^by^weight,^in^other^embodiments^at^least^2%^by^weight,^in^other^embodiments^at^least^5%^by^weight,^and^in^other^embodiments^at^least^7%^by^weight expandable^graphite^based^on^the^total^weight^of^the^middle^carrier^layer.^^In^these^or^other^embodiments,^the^middle^carrier^ layer^includes^at^most^50%^by^weight,^in^other^embodiments^at^most^40%^by^weight,^and^in^other^embodiments^at^most^30%^by^weight expandable^graphite^based^on^the^total^weight^of^the^middle^carrier^layer.^^In^one^or^more^embodiments,^the^middle^carrier^layer^includes^from^about^2^ to^about^50,^ in^ other^embodiments^ from^about^5^ to^about^40,^and^ in^other^embodiments^from^about^7^to^about^30%^by^weight expandable^graphite^based^on^the^total^weight^of^the^middle^carrier^layer.RELEASE^MEMBER

[0073] In^one^or^more^embodiments,^the^release^liners (e.g.^liners^46 and^67),^which^may^also^be referred^to^as^release^members,^may^include^polymeric^films or^extrudates.^ For^example,^the film^or^extrudate^may^include^a^single^polymeric^layer^or^may^include^two^or^more^polymeric^layers^laminated^or^coextruded^to^one^another.^ In^other^embodiments,^the^release^linersmay^include^woven^or^non-woven^substrates^(e.g.^cellulosic^substrates) having^a^polymeric^film^or^coating^applied^thereon,^which^film^or^coating^may^be^referred^to^as^a^polymeric^layer.^ The^polymeric^layer^may^be^a^single^layer^or^it^may^include^multiple^layers.

[0074] Suitable^ materials^ for^ forming^ a^ release^ liner^ that^ is^ a^ polymeric^ film^ or^extrudate^ include^ polypropylene,^ polyester,^ high-density^ polyethylene,^ medium-density^polyethylene,^ low-density^polyethylene,^polystyrene^or^high-impact^polystyrene.^ Suitable^materials^for^forming^a^polymeric^layer^on^a^cellulosic-based^release^liner^include^siloxane-based^ materials,^ butadiene-based^ materials,^ organic^ materials (e.g.^ styrene-butadiene^rubber^latex),^as^well^as^those^polymeric^materials^employed^to^form^a^film^or^extrudate^as^ described^above.^These^polymeric^materials^may^offer^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^referenced^films^and^materials^may^be^coated^with^a^release^agent,^(e.g.^– silicone).

[0075] In^ one^ or^ more^ embodiments,^ the^ release^ member^ is^ characterized^ by^ a^thickness^of^from^about^15^to^about^80,^in^other^embodiments^from^about^18^to^about^75,^ and^in^other^embodiments^from^about^20^to^about^50^µm. CHARACTERISTICS^OF^DOUBLE-SIDED^ADHESIVE^SHEET

[0076] In^one^or^more^embodiments,^the^double-sided^adhesive^sheet^has^a^thickness^of^greater^ than^25,^ in^other^embodiments^greater^ than^50,^ in^other^embodiments^greater^than^75,^and^in^other^embodiments^greater^than^100^μm.^^In^these^or^other^embodiments,^the^ double-sided^ adhesive^ sheet^ may^ have^ a^ thickness^ of^ less^ than^ 890,^ in^ other^embodiments^less^than^760,^in^other^embodiments^less^than^635,^in^other^embodiments^less^ than^508,^and^in^other^embodiments^less^than^380^μm.^^In^one^or^more^embodiments,^the^double-sided^adhesive^ sheet^has^ a^ thickness^of^ from^about^25^ to^ about^890^μm,^ in^other^embodiments^from^about^50^to^about^760^μm,^in^other^embodiments^from^about^75^to^about^ 635^μm,^and^in^other^embodiments^from^about^100^to^about^508^μm.

[0077] In^one^or^more^embodiments,^the^double-sided^adhesive^sheet^has^a^width^of^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^double-sided^adhesive^sheet^may^have^a^width^of^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^double-sided^adhesive^sheet^has^a^width^of^from^about^30^ cm^ to^ about^15^m,^ in^ other^ embodiments^ from^ about^45^ cm^ to^ about^ 12^m,^ in^ other^embodiments^from^about^60^cm^to^about^9^m,^and^in^other^embodiments^from^about^75^cm^ to^about^6^m.

[0078] In^one^or^more^embodiments,^the^double-sided^adhesive^sheet^is^provided^in^the^form^of^a^roll,^and^therefore^the^double-sided^adhesive^sheet^may^have^an^extended^length.^^ In^one^or^more^embodiments,^the^double-sided^adhesive^sheet^has^a^length^of^greater^than^ 30^cm,^in^other^embodiments^greater^than^6^m,^in^other^embodiments^greater^than^10^m,^ and^in^other^embodiments^greater^than^50^m.^^In^these^or^other^embodiments,^the^double-sided^adhesive^sheet^may^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^from^about^30^cm^to^about^900^m,^in^other^embodiments^from^about^6^m^to^about^ 750^m,^in^other^embodiments^from^about^10^m^to^about^600^m,^and^in^other^embodiments^ from^about^20^m^to^about^300^m.

[0079] In^ one^ or^ more^ embodiments,^ the^ double-sided^ adhesive^ sheet^ may^ be^characterized^by^tensile^strength^measured^perpendicular^to^the^planar^surface^of^the^carrier^ layer,^which^may^also^be^referred^to^as^the^Z-direction^tensile^strength.^^The^skilled^person^appreciates^ that^ Z-direction^ tensile^ strength^ of^ the^ carrier^ layer^ can^ be^ determined^ by^employing^an^adaptation^of^ASTM^C209-20,^wherein^the^adaptation^included^employing^a^2^inch^ x^ 2^ inch^metal^ plates^ (affixed^ to^ Instron^ operating^ pursuant^ to^ the^ ASTM^ C209-20specification)^ and^adhere^ each^of^ the^respective^ sides^of^ a^2^ inch^ x^2^ inch^composite^(i.e.^double-sided^ sheet)^ directly^ to^ the^ respective^ plates.^ ^ In^ one^ or^more^ embodiments,^ the^carrier^layer is^characterized^by^a^Z-direction^tensile^strength^of^greater^than^4^psi^(27.58^kPa),^ in^other^embodiments^greater^than^5^psi^(34.47^kPa),^in^other^embodiments^greater^than^ 6^ psi^ (41.37^ kPa),^ in^ other^ embodiments^ greater^ than^ 7^ psi^ (48.26^ kPa),^ in^ other^embodiments^greater^than^10^psi^(68.95^kPa),^ in^other^embodiments^greater^ than^12^psi^(82.74^kPa),^in^other^embodiments^greater^than^15^(103.42^kPa),^and^in^other^embodiments^greater^ than^ 18^ psi^ (124.11^ kPa).^ ^ In^ these^ or^ other^ embodiments,^ the carrier^ layer is^characterized^by^a^Z-direction^tensile^strength^of^from^about^3^psi^(20.68^kPa)^to^about^45^psi^ (310.26^ kPa),^ in^ other^ embodiments^ from^ about^ 10^ psi^ (68.95^ kPa)^ to^ about^ 40^ psi^(275.79^kPa),^and^in^other^embodiments^ from^about^15^psi^ (103.42^kPa)^ to^about^35^psi^(241.32^kPa).

[0080] In^ one^ or^ more^ embodiments,^ the^ double-sided^ adhesive^ sheet^ may^ be^characterized^by^its^permeability^(or^lack^thereof).^^The^skilled^person^appreciates^that^the^permeability^of^the^carrier^layer can^be^determined^by^ASTM^E96 / E96M-23.^^In^one^or^more^embodiments,^ the^ double-sided^ adhesive^ sheet^ is^ non-permeable,^ which^ refers^ to^ a^composite^characterized^by^less^than^0.1^perms^pursuant^to^ASTM^E96 / E96M-23.^^In^other^embodiments,^ the^ double-sided^ adhesive^ sheet^ is^ semi-impermeable,^ which^ refers^ to^ a^composite^ characterized^by^ 0.1^ to^ 1.0^perms^pursuant^ to^ ASTM^E96 / E96M-23.^ ^ In^other^embodiments,^ the^ double-sided^ adhesive^ sheet^ is^ semi-permeable,^ which^ refers^ to^ a^composite^characterized^by^1.0^to^10^perms^pursuant^to^ASTM^E96- / E96M-23.

[0081] In^ one^ or^ more^ embodiments,^ the^ double-sided^ adhesive^ sheet^ may^ be^characterized^by^its^bond^strength^to^stainless^steel^panel,^which^can^be^determined^by^the^ dead^load^shear^test^provided^in^Pressure^Sensitive^Tape^Council^(PSTC)^107,^Method^A^(revised^May^ 2007),^ at^ 23^ °C^ + / -1^ °C.^ ^ For^ purposes^ of^ this^ specification,^Method^A is^followed^except^that^polyester^film^is^adhered^to^the^exposed^surfaces^of^the^test^specimen^ to^ensure^that^failure^occurs^at^the^interface^of^the^adhesive^and^the^stainless^steel^plate.^^The^sample^ is^ aged^ for^ one^ minute^ after^ application^ of^ the^ polyester^ film.^ ^ In^ one^ or^more^embodiments,^double-sided^adhesive^sheet^is^characterized^by^a^dead^load^shear^at^22^°C^of^at^ least^60^minutes,^in^other^embodiments^at^least^120^minutes,^in^other^embodiments^at^least^180^minutes,^and^in^other^embodiments^at^least^240^minutes.METHOD^OF^MANUFACTURING^COMPOSITE^ROOFING^MEMBRANES

[0082] In^one^or^more^embodiments,^the^composite^roofing^membranes^of^the^present^invention^may^be^fabricated^by^mating^a^roofing^membrane^to^a^double-sided^adhesive^sheet.

[0083] The^roofing^membrane^may^be^provided^by^preparing^a^roofing^membrane^by^using^ conventional^ techniques.^ ^ For^ example,^ thermoplastic^ membrane^ panels^ may^ be^formed^by^the^extrusion^of^thermoplastic^compositions^into^one^or^more^layers^that^can^be^laminated^ into^ a^membrane^ panel.^ ^ Thermoset^membranes^ can^ be^ formed^ using^ known^calendering^and^curing^techniques.^^Alternatively,^thermoset^membranes^can^be^made^by^a^continuous^ process^ such^ as^ those^ disclosed^ in^WO^ 2013 / 142562,^ which^ is^ incorporated^herein^by^reference.

[0084] The^ double-sided^ adhesive^ component,^ which^may^ also^ be^ referred^ to^ as^ an^adhesive^sheet,^may^be^provided^as^follows.^^As^suggested^above,^the^double-sided^adhesive^component^includes^a^ first^pressure-sensitive^adhesive^ layer,^a^second^pressure-sensitive^adhesive^ layer,^ and^ a^ carrier^ layer.^ ^ Prior^ to^being^mated^ to^ the^ construction^ board,^ the^adhesive^component^may^be^in^the^form^of^a^roll^with^at^least^one^release^member^protecting^ the^adhesive^layers.^^The^skilled^person^will^appreciate^that^the^pressure-sensitive^layers^and^ the^carrier^layer^will^have^the^characteristics^outlined^above^with^respect^to^the^composite.^^Useful^ double-sided^ adhesive^ components^ are^ also^ described^ in^ co-pending^PCT / EP2024 / 058094,^which^is^incorporated^herein^by^reference.

[0085] In^one^or^more^embodiments,^where^the^adhesive^layers^include^cured^adhesive^compositions,^the^adhesive^layers^may^be^cured^by^employing^one^or^more^curing^techniques^including,^ but^ not^ limited^ to,^ UV^ curing,^ electron^ beam^ curing,^ and^ thermal^ curing.^ ^ In^particular^embodiments,^UV^curing^is^employed,^and^in^this^respect,^reference^can^be^made^to U.S.^ Publication^Nos.^ 2016 / 0230392,^2017 / 0015083,^2017 / 0114543,^ ^2019 / 0071872,^^2019 / 0316359,^and^^2020 / 0299965.

[0086] In^ one^ or^ more^ embodiments,^ the^ roofing^ membrane^ and^ the^ double-sided^adhesive^component^are^mated.^^For^example,^the^membrane^the^double-sided^adhesive^can^ be^mated^by^using^conventional^laminating^techniques.^^In^one^or^more^embodiments,^where^ the^double-sided^adhesive^component^is^provided^in^the^form^of^a^roll^with^a^single^layer^of^release^ liner,^ the^ adhesive^ component^ can^ be^ unwound^ to^ expose^ a^ layer^of^ adhesive to^thereby^allow^it^to^be mated^to^the^roofing^membrane while^retaining^the^release^liner^to^protect^the^adhesive^during^shipment^and^handling^of^the^composite. METHOD^OF^ASSEMBLING^ROOF^SYSTEM

[0087] The^composite^roofing^membranes of^one^or^more^embodiments^of^the^present^invention^ can^ advantageously^ be^ adhered^ to^ a^ roof^ structure,^ such^ as^ a^ roof^ deck or^intervening^ construction^ board^ layers,^ by^ using^ convenient peel-and-stick installation^techniques.^^In^one^or^more^embodiments,^the^roofing^membranes^can^be^adhered^without^ the^use^of^adhesives^or^primers,^which^may^include^volatile^organic^compounds.

[0088] According^to^one^or^more^embodiments,^the^composite^roofing^membranes can^be^ pre-fabricated at a^ location^ other^ than^where^ the^ composite^ roofing^membranes are^installed.^^For^example,^the^composite^roofing^membranes can^be^prepared^at^a^fabrication^facility^including^the^facility^where^the^roofing^membranes are^fabricated.^ ^The^composite^roofing^membranes can^then^be^rolled and^shipped^to^the^location^where^they^are^ultimately^installed^on^a^roof^structure.^^To^the^extent^that^the^composite^roofing^membrane is^rolled^for^ storage^ and^ shipment,^ the^ step^ of^ providing^ the^ composite^ roofing^ membrane^ may^include^providing^a^rolled^composite^roofing^membrane^to^the^location^where^the^composite^roofing^membrane will^be^installed.^^As^the^skilled^person^will^appreciate,^in^order^to^place^the^ composite^ roofing^ membrane^ into^ position^ for^ installation,^ the^ composite^ roofing^membrane^is^unrolled.

[0089] In^ one^ or^ more^ embodiments,^ the^ roof^ may^ be^ assembled^ by^ providing^ a^composite^roofing^membrane^of^this^invention,^positioning^the^composite^roofing^membraneat^a^ location^at^or^proximate^ to^where^the^composite^roofing^membrane^will^be^installed,^removing^the^release^member^to^expose^the^layer^of^pressure-sensitive^adhesive,^and^then^securing^ the^composite^roofing^membrane^ to^ the^ roof^substrate.^ ^ The^ skilled^person^also^appreciates^ that^ in^addition^to^securing^ the^membrane^composite^of^ this^invention^to^ the^underlying^roof^substrate,^adjacent^membranes^are^seamed^to^each^other^to^thereby^provide^ a^waterproof^barrier.^^In^one^or^more^embodiments,^seaming^takes^place^by^employing^the^ pressure-sensitive^adhesive^associated^with^the^membrane^composites^as^shown^in^FIG.^2.INDUSTRIAL^APPLICABILITY

[0090] Practice^of^the^present^invention^is^not^necessarily^limited^by^the^selection^of^any^particular^roof^ substrate^ to^which^ the^membranes^ can^be^attached^ in^ forming^a^roof^system.^^In^one^or^more^embodiments,^the^roof^substrate^may^include^the^roof^deck.^^In^other^embodiments,^ the^roof^substrate^may^ include^ an^ intervening^construction^ layer^disposed^above^ the^ roof^deck.^ ^As^ the^ skilled^person^will^ appreciate,^ these^ intervening^ layers^may^include,^but^are^not^limited^to,^insulation^boards,^cover^boards,^underlayment,^and^existing^ membranes.

[0091] In^one^ or^more^ embodiments,^ roof^ systems^ can^be^ constructed^by^using^ the^composite^roofing^membranes of^the^present^invention.^^In^one^or^more^embodiments,^this^will^include^application^of^the^composite membrane^over^a construction^board;^i.e.^after^at^least^one^layer^of^construction^boards^is^installed.^^Practice^of^the^present^invention^is^not^necessarily^limited^by^the^selection^of^a^particular^roofing^membrane or^construction^board.^^

[0092] As^indicated^above,^practice^of^the^present^invention^provides^a^roofing system^wherein^the^roofing^membranes are^fully^adhered^within^the^roofing^system (e.g.^they^may^be^partially^or^fully^adhered^to^ the^substrate).^ ^ In^one^or^more^embodiments,^ these^ fully-adhered^ systems^ have^ improved^ resistance^ to^ wind^ uplift^ forces,^ and^ improved^ ease^ of^application^ and^ installation.^ ^ Also,^ roofing^ membranes^ can^ advantageously^ be^ installed^without^release^of^volatile^organic^compounds^to^the^atmosphere.^^Moreover,^the^adhesion^of^the^roofing^membranes to^the^underlying^substrate^is^technologically^advantageous.^ ^In^one^or^more^embodiments,^the^adhesion^between^the^roofing^membrane^and^the^underlying^substrate^may^be^characterized^by^a^Factory^Mutual^4450^wind^uplift test^or^a^Underwriters^Laboratories^UL580^wind^uplift^test,^with^values^in^excess^of^90^pounds^per^square^foot.

[0093] 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.^^This^invention^is^not^ to^be^duly^limited^to^the^illustrative^embodiments^set^forth^herein.

Claims

CLAIMS What^is^claimed^is:

1. A^roofing^membrane^composite^comprising:(a) a^roofing^membrane^subcomponent;^and(b) a^double-sided^adhesive^subcomponent.

2. The^roofing^membrane^composite^of^claim^1,^further^comprising^a^release^member.

3. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^said^double-sided^adhesive^subcomponent^includes^a^carrier layer^and^first^and^second^pressure-sensitive^adhesive^layers^disposed^on^opposite^sides^of^the^carrier layer.^4. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the first^and^second^pressure-sensitive^adhesive^layers^include^a^cured^polyacrylate.^5. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^first^and^second^pressure-sensitive^adhesive^layers^have^a^thickness^of^from^about^51^to^about^ 381^µm.

6. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^first^and^second^pressure-sensitive^adhesive^layers^have^a^Tg^of^less^than^0°C.

7. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the roofing^membrane^ subcomponent^ includes^ a^ roofing^ membrane^ that is^ an^ EPDM-basedmembrane,^ a^ TPO-based membrane, a PVC-based membrane, a TPV-basedmembrane, a CSPE-based membrane,^and^an^asphalt-based membrane.

8. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where the roofing^membrane^subcomponent^is^an^EPDM-based membrane.

9. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where the roofing^membrane^subcomponent^is^a^TPO-based membrane.^10. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where the roofing^membrane^subcomponent^is^a PVC-based membrane.

11. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where the roofing^membrane^composite is^in^the^form^of^a^roll.

12. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the roofing^membrane^ subcomponent^ is^ an^ EPDM-based roofing^ membrane^ meeting^ the^specifications^of^ASTM^D-4637-21.^13. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^roofing^membrane^ subcomponent^ is^ a^ thermoplastic^ olefin-based^membrane^meeting^ the^specifications^of^ASTM^D-6878-03.

14. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^roofing^membrane^ subcomponent^ is^ a polyvinyl^ chloride-based^ membrane^ meeting^ the^specifications^of^ASTM^D-4434-21.

15. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^roofing^membrane^subcomponent^includes^a roofing^membrane^having^a^thickness^of^from^about^500^µm^to^about^3^mm.^16. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^roofing^membrane^subcomponent^includes^a roofing^membrane^having^a^width^of^about^1^m^to^about^20^m.

17. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^carrier^layer^is^a^non-rigid^foam^layer.^18. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^foamed^thermoplastic^resin.

19. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^foamed^thermoplastic^resin^is^a^foamed^polyolefin.

20. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^foamed^acrylic^resin.

21. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^foamed^elastomer.

22. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^foamed^ethylene^vinyl^acetate^resin.

23. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^foamed^polyurethane.

24. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a foamed^polyethylene^terephthalate^resin.

25. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^has^a^thickness^of^about^500^to^about^10,000^µm.

26. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^a^closed^cell^foam.

27. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^is^an^open cell^foam.

28. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^has^a^density^of^from^about^0.8^to^about^10^lbs^per^ft3.

29. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^non-rigid^foam^layer^has,^prior^to^sandwiching^between^the^pressure-sensitive^adhesive^layers,^ a^tensile^strength^of^about^30^to^about^100^psi.

30. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^the^carrier^layer^is^a^fabric^layer.^31. The^roofing^membrane^composite^of^any^of^the^preceding^claims,^where^ the^fabric^layer^is^fleece.^32. A^ roof^ system^ including^ the^roofing^membrane^composite^of^any^of^ the^preceding^claims.

33. The^roof system^of any^of^the^preceding^claims,^where the^carrier^layer^includes^an^intumescent^material.

34. The^ roof system^ of any^ of^ the^ preceding^ claims,^ where the^ roofing^ membrane^subcomponent^ is^ a^ PVC-based^ membrane,^ and^ where^ the^ carrier^ is^ foamed^polyethylene^terephthalate^resin.

35. A^ method^ of^ installing^ the^ roofing^membrane^ composite^ of^ any^ of^ the^ preceding^claims^on^a^roof,^the^method^comprising^positioning^the^roofing^membrane^composite^ on^a^roof^surface,^removing^the^release^member;^and^securing^the^roofing^membrane^ composite^to^the^roof.

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