Method of making construction board composites

Abstract

A method of making a construction board composite for a roof system includes (i) mixing an A-side stream and a B-side stream to thereby form a foam mixture; (ii) depositing the foam mixture to a first planar surface of a foam carrier layer to thereby form a developing foam on the first planar surface of the foam carrier layer; and (hi) allowing the developing foam to form a foam body mated to the first planar surface of the foam carrier layer. The foam carrier layer can be part of an adhesive subcomponent further including a pressure-sensitive adhesive layer mated with a second planar surface of the foam carrier layer and a release member protecting the pressure-sensitive adhesive layer. Alternatively, the method can further include (iv) applying a pressure-sensitive adhesive layer on a second planar surface of the foam carrier layer to mate the pressure-sensitive adhesive with the foam carrier layer.

Description

METHOD OF MAKING CONSTRUCTION BOARD COMPOSITESFIELD OF THE INVENTION

[0001] Embodiments of the present invention provide a method of making construction board composites including an adhesive composite with a foam carrier layer.BACKGROUND OF THE INVENTION

[0002] Construction boards, particularly those employed in the construction industry, may include a foam layer and at least one facer. Often, the foam layer is sandwiched between two facers. The foam layer can include a closed cell polyurethane, closed cell polyurea, closed cell phenolic foam, or polyisocyanurate foam. Examples of construction boards include polyisocyanurate or polyurethane foam construction boards used in the roofing industry, particularly those used to cover low-sloped or flat roofs. These boards may include insulation boards that are used primarily as a roof insulation, or foam cover boards, which are typically higher in density and are primarily used to protect the underlying substrate (e.g., underlying insulation boards).

[0003] Construction boards, especially those used to cover a roof surface, are often applied by using mechanical fasteners. These fasteners typically include a plate that extends the surface area that is contacted between the fastener and the board. The fastener is an element (e.g., screw) that protrudes through the plate and can pierce the board and penetrate the underlying roof deck (e.g., a wood deck). Multiple fasteners and plates are employed for each board in predetermined patterns to counteract strong wind uplift forces that are often encountered on the roof.

[0004] While mechanical fasteners are commonly used and accepted by the industry, they have several drawbacks. First, installation using mechanical fasteners is labor intensive, especially in view of the number of fasteners and plates used for each board. This increases both installation time and costs. Also, the fasteners can act as "thermal bridges” and thereby transfer heat between the upper surface of the roof construction and the underlying roof deck (or even the interior of the structure).

[0005] In the alternative, construction boards have been applied to a roof surface using adhesives. For example, hot asphalt or polyurethane foam adhesives have been employed tosecure insulation board by applying a layer of adhesive (e.g., a two-part polyurethane adhesive), and then subsequently positioning the construction boards over the adhesive layer. While this technique may be less labor intensive and provides adhesion over the entire surface of the board (i.e., it creates a fully-adhered system), drawbacks nonetheless exist. First, hot asphalt requires specialized training and equipment to install safely. Polyurethane foam adhesives are difficult to handle and can require trained applicators to apply. Also, these adhesives may contain volatile organics that are released into the environment during installation.

[0006] It has also been proposed to apply a layer of pressure-sensitive adhesive to a facer of a construction board to thereby provide a means of adhesively attaching construction boards to a roof surface. Conventional wisdom suggests applying the adhesive to the facer as a liquid, such as a solvent-borne composition or a hot melt, to thereby form a layer of pressure-sensitive adhesive. A release liner can then be applied over the pressuresensitive layer to protect the adhesive layer during storage and shipment. The release liner can be removed during installation and the construction boards installed by using the so- called peel-and-stick method. Despite the apparent ease of this type of system, these composites have not gained widespread adoption in the industry.SUMMARY OF THE INVENTION

[0007] One or more embodiments of the present invention provide a method of making a construction board composite for a roof system, the method comprising: mixing an A-side stream and a B-side stream to thereby form a foam mixture; depositing the foam mixture to a first planar surface of a foam carrier layer to thereby form a developing foam on the first planar surface of the foam carrier layer, the foam carrier layer being part of an adhesive composite further including a pressure-sensitive adhesive layer mated with a second planar surface of the foam carrier layer and a release member protecting the pressure-sensitive adhesive layer; and allowing the developing foam to form a foam body mated to the first planar surface of the foam carrier layer.

[0008] Other embodiments of the present invention provide a method of making a construction board composite for a roof system, the method comprising: mixing an A-side stream and a B-side stream to thereby form a foam mixture; depositing the foam mixture toa first planar surface of a foam carrier layer to thereby form a developing foam on the first planar surface of the foam carrier layer; allowing the developing foam to form a foam body mated to the first planar surface of the foam carrier layer; and applying a pressure-sensitive adhesive on a second planar surface of the foam carrier layer to mate the pressure-sensitive adhesive with the foam carrier layer, where the applying the pressure-sensitive adhesive includes the pressure-sensitive adhesive being part of a transfer film subcomponent which includes the pressure-sensitive adhesive mated with a release liner.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a schematic of a method of making a construction board composite according to embodiments of the present invention.

[0010] FIG. 2 is a schematic of an alternative method of making a construction board composite according to embodiments of the present invention.

[0011] FIG. 3 is a cross-sectional side view of a construction board composite according to embodiments of the present invention.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0012] Embodiments of the invention are based, at least in part, on the discovery of a method of making a construction board composite which includes an adhesive composite with a carrier layer, which can be a foam carrier layer. The method advantageously produces improved construction board composites. The method allows for the production of composite construction boards with a single pressure-sensitive adhesive layer mated with the foam carrier layer. The foam carrier layer can be adapted to withstand the elevated temperatures involved with producing the construction board composite. The foam carrier layer further allows an adhesive layer of the adhesive composite to securely mate the foam construction boards to a desired substrate even though many foam construction boards, especially polyisocyanurate foam boards, have irregular bonding surfaces and / or the substrates to which the construction boards are attached often have irregular surfaces. Thus, while the prior art contemplates composite construction boards with pressuresensitive adhesive layers for peel-and-stick applications, it has been discovered that variability in the surface of the construction board and the substrates to which the boardsare attached frustrate the adhesion offered by the layer of pressure-sensitive adhesive. The present invention, which provides a construction board composite having an adhesive composite with a foam carrier layer adjacent to a pressure-sensitive adhesive layer, advantageously overcomes problems associated with prior art composite construction boards. It has been discovered that these construction boards, which can be used, for example, as insulation boards or cover boards on low-sloped or flat roofs, can be secured through the pressure-sensitive adhesive layer and withstand the requisite wind uplift forces at technologically useful high temperatures. Also, where the adhesive composite, which may be referred to as an adhesive subcomponent, is applied as a continuous layer over the surface of the construction boards, the use of the adhesive subcomponent advantageously provides a vapor barrier layer for the roof system.METHOD OF MAKING CONSTRUCTION BOARD COMPOSITES

[0013] Embodiments of the present invention can be described with reference to FIG. 1, which shows a system 10 for conducting a continuous process for producing construction board composites 35 employing a conveyor system 13. In a first step of the process, a carrier layer 17, which may be referred to as carrier 17, adhesive substrate 17, foam carrier 17, foam carrier layer 17, foamed carrier layer 17, or non-rigid foam layer 17 is placed indirectly on conveyor system 13. Foam carrier layer 17 has a subcomponent 31 mated therewith, which may be referred to as a release liner subcomponent 31, which directly contacts conveyor system 13. Release liner subcomponent 31 includes a pressure-sensitive adhesive layer 37 with a release liner 44 removably mated thereto (see also FIG. 3). The combination of foam carrier layer 17 and subcomponent 31 (i.e., including the pressure-sensitive adhesive layer 37) may be referred to as an adhesive composite 19 or an adhesive subcomponent 19. Following the step of placing the adhesive composite 19 including foam carrier layer 17 on conveyor system 13, a developing foam 30 is deposited on at least a portion of a first planar surface of foam carrier layer 17.

[0014] The production technique for developing foam 30, which may be referred to as continuous foam mass 30 or rising foam mixture 30, includes providing an A-side stream of reagents 27 and a B-side stream of reagents 29. The A-side stream and the B-side stream are mixed in a mixing step within, for example, a plurality of mix heads 25. This step of mixing the A-side stream and the B-side stream forms a reaction mixture, which may also bereferred to as a foam reaction mixture or simply a foam mixture. The reaction mixture is then deposited onto foam carrier layer 17 from multiple sources (e.g., multiple mix heads). As those skilled in the art appreciate, foam carrier layer 17 is conveyed as it receives the foam mixture, and the plurality of foam masses formed on foam carrier layer 17 from the multiple sources generally flow toward each other to form the continuous foam mass 30 across the width of foam carrier layer 17. Foam body 32 is mated to the first planar surface of foam carrier layer 17 to thereby form construction board composite 35. As those skilled in the art appreciate, a facer (not shown) can be positioned over the rising foam mixture 30 (i.e., continuous foam mass 30) in a facer marrying step, which facer can be supplied from a pour roller. The reaction mixture then rises to become married to the facer to form a precursor construction board, which precursor construction board can be conveyed to a laminator. Notably, the rising foam mixture 30 will generate heat and additional heat may be supplied to the precursor board while in the laminator, or the overall environment within the laminator may be maintained to provide for appropriate reaction conditions within the laminator. This can be accomplished by heating the laminator or the environment in which the laminator is contained. Likewise, the laminator or the environment in which the laminator is contained may be adapted to provide multiple heating zones where the precursor board can be exposed to different temperatures or overall heat conditions. Those skilled in the art also appreciate that the foam construction boards 35 can be prepared without facers as described in U.S. Patent No. 6,117,375, which is incorporated herein by reference, and the skilled person can readily adaptthe process steps of the present invention to adapt for practicing embodiments without the use of a facer. Upon allowing the developing foam 30 to form a foam body 32, the foam body 32 is mated to the first planar surface of foam carrier layer 17 to thereby form construction board composite 35.

[0015] Alternative embodiments of the present invention can be described with reference to FIG. 2, which shows a system 11 for conducting a continuous process for producing construction board composites 35 employing conveyor system 13. In a first step of the process, foam carrier layer 17 is placed directly on conveyor system 13. In the embodiment of FIG. 2, foam carrier layer 17 does not initially have release liner subcomponent 31 provided therewith when placed on conveyor system 13. The foam production technique otherwise proceeds as described above relative to FIG. 1. Concurrently with or after the foambody 32 is formed, a pressure-sensitive adhesive layer 37 (see also FIG. 3) is applied on a second planar surface of foam carrier layer 17 to mate pressure-sensitive adhesive layer 37 with foam carrier layer 17. This step can include applying pressure-sensitive adhesive layer 37 via release liner subcomponent 31, which may also be referred to as transfer film subcomponent 31. Transfer film subcomponent 31 can be applied according to standard techniques, such as a laminating technique. As with FIG. 1, subcomponent 31 includes pressure-sensitive adhesive layer 37 with release liner 44 removably mated thereto (see also FIG. 3). Upon application of the subcomponent 31, system 11 produces construction board composite 35. In one or more embodiments, transfer film subcomponent 31 can be applied after the foam material (e.g., foam body 32) passes through the laminator such that subcomponent 31 does not have to endure the heat of the laminator.

[0016] It will be appreciated that the embodiments described with reference to FIG. 1 and FIG. 2 may include conventional downstream subprocesses, such as trimming and cross cutting, which are conventional steps of a continuous foam construction board process. For example, the continuous foam construction board product can undergo cross-cutting to form individual foam construction boards having a desired length, which may be a first length where multiple cross-cutting steps are involved. The process may include one or more additional steps, such as a finishing step where the boards are trimmed to width. This step may take place before or after cross-cutting. Other finishing steps may include heating or cooling the boards, wrapping or otherwise packaging the boards, stacking the boards, storing the boards, and shipping the boards.

[0017] Further regarding the embodiments described with reference to FIG. 1 and FIG. 2, the width and length dimensions of foam carrier layer 17 and the foam material (e.g., foam body 32) will generally correspond with each other, especially for construction board composites 35. The width and length dimensions of the pressure-sensitive adhesive layer 37 (e.g., via release liner subcomponent 31) can also correspond with the dimensions of foam carrier layer 17 and the foam material (e.g., foam body 32). In other embodiments, the width and / or length dimensions of the pressure-sensitive adhesive layer 37 and release liner 44 (i.e., release liner subcomponent 31) may be less than the width and / or length of foam carrier layer 17, where partial coverage might be desired. That is, pressure-sensitive adhesive layer 37 and release liner 44 might be disposed on only a portion of foam carrierlayer 17. This can include pressure-sensitive adhesive layer 37 and release liner 44 being disposed in the form of strips, such as along lateral edges of foam carrier layer 17 or being offset from one or both lateral edges of foam carrier layer 17.

[0018] The skilled person appreciates that the composite boards (e.g., composite 35) of the present invention can be sized (i.e., length and width) in a conventional manner, which may include, for example, 4” x 8” and 4” x 4” sizes. Where pressure-sensitive adhesive layer 37 and release liner 44 are provided in strips that do not extend across the entire width of the composite boards, the width of the strips can be provided in desired widths. For example, the width of the strips may be 10 to about 20 inches (25.4 - 50.8 cm), in other embodiments 12 to about 18 inches (30.48 - 45.72 cm), and in other embodiments 14 to about 16 inches (35.56 - 40.64 cm).

[0019] In one or more embodiments, the composite boards (e.g., composite 35) maybe characterized by the degree to which the pressure-sensitive adhesive layer 37 and release liner 44 cover the surface of the foam material (e.g., foam body 32). This degree of coverage may be referred to as coverage rate, which may be quantified as a percentage of the surface covered by the pressure-sensitive adhesive layer 37 and release liner 44 (i.e., subcomponent 31). In one or more embodiments, the coverage rate is greater than 30%, in other embodiments greater than 40%, in other embodiments greater than 50%, in other embodiments greater than 60%, and in other embodiments greater than 70%. In one or more embodiments, the coverage rate is from about 30 to about 100%, in other embodiments from about 40 to about 90%, in other embodiments from about 50 to about 80%, and in other embodiments from about 60 to about 75%.FOAM CONSTRUCTION BOARDS

[0020] Other aspects of producing foam construction boards (e.g. foam body 32) will be generally known to the skilled person. In one or more embodiments, the foam body 32, which may also be referred to as rigid foam body32 or rigid foam layer 32, includes a rigid closedcell foam structure. In one or more embodiments, the rigid foam body 32 may include a polyurethane, polyurea, phenolic, or polyisocyanurate foam. For example, processes and techniques for the production of polyurethane or polyisocyanurate construction boards (known as boardstock) are generally known as described in U.S. Patent Nos. 10,000,922; 8,153,039; 7,838,568; 7,612,120; 7,387,753; 6,117,375; 6,044,604; 5,891,563; 5,573,092;as well as U.S. Publication Nos. 2019 / 0061313; 2006 / 0179749; 2004 / 0109983; 2003 / 0082365; 2003 / 0153656; 2003 / 0032351; and 2002 / 0013379, which are each incorporated herein by reference.

[0021] In one or more embodiments, these conventional techniques generally include (i) providing reactant streams, (ii) combining reactant streams to form a foam mixture, (iii) depositing the foam mixture onto a substrate (e.g., facer) from multiple mix heads, which thereby forms multiple rising foam masses on the substrate, (iv) optionally allowing the multiple foam masses to merge into a single foam mass, (v) contacting a second facer to the rising foam masses or the single foam mass to form a foam board precursor, (vi) restricting the foam board precursor within a laminator to form a continuous foam board, (vii) removing the foam precursor from the laminator, and (viii) cross-cutting the continuous foam board to form construction boards of desired length. These conventional techniques may also optionally include heating the foam or foam board precursor at one or more steps (e.g. within the laminator). These techniques may also include one or more post-laminator fabrication steps such as lateral trimming where the sides of the continuous foam construction board or the cross-cut construction boards are trimmed in the machine direction. Those skilled in the art also appreciate that the cross-cutting step can take place in multiple steps; for example, the continuous foam construction board can be cut to a first length (e.g., 8 ft. in length), and then these boards can be subsequently cut to a second length (e.g., 4 ft. in length) in a second cross-cutting step.

[0022] In one or more embodiments, the foam is prepared by mixing a first stream that includes an isocyanate-containing compound with a second stream that includes an isocyanate-reactive compound. Using conventional terminology, the first stream (i.e., the stream including an isocyanate-containing compound) may be referred to as an A-side stream, an A-side reactant stream, or simply an A stream. Likewise, the second stream (i.e., the stream including an isocyanate-reactive compound) may be referred to as a B-side stream, B-side reactant stream, or simply B stream. In one or more embodiments, either stream may carry additional ingredients including, but not limited to, flame -retardants, surfactants, blowing agents, catalysts, emulsifiers / solubilizers, fillers, fungicides, anti-static substances, and mixtures of two or more thereof.

[0023] In one or more embodiments, the A-side stream may only contain the isocyanate-containing compound. In one or more embodiments, multiple isocyanate- containing compounds may be included in the A-side. In other embodiments, the A-side stream may also contain other constituents such as, but not limited to, flame -retardants, surfactants, blowing agents and other non-isocyanate-reactive components. In one or more embodiments, the complementary constituents added to the A-side are non-isocyanate reactive. And, as suggested above, the A-side may include the acyclic pentane blowing agent and the blowing agent additive in accordance with the present invention. In other embodiments, the A-side is devoid or substantially devoid of the acyclic blowing agent and the blowing agent additive.

[0024] Suitable isocyanate-containing compounds useful for the manufacture of polyisocyanurate construction board are generally known in the art and embodiments of this 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 diphenyl methane diisocyanate in the form of its 2,4'-, 2,2'-, and 4,4'-isomers and mixtures thereof. The mixtures of diphenyl methane diisocyanates (MDI) and oligomers thereof may be referred to as "crude” or polymeric MDI, and these polyisocyanates may have an isocyanate functionality of greater than 2. Other examples include toluene diisocyanate in the form of its 2,4' and 2,6'-isomers 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).

[0025] In one or more embodiments, the B-side stream may only include the isocyanate-reactive compound. In one or more embodiments, multiple isocyanate-reactive compounds may be included in the B-side. In other embodiments, the B-side stream may also contain other constituents such as, but not limited to, water, flame -retardants, surfactants, blowing agents and other non-isocyanate-containing components. In particular embodiments, the B-side includes an isocyanate reactive compound, the acyclic pentane blowing agent, and the blowing agent additive. In these or other embodiments, the B-side may also include flame retardants, catalysts, emulsifiers / solubilizers, surfactants, fillers, fungicides, anti-static substances, and other ingredients that are conventional in the art.

[0026] An exemplary isocyanate-reactive compound is a polyol. The term polyol, or polyol compound, includes diols, polyols, and glycols, which may contain water as generally known in the art. Primary and secondary amines are suitable, as are polyether polyols and polyester polyols. In particular embodiments, aromatic polyester polyols are employed. Exemplary polyester polyols include phthalic anhydride based PS-2352 (Stepan), phthalic anhydride based polyol PS-2412 (Stepan), terephthalic based polyol 3522 (Invista), and a blended polyol TR 564 (Huntsman). 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, without limitation, ethylene diamine, and diethanolamine. In one or more embodiments, a polyester polyol is employed. In one or more embodiments, the present invention may be practiced in the appreciable absence of any polyether polyol. In certain embodiments, the ingredients are devoid of polyether polyols.

[0027] Catalysts, which are believed to initiate the polymerization reaction between the isocyanate and the polyol, as well as a trimerization reaction between free isocyanate groups when polyisocyanurate foam is desired, may be employed. While some catalysts expedite both reactions, two or more catalysts may be employed to achieve both reactions. Useful catalysts include salts of alkali metals and carboxylic acids or phenols, such as, for example potassium octoate; mononuclear or polynuclear Mannich bases of condensable phenols, oxocompounds, and secondary amines, which are optionally substituted with alkyl groups, aryl groups, or aralkyl groups; tertiary amines, such as pentamethyldiethylene triamine (PMDETA), 2,4,6-tris[(dimethylamino)methyl]phenol, triethyl amine, tributyl amine, N- methyl morpholine, and N-ethyl morpholine; basic nitrogen compounds, such as tetra alkyl ammonium hydroxides, alkali metal hydroxides, alkali metal phenolates, and alkali metal acholates; and organic metal compounds, such as tin(II)-salts of carboxylic acids, tin(IV)- compounds, and organo lead compounds, such as lead naphthenate and lead octoate.

[0028] Surfactants, emulsifiers, and / or solubilizers may also be employed in the production of polyurethane and polyisocyanurate foams in order to increase the compatibility of the blowing agents with the isocyanate and polyol components. Surfactants may serve two purposes. First, they may help to emulsify / solubilize all the components so that they react completely. Second, they may promote cell nucleation and cell stabilization.

[0029] Exemplary surfactants include silicone co-polymers or organic polymers bonded to a silicone polymer. Although surfactants can serve both functions, it may also be useful to ensure emulsification / solubilization by using enough emulsifiers / solubilizers to maintain emulsification / solubilization and a minimal amount of the surfactant to obtain good cell nucleation and cell stabilization. Examples of surfactants include Pelron surfactant 9920, Evonik B8489, and GE 6912. U.S. Patent Nos. 5,686,499 and 5,837,742 are incorporated herein by reference to show various useful surfactants.

[0030] Suitable emulsifiers / solubilizers include DAB CO Ketene 20 AS (Air Products), and Tergitol NP-9 (nonylphenol + 9 moles ethylene oxide).

[0031] Flame retardants may be used in the production of polyurethane and polyisocyanurate foams, especially when the foams contain flammable blowing agents such as pentane isomers. Useful flame retardants include tri(monochloropropyl) phosphate (a.k.a. tris(cloro-propyl) phosphate), tri-2 -chloroethyl phosphate (a.k.a. tris(chloro-ethyl) 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.

[0032] In one or more embodiments, the blowing agent includes one or more pentane isomers selected from n-pentane, isopentane, cyclopentane and mixtures thereof. In particular embodiments, the pentane blowing agent is an acyclic pentane such as isopentane, n-pentane, or mixtures thereof. In some embodiments, the acyclic pentane is a blend of n- pentane and isopentane. In this respect, U.S. Patent Nos. 7,612,120; 7,838,568; 8,106,106; and 8,453,390 are incorporated herein by reference.

[0033] In other embodiments, the blowing agent (physical blowing agent) may include halogenated organic compounds including, but not limited to, halocarbons and halogenated olefins (HFOs).

[0034] Additionally, in one or more embodiments, the blowing agent may include a blowing agent additive such as, but not limited to, low molecular weight aldehydes or ketones, esters, aromatic hydrocarbons, and halogenated hydrocarbons and ethers.

[0035] In one or more embodiments, the blowing agent may include a chemical blowing agent such as water.

[0036] An isocyanurate is a trimeric reaction product of three isocyanates forming a six-membered ring. The ratio of the equivalents of NCO groups (provided by the isocyanate-containing compound or A-side) to isocyanate-reactive groups (provided by the isocyanate- containing compound or B side) may be referred to as the index or ISO index. When the NCO equivalents to the isocyanate-reactive group equivalents is equal, then the index is 1.00, which is referred to as an index of 100, and the mixture is said to be stoichiometrically equal. As the ratio of NCO equivalents to isocyanate-reactive groups equivalents increases, the index increases. Above an index of about 150, the material is generally known as a polyisocyanurate foam, even though there are still many polyurethane linkages that may not be trimerized. When the index is below about 150, the foam is generally known as a polyurethane foam even though there may be some isocyanurate linkages. For purposes of this specification, reference to polyisocyanurate and polyurethane will be used interchangeably unless a specific ISO index is referenced.

[0037] In one or more embodiments, the concentration of the isocyanate-containing compound to the isocyanate-reactive compounds within the respective A-side and B-side streams is adjusted to provide the foam product with an ISO index of at least 150, in other embodiments at least 170, in other embodiments at least 190, in other embodiments at least 210, in other embodiments at least 220, in other embodiments at least 225, in other embodiments atleast 230, in other embodiments atleast 235, in other embodiments at least 240, in other embodiments at least 245, and in other embodiments at least 250. In these or other embodiments, the concentration of the isocyanate-containing compound to the isocyanate-reactive compounds within the respective A-side and B-side streams is adjusted to provide the foam product with an ISO index of at most 400, in other embodiments at most 350, andin other embodiments atmost 300. In one or more embodiments, the concentration of the isocyanate-containing compound to the isocyanate-reactive compounds within the respective A-side and B-side streams is adjusted to provide the foam product with an ISO index of from about 150 to about 400, in other embodiments from about 170 to about 350, and in other embodiments from about 190 to about 330, and in other embodiments from about 220 to about 280.

[0038] In one or more embodiments, the amount of physical blowing agent (i.e., acyclic pentane and blowing agent additive) used in the manufacture of polyisocyanurate foam construction board according to the present invention may be described with reference to the amount of isocyanate-reactive compound employed (e.g., polyol). Forexample, in one or more embodiments at least 12, in other embodiments at least 14, and in other embodiments at least 18 parts by weight physical blowing agent per 100 parts by weight of polyol may be used. In these or other embodiments, at most 40, in other embodiments at most 36, and in other embodiments at most 33 parts by weight physical blowing agent per 100 parts by weight of polyol may be used. In one or more embodiments from about 12 to about 40, in other embodiments from about 14 to about 36, and in other embodiments from about 18 to about 33 of physical blowing agent per 100 parts by weight of polyol may be used.

[0039] In one or more embodiments, the amount of physical blowing agent (i.e., acyclic pentane and blowing agent additive), optionally together with any chemical blowing agent employed, used in the manufacture of polyisocyanurate foam construction board according to the present invention may be described with reference to the density of the resulting foam. In other words, the skilled person appreciates that the amount of blowing agent employed has a direct impact on the density of the foam produced, and these amounts can be determined without undue calculation or experimentation. Accordingly, in one or more embodiments, the amount of blowing agent employed (both physical and chemical blowing agent) is tailored to produce a foam having a density (as determined by ASTM C303-10) of from about 1.0 to about 2.5 lbs / ft3, in other embodiments from about 1.2 to about 2.2 lbs / ft3, in other embodiments from about 1.4 to about 2.0 lbs / ft3, and in other embodiments from about 1.5 to about 1.8 lbs / ft3. In particular embodiments, the amount of blowing agent employed is tailored to produce a foam having a density of less than 2.5 lbs / ft3, in other embodiments less than 2.2 lbs / ft3, in other embodiments less than 2.0 lbs / ft3, and in other embodiments less than 1.8 lbs / ft3.

[0040] In one or more embodiments, the amount of surfactant (e.g., silicone copolymer) used in the manufacture of polyisocyanurate foam construction board according to the present invention may be described with reference to the amount of isocyanate-reactive compound employed (e.g. polyol). For example, in one or more embodiments, at least 1.0, in other embodiments at least 1.5, and in other embodiments at least 2.0 parts by weight surfactant per 100 parts by weight of polyol may be used. In these or other embodiments, at most 5.0, in other embodiments at most 4.0, and in other embodiments at most 3.0 parts byweight surfactant per 100 parts by weight of polyol may be used. In one or more embodiments, from about 1.0 to about 5.0, in other embodiments from about 1.5 to about 4.0, and in other embodiments from about 2.0 to about 3.0 of surfactant per 100 parts by weight of polyol may be used.

[0041] In one or more embodiments, the amount of flame retardant (e.g., liquid phosphates) used in the manufacture of polyisocyanurate foam construction board according to the present invention may be described with reference to the amount of isocyanate-reactive compound employed (e.g. polyol). For example, in one or more embodiments, at least 5, in other embodiments at least 10, and in other embodiments at least 12 parts by weight flame retardant per 100 parts by weight of polyol may be used. In these or other embodiments, at most 30, in other embodiments at most 25, and in other embodiments at most 20 parts by weight flame retardant per 100 parts by weight of polyol may be used. In one or more embodiments, from about 5 to about 30, in other embodiments from about 10 to about 25, and in other embodiments from about 12 to about 20 of flame retardant per 100 parts by weight of polyol may be used.

[0042] In one or more embodiments, the amount of catalyst(s) employed in practice of the present invention can be readily determined by the skilled person without undue experimentation or calculation. Indeed, the skilled person is aware of the various process parameters that will impact the amount of desired catalyst.

[0043] In one or more embodiments, the amountof physical blowing agent (i.e. pentane together with the amount of blowing agent additives) that is employed is sufficient to provide a foam having a foam density (ASTM C303-10) that is less than 2.5 pounds per cubic foot (12 kg / m2), in other embodiments less than 2.0 pounds per cubic foot (9.8 kg / m2), in other embodiments less than 1.9 pounds per cubic foot (9.3 kg / m2), and still in other embodiments less than 1.8 pounds per cubic foot (8.8 kg / m2). In one or more embodiments, the amount of blowing agent (together with the amount of blowing agent additives) that is employed is sufficient to provide a density that is greater than 1.50 pounds per cubic foot (7.32 kg / m2), or in other embodiments, greater than 1.55 pounds per cubic foot (7.57 kg / m2).

[0044] The foam bodies (as well as the corresponding construction boards) that are characterized by a foam density of less than 2.5 pounds per cubic foot may generally bereferred to as low-density construction boards or insulation boards. Where the density of the foam body is a polyisocyanurate foam with a density of less than 2.5 pounds per cubic foot, it may be advantageous for the foam body to be characterized by having an index of at least 120, in other embodiments at least 150, in other embodiments at least 175, in other embodiments at least 200, and in other embodiments at least 225, as determined by PIR / PUR ratio as determined by IR spectroscopy using standard foams of known index (note that ratio of 3 PIR / PUR provides an ISO Index of 300).

[0045] In other embodiments, the foam body may be characterized by a density that is greater than 2.5 pounds per cubic foot (12.2 kg / m2), as determined according to ASTM C303, in other embodiments the density is greater than 2.8 pounds per cubic foot (13.7 kg / m2), in other embodiments greater than 3.0 pounds per cubic foot (14.6 kg / m2), and still in other embodiments greater than 3.5 pounds per cubic foot (17.1 kg / m2). In one or more embodiments, the foam body may have a density of less than 20 pounds per cubic foot (97.6 kg / m2), in other embodiments less than 10 pounds per cubic foot (48.8 kg / m2), in other embodiments less than 6 pounds per cubic foot (29.3 kg / m2), in other embodiments less than 5.9 pounds per cubic foot (28.8 kg / m2), in other embodiments less than 5.8 pounds per cubic foot (28.3 kg / m2), in other embodiments less than 5.7 pounds per cubic foot (27.8 kg / m2), in other embodiments less than 5.6 pounds per cubic foot (27.3 kg / m2), and still in other embodiments less than 5.5 pounds per cubic foot (26.9 kg / m2). Foam construction boards having a foam layer of similar nature are described in U.S. Patent Nos. 8,453,390 and 7,972,688, which are incorporated herein by reference. The foam bodies (as well as the corresponding construction boards) that are characterized by a foam density of greater than 2.5 pounds per cubic foot may generally be referred to as high-density construction boards or cover boards.

[0046] Where the foam body is a polyisocyanurate foam body and has a density of greater than 2.5 pounds per cubic foot, it may be advantageous for the foam body to be characterized by an ISO Index, as determined by PIR / PUR ratio as determined by IR spectroscopy using standard foams of known index (note that ratio of 3 PIR / PUR provides an ISO Index of 300) of at least 180, in other embodiments at least 200, in other embodiments at least 220, in other embodiments at least 270, in other embodiments at least 285, in otherembodiments at least 300, in other embodiments at least 315, and in other embodiments at least 325. In these or other embodiments, the ISO Index may be less than 360, in other embodiments less than 350, in other embodiments less than 340, and in other embodiments less than 335.

[0047] In one or more embodiments, the foam body may have a thickness of greater than 0.25 inches (0.64 cm), in other embodiments greater than 0.50 inches (1.27 cm), in other embodiments greater than 1.0 inches (2.54 cm), and in other embodiments greater than 2.0 inches (5.08 cm). In these or other embodiments, the foam body may have a thickness of less than 6.0 inches (15.24 cm), in other embodiments less than 5.0 inches (12.7 cm), in other embodiments less than 3.0 inches (7.62 cm), and in other embodiments less than 1.0 inch (2.54 cm). In one or more embodiments, the foam body may have a thickness of from about 0.25 to about 6.0 inches (0.64 - 15.24 cm), in other embodiments from about 0.50 to about 5.0 inches (1.27 - 12.7 cm), and in other embodiments from about 1.5 to about 4.0 inches (3.81 - 10.16 cm).

[0048] As suggested above, the construction boards of the present invention may be produced in the presence of a chemical blowing agent in addition to the physical blowing agents described above. The presence of excessive amounts of chemical blowing agents, such as water, has a deleterious impact on the overall balance of properties of the construction boards of the present invention. Accordingly, in one or more embodiments, the amount of chemical blowing agent employed in the manufacture of the construction boards of this invention, such as water, is limited. Accordingly, the amount of chemical blowing agent (e.g., water) included within the foam-forming ingredients according to the present invention, particularly the B-side stream of reactants) is less than 1.5, in other embodiments less than 1.3, in other embodiments less than 1.0, in other embodiments less than 0.8, in other embodiments less than 0.6, and in other embodiments less than 0.4 parts by weight chemical blowing agent (e.g., water) per 100 parts by weight of the isocyanate-reactive component (e.g., 100 parts by weight polyol, php).

[0049] The skilled person understands that the ingredients employed in the manufacture of polyurethane-polyisocyanurate foams in accordance with the present invention employs ingredients that inherently include water. Thus, unless efforts are made to remove water from the ingredients, certain levels of water are inherently introduced tothe reaction mixture. It is conventionally believed that the amount of water inherently present within the reactants is about 0.15 to about 0.2 parts by weight water per 100 parts by weight polyol (php). Accordingly, the total amount of chemical blowing agent within the foam forming mixture includes the amount of inherent water within the reactants plus any added chemical blowing agent, such as added water. In one or more embodiments, chemical blowing agent, particularly water, may be added to the foam-forming ingredients while staying within the maximum amounts set forth above. For example, in one or more embodiments, from about 0.1 to about 0.8, in other embodiments from about 0.2 to about 0.7, and in other embodiments from about 0.25 to about 0.6 parts by weight water per 100 parts by weight polyol (php) may be added to the foam forming ingredients. In particular embodiments, the chemical blowing agent is added to the B-side stream of reactants.

[0050] In one or more embodiments, the respective streams are mixed within, for example, a mixhead such an impingement mixhead. In particular embodiments, mixing takes place ata temperature of from about 5 to about45 °C. In these or other embodiments, mixing takes place at a pressure in excess of 1,000, in other embodiments in excess of 1,500, and in other embodiments in excess of 2,000 psi.

[0051] As indicated above, the foam mixture is deposited onto foam carrier layer 17 that is positioned on and carried by a conveyor system. In one or more embodiments, the foam mixture is deposited onto foam carrier layer 17 from multiple mix heads thereby initially forming multiple masses of foaming mixture on foam carrier layer 17. In particular embodiments, the foam is deposited from greater than 2 mix heads, in other embodiments greater than 3 mix heads, and in other embodiments greater than 4 mix heads. In one or more embodiments, the foam is deposited from about 2 to about 10, in other embodiments from about 3 to about 8, and in other embodiments from about 3 to about 6 mix heads onto foam carrier layer 17.PRESSURE-SENSITIVE ADHESIVE LAYER

[0052] As indicated above, a pressure-sensitive adhesive layer (e.g., pressure-sensitive adhesive layer 37) is provided as part of an adhesive composite (e.g., adhesive composite 19) and / or a transfer film subcomponent (e.g., transfer film subcomponent 31). The adhesive composite may also be referred to as an adhesive sheet. Further aspects of the pressuresensitive adhesive layer are provided here.

[0053] In one or more embodiments, the pressure-sensitive adhesive layer (e.g. pressure-sensitive adhesive layer 37) 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 pm. In these or other embodiments, the thickness of the pressure-sensitive adhesive layer 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 pm. In one or more embodiments, the thickness of the pressure-sensitive adhesive layer of the adhesive sheet may be from about 25 to about 500 pm, in other embodiments from about 50 to about 400 pm, and in other embodiments from about 100 to about 300 pm.

[0054] In one or more embodiments, the pressure-sensitive adhesive layer may be characterized by 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 layer is 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 layer 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.

[0055] In one or more embodiments, the pressure-sensitive adhesive layer may be characterized by 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 layer 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.

[0056] In one or more embodiments, the pressure-sensitive adhesive layer includes, as major polymeric component, a rubber such as ethylene-propylene-diene rubber, ethylenepropylene rubber, polychloroprene, and / or butyl rubber. In other embodiments, thepressure-sensitive adhesive layer includes, 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 more functional 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.

[0057] 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 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.

[0058] In other embodiments, the pressure-sensitive adhesive layer is formed from a hot-melt pressure-sensitive adhesive composition that can be melt-extruded onto the surface of the carrier layer 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.

[0059] In one or more embodiments, the pressure-sensitive adhesive is noncrosslinked. In other embodiments, the pressure-sensitive adhesive is crosslinked. In particular embodiments, the adhesive layer includes 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 Nos. WO2015 / 042258, WO 2017 / 165868, WO 2017 / 165870, and WO 2017 / 165871 which are incorporated herein by reference.

[0060] 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 polyacrylate such 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.

[0061] 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 R2is an alkyl group having at least 4 carbon atoms. In particular embodiments, R1is hydrogen and R2is selected from the group consisting of butyl, 2 -ethylhexyl, and mixtures thereof.

[0062] In one or more embodiments, the polyacrylate elastomers that are useful in preparing the adhesive layer may be characterized by a glass transition temperature (Tg) ofless 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).

[0063] In one or more embodiments, the polyacrylate elastomers that are useful in preparing the adhesive layer 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.

[0064] In one or more embodiments, the polyacrylate elastomers that are useful in preparing the adhesive layer maybe 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.

[0065] Specific examples of polyacrylate elastomers that are useful in preparing the adhesive layer include poly (butylacrylate), and poly(2-ethylhexylacryalte). These polyacrylate elastomers maybe 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.

[0066] 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.

[0067] 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.

[0068] In one or more embodiments, the adhesive layer substantially includes a cured polyacrylate elastomer. In other words, the adhesive layer is substantially devoid of other constituents such as plasticizers and the like. In one or more embodiments, the adhesive layer includes 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 layer.

[0069] In one or more embodiments, the adhesive layer (e.g. polyacrylate hot-melt adhesive) is 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 layer is 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.

[0070] In one or more embodiments, the adhesive layer 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.

[0071] 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.NON-RIGID FOAM LAYER

[0072] In one or more embodiments, the carrier layer of the adhesive subcomponent includes a non-rigid foam layer (e.g., foam carrier layer 17), 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.

[0073] 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.

[0074] 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 layer with the non-rigid foam layer and also prior to incorporating the non-rigid foam layer into the composites of the present invention.

[0075] 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 layer. As a skilled person appreciates, the density of the foam layer can be determined by ASTM D1056- 20 for rubber foams and ASTM D3575-20 for polyolefin (thermoplastic) foams. In one or more embodiments, the density ofthe 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 ofthe 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 otherembodiments 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).

[0076] 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 layer. 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 ofthe foamed carrier layer maybe 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).

[0077] The non-rigid foam layer may be characterized by tensile strength, in the machine direction, as determined prior to being mated to the adhesive layer. 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 ofthe 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 (344.5kPa). In one or more embodiments, the machine direction tensile strength of the foamed carrier layer maybe 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.

[0078] The non-rigid foam layer may be characterized by its thickness prior to being mated to the adhesive layer. In one or more embodiments, the thickness of the foamed carrier layer is greater than 100 pm, in other embodiments greater than 250 pm, in other embodiments greater than 500 pm, in other embodiments greater than 1,000 pm, in other embodiments greater than 1,500 pm, in other embodiments greater than 2,000 pm, and in other embodiments greater than 3,500 pm. In these or other embodiments, the thickness of the foamed carrier layer is less than 10,000 pm, in other embodiments less than 8,000 pm, in other embodiments less than 7,000 pm, in other embodiments less than 5,000 pm and in other embodiments less than 4,000 pm. In one or more embodiments, the thickness of the foamed carrier layer may include from about 500 pm to about 10,000 pm, in other embodiments from about 1,000 pm to about 7,000 pm, and in other embodiments from about 1,500 pm to about 5,000 pm.

[0079] In one or more embodiments, the non-rigid foam layer may be characterized by a Shore A hardness, which maybe determined by ASTM D2240-15, prior to being mated with the adhesive layer. 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.

[0080] 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 layer. 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 otherembodiments 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).

[0081] 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%.

[0082] 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%.CARRIER LAYER THERMAL STABILITY

[0083] In one or more embodiments, the non-rigid foam layer (e.g., foam carrier layer 17) can be adapted to be thermally stable with respect to heat generated by the rising foam mixture and any additional heat to be supplied to the precursor board or final construction board. That is, the non-rigid foam layer can be capable of surviving or withstanding the elevated temperatures involved with producing the construction board composite 35. Inother words, the non-rigid foam layer is not deleteriously impacted relative to the one or more functions thereof, as described further herein.

[0084] In one or more embodiments, the non-rigid foam layer can be made of a rubber foam material, which can be closed cell foam. Suitable rubber foam material includes vinyl nitrile foam, EPDM foam, crushed EPDM foam, neoprene foam, and other suitable blends. Vinyl nitrile foam is produced from a combination of nitrile butadiene rubber (NBR) and polyvinyl chloride (PVC). Another suitable blend includes NBR, PVC, and neoprene. Another suitable blend includes crushed EPDM with EPDM.

[0085] In one or more embodiments, the non-rigid foam layer is capable of withstanding temperatures up to about 150 °F, in other embodiments up to about 200 °F, in other embodiments up to about 230 °F, in other embodiments up to 250 °F, in other embodiments up to about 270 °F, in other embodiments up to 300 °F, and in other embodiments up to 330 °F, without being deleteriously impacted. In one or more embodiments, the non-rigid foam layer is capable of withstanding temperatures of from about 150 °F to about 330 °F, in other embodiments from about 200 °F to about 300 °F, in other embodiments from about 250 °F to about 300 °F, and in other embodiments from about 250 °F to about 270 °F, without being deleteriously impacted.

[0086] In one or more embodiments, the non-rigid foam layer has a maximum service temperature (ASTM D 1056-20) of up to about 150 °F, in other embodiments up to about 200 °F, in other embodiments up to about 230 °F, in other embodiments up to 250 °F, in other embodiments up to about 270 °F, in other embodiments up to 300 °F, and in other embodiments up to 330 °F. In one or more embodiments, the non-rigid foam layer has a service temperature (ASTM D 1056-20) in a range of from about -60 °F to about 300 °F, in other embodiments from about -50 °F to about 250 °F, and in other embodiments from about - 40 °F to about 200 °F.

[0087] In one or more embodiments, the non-rigid foam layer has a thermal conductivity of at least 0.05 W / (m-K), in other embodiments at least 0.1 W / (m-K), in other embodiments at least 0.2 W / (m-K), in other embodiments at least 0.3 W / (m-K), in other embodiments at least 0.4 W / (m-K), and in other embodiments at least 0.5 W / (m-K), as measured by ASTM C177-19 or C518-21, @ 75 °F. In one or more embodiments, the non- rigid foam layer has a thermal conductivity of from about 0.05 W / (m-K) to about 0.5W / (m-K), in other embodiments from about 0.1 W / (m-K) to about 0.4 W / (m-K), in other embodiments from about 0.2 W / (m-K) to about 0.3 W / (m-K), and in other embodiments from about 0.2 W / (m-K) to about 0.25 W / (m-K), as measured by ASTM C177-19 or C518-21, @ 75 °F.RELEASE MEMBER

[0088] In one or more embodiments, the release liner (e.g. liner 44), which may also be referred to as release member, 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 liner may 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.

[0089] 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).

[0090] In one or more embodiments, the release member is characterized by a thickness of from about 15 to about 80 pm, in other embodiments from about 18 to about 75 pm, and in other embodiments from about 20 to about 50 pm.ADHESIVE SUBCOMPONENT

[0091] The adhesive subcomponent, which may also be referred to as an adhesive composite or adhesive sheet, may be provided as follows. As mentioned above, the adhesive sheet includes a pressure-sensitive adhesive layer and a foam carrier layer. Prior to being mated to the construction board, the adhesive sheet may be in the form of a roll with at least one release member protecting the adhesive layer. The skilled person will appreciate thatthe pressure-sensitive layer and the foam carrier layer will have the characteristics outlined above with respect to the composite.

[0092] In one or more embodiments, the adhesive layer 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.

[0093] In one or more embodiments, the 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 pm. In these or other embodiments, the 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 pm. In one or more embodiments, the adhesive sheet has a thickness of from about 25 to about 890 pm, in other embodiments from about 50 to about 760 pm, in other embodiments from about 75 to about 635 pm, and in other embodiments from about 100 to about 508 pm.

[0094] In one or more embodiments, the 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 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 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.

[0095] In one or more embodiments, the adhesive sheet is provided in the form of a roll, and therefore the adhesive sheet may have an extended length. In one or more embodiments, the 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 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. Inone or more embodiments, the adhesive sheet 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.CHARACTERISTICS OF ADHESIVE SHEET

[0096] In one or more embodiments, the 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, wherein the adaptation included employing a 2 inch x 2 inch metal plates (affixed to Instron operating pursuant to the ASTM C209 specification) 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 psi (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 to about 45 psi (20.68 - 310.26 kPa), in other embodiments from about 10 to about 40 psi (68.95 - 275.79 kPa), and in other embodiments from about 15 to about 35 psi (103.42 - 241.32 kPa).

[0097] In one or more embodiments, the 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 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 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 adhesive sheet is semi-permeable, which refers to a composite characterized by 1.0 to 10 perms pursuant to ASTM E96- / E96M-23.

[0098] In one or more embodiments, the adhesive sheet may be characterized by its bond strength to stainless steel panel, which can be determined by the dead load shear testprovided in Pressure Sensitive Tape Council (PSTC) 107, Method A (revised May 2007), at23 °C + / -1 °C. For purposes ofthis 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 adhesive sheet was aged for24 hours at 70 °C prior to testing. Once the adhesive sheet was secured to the steel plate, a dwell time of 1 minute was provided before conducting the test. In one or more embodiments, the 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. In one or more embodiments, the double-sided adhesive sheet is characterized by a deadload shear at 22 °C after aging at 70 °C for 2 weeks, in other embodiments after aging for 12 weeks, and in other embodiments after aging for 24 weeks, 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 ASSEMBLING ROOF SYSTEM

[0099] The composite construction boards of one or more embodiments of the present invention can advantageously be adhered to a roof structure, such as a roof deck, by using convenient peel-and-stick installation techniques. In one or more embodiments, the construction boards can be adhered without the use of additional adhesives or primers, which may include volatile organic compounds.

[0100] According to one or more embodiments, the composite construction boards can be pre-fabricated at a location other than where the composite construction boards are installed. For example, the composite construction boards can be prepared in a fabrication facility including the facility where the foam construction boards are fabricated. The composite construction boards can then be bundled and shipped to the location where they are ultimately installed on a roof structure.

[0101] In one or more embodiments, the roof system may be assembled by providing a composite construction board of this invention, positioning the composite construction board at location at or proximate to where the composite construction board will be installed, removing the release member to expose the layer of pressure-sensitive adhesive, and then securing the composite construction board to the roof surface.INDUSTRIAL APPLICABILITY

[0102] Practice of the present invention is advantageous in the construction of flat or low-sloped roofs. As the skilled person appreciates, a low-sloped roof includes a roof having a slope of less than 3:12, in other embodiments less than 2.5:12, and in other embodiments less than 2:12.

[0103] Practice of the present invention is not limited by the type of roof deck to which the construction boards of the present invention may be secured. For example, the roof decks may include conventional roof decks, such as those constructed of wood, steel, and / or concrete.

[0104] In one or more embodiments, roof systems can be constructed by using the composite boards of the present invention. In one or more embodiments, this will include application of a membrane over the composite 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. As is known in the art, numerous roofing membranes have been proposed in the art and several are used commercially including thermoset and thermoplastic roofing membranes. Commercially available thermoplastic roofing membranes may include polyvinyl chloride, or polyolefin copolymers. For example, thermoplastic olefin (TPO) membranes are available under the trade names UltraPly™, and ReflexEON™ (ELEVATE) and SureWeld™ (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 RubberGard™, RubberGard Platinum™, RubberGard EcoWhite™, and RubberGard MAX™ (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).

[0105] Embodiments of the present invention may provide an adhered system wherein one or more layers of insulation boards and / or cover boards are fully adhered within theroofing system (e.g. they may be partially or fully adhered to the substrate). Optionally, the membrane system may be fully adhered with the system as well. In one or more embodiments, the systems of the present invention have improved resistance to wind uplift forces, and improved ease of application and installation. Also, 4’ x 8’ insulation boards can advantageously be installed without release of volatile organic compounds to the atmosphere. Moreover, the adhesion of the board to the underlying substrate is technologically advantageous. In one or more embodiments, the adhesion between the construction board 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 (lbs / ft2) (4.3 kPa), in other embodiments greater than 120 lbs / ft2(5.7 kPa), in other embodiments greater than 180 lbs / ft2(8.6 kPa), in other embodiments greater than 240 lbs / ft2(11.5 kPa), in other embodiments greater than 280 lbs / ft2(13.41 kPa), and in other embodiments greater than 300 lbs / ft2(14.4 kPa). These tests are conducted by mechanically fastening a first layer of construction boards to a metal deck and then securing a second layer of construction boards to the first layer by using the composite formed by the method of this invention.

[0106] In one or more embodiments, the composite construction boards include insulation boards that meet the requirements of ASTM C1289-22. In other embodiments, the composite construction boards include cover boards that meet the specifications of ASTM C1289-22.

[0107] 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

CLAIMSWhat is claimed is:

1. A method of making a construction board composite for a roof system, the method comprising:(i) mixing an A-side stream and a B-side stream to thereby form a foam mixture;(ii) depositing the foam mixture to a first planar surface of a foam carrier layer to thereby form a developing foam on the first planar surface of the foam carrier layer, the foam carrier layer being part of an adhesive composite further including a pressure-sensitive adhesive layer mated with a second planar surface of the foam carrier layer and a release member protecting the pressure-sensitive adhesive layer; and(iii) allowing the developing foam to form a foam body mated to the first planar surface of the foam carrier layer.

2. A method of making a construction board composite for a roof system, the method comprising:(i) mixing an A-side stream and a B-side stream to thereby form a foam mixture;(ii) depositing the foam mixture to a first planar surface of a foam carrier layer to thereby form a developing foam on the first planar surface of the foam carrier layer;(iii) allowing the developing foam to form a foam body mated to the first planar surface of the foam carrier layer; and(iv) applying a pressure-sensitive adhesive on a second planar surface of the foam carrier layer to mate the pressure-sensitive adhesive with the foam carrier layer, where the applying the pressure-sensitive adhesive includes the pressure-sensitive adhesive being part of a transfer film subcomponent which includes the pressure-sensitive adhesive mated with a release liner.

3. The method of any of the above claims, where the foam carrier layer includes closed cell foam.

4. The method of any of the above claims, where the foam carrier layer is a rubber foam carrier layer.

5. The method of any of the above claims, where the foam carrier layer is capable of withstanding temperatures of from about 250 °F to about 300 °F without being deleteriously impacted.

6. The method of any of the above claims, where the foam carrier layer is capable of withstanding temperatures up to about 270 °F without being deleteriously impacted.

7. The method of any of the above claims, where the foam carrier layer includes vinyl nitrile foam, EPDM foam, crushed EPDM foam, or neoprene foam.

8. The method of any of the above claims, where the foam carrier layer includes vinyl nitrile foam produced from a combination of nitrile butadiene rubber (NBR) and polyvinyl chloride (PVC).

9. The method of any of the above claims, where the foam carrier layer is produced from a combination of NBR, PVC, and neoprene.

10. The method of any of the above claims, where the foam carrier layer is produced from a combination of crushed EPDM with EPDM.

11. The method of any of the above claims, where the foam carrier layer has a thermal conductivity of from about 0.05 W / (m-K] to about 0.5 W / (m-K], as measured by ASTM C177-19 or C518-21, @ 75 °F.

12. The method of any of the above claims, where the foam carrier layer has a thermal conductivity of from about 0.2 W / (m-K] to about 0.25 W / (m-K], as measured by ASTM C177-19 or C518-21, @ 75 °F.

13. The method of any of the above claims, where the foam carrier layer is a non-rigid foam layer.

14. The method of any of the above claims, where the foam carrier layer has a thickness of about 500 to about 10,000 pm.

15. The method of any of the above claims, where the foam carrier layer has a density of from about 0.8 to about 10 lbs. per ft3.

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