Roof system and composite boards with encapsulated fragile insulation materials

Abstract

A flat or low-sloped roof system comprising a roof deck and one or more fragile insulation materials secured directly or indirectly to the roof deck, where the one or more fragile insulation materials are secured directly or indirectly to the roof deck through a double-sided adhesive sheet that includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer.

Description

ROOF SYSTEM AND COMPOSITE BOARDS WITH ENCAPSULATED FRAGILE INSULATION MATERIALSFIELD OF THE INVENTION

[0001] Embodiments of the present invention provide roof systems and composite boards with one or more fragile insulation materials.BACKGROUND OF THE INVENTION

[0002] Pressure-sensitive adhesives have been used in the construction industry. For example, in the construction of low-sloped or flat roofs, polymeric single-ply membranes including a layer of pressure-sensitive adhesive have been used. The pressure-sensitive adhesive is used to secure the membrane to the underlying surface. The membrane provides a weather-protective layer for the roof system. These membrane composites are advantageously installed by the so-called "peel-and-stick” method. Numerous advantages are realized by using peel-and-stick methods including reduced installation time and labor, as well as the fact that the adhered systems can be formed without the use of significant volatile organic compounds.

[0003] Also, the construction of membranes carrying a pressure-sensitive adhesive is relatively straightforward since efficient techniques are available for applying the pressuresensitive adhesive to the membrane within a factory setting. For example, the pressuresensitive adhesive can be efficiently applied to the surface of a membrane as a hot-melt composition using relatively common coating techniques.

[0004] The skilled person appreciates that many flat or low-sloped roof systems also include one or more layers of construction board disposed between the roof deck and the membrane. In many situations, this may include a multi-layered assembly that includes, for example, two or more layers of insulation board and a layer of coverboard to protect the insulation board layer. The insulation boards, which are often referred to as board stock, can include a polyisocyanurate foam body that often ranges in thickness of from about 2 to about 4 inches. These boards also typically carry opposed facers that sandwich the foam body. In multi-layered roof systems, the bottom insulation layer is often mechanicallyfastened to the roof deck, and the subsequent layers, including the coverboard layer, can advantageously be adhered using, for example, a low-rise foam adhesive.

[0005] While low-rise foam adhesives are commonly used where there is a desire to adhere construction boards in place, it has also been proposed to factory-apply a pressuresensitive adhesive to the facer of the boards. In other words, like the membranes that carry a pressure-sensitive adhesive layer, the construction boards can likewise be installed using the peel-and-stick installation method. These construction boards, however, have not been widely adopted.SUMMARY OF THE INVENTION

[0006] One or more embodiments of the present invention provide a flat or low-sloped roof system comprising a roof deck and one or more fragile insulation materials secured directly or indirectly to the roof deck, where the one or more fragile insulation materials are secured directly or indirectly to the roof deck through a double-sided adhesive sheet that includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer.

[0007] Other embodiments of the present invention provide a flat or low-sloped roof system comprising (i) a roof deck; (ii) a first layer of construction boards secured directly or indirectly to the roof deck; (in) a second layer of construction boards adhered to the first layer of construction board, the second layer of construction boards including one or more fragile insulation materials; and (iv) a roofing membrane forming a water-proof protective layer over the roof system, where the second layer of construction board is adhered to the first layer of construction boards through a double-sided adhesive sheet that includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer.

[0008] Still other embodiments of the present invention provide a method of installing construction boards on a roof, the method comprising (i) providing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet; (ii) providing a first layer of construction boards secured to a roof deck; (iii) positioning the double-sided adhesive sheet on a desired exposed surface of the first layer of construction boards; (iv) contacting and adhering thebottom surface of the adhesive sheet to the first layer of construction boards; and (y) placing a second layer of construction boards into contact with the upper surface of the adhesive sheet, the second layer of construction boards including one or more fragile insulation materials.

[0009] Yet other embodiments of the present invention provide a method of installing fragile insulating materials on a roof, the method comprising (i) providing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressuresensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet; (ii) positioning the double-sided adhesive sheet on a desired area of a roof deck; (hi) contacting and adhering the bottom surface of the adhesive sheet to the roof deck; (iv) providing one or more fragile insulation materials; and (v) contacting and adhering the one or more fragile insulation materials or to the upper surface of the double-sided adhesive sheet to thereby form a layer of one or more fragile insulation materials adhered to the roof deck.

[0010] Still other embodiments of the present invention provide the use of a doublesided adhesive sheet to secure construction boards into a roofing system by securing a plurality of construction boards to a layer of construction boards, the plurality of construction boards including one or more fragile insulation materials, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet.

[0011] Yet other embodiments of the present invention provide the use of a doublesided adhesive sheet to secure fragile insulation materials into a roofing system by securing a plurality of fragile insulation materials to a roof deck, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet.

[0012] Still other embodiments of the present invention provide a composite construction board comprising (i) a construction board subcomponent including at least one fragile insulating material; and (ii) a double-sided adhesive subcomponent.

[0013] Other embodiments ofthe present invention provide a roof system including the composite construction board comprising (i) a construction board subcomponent including at least one fragile insulating material; and (ii) a double-sided adhesive subcomponent.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a cross-sectional side view of a roofing system according to embodiments ofthe present invention.

[0015] FIG. 2 is a cross-sectional side view of a roofing system according to embodiments ofthe present invention.

[0016] FIG. 3 is a cross-sectional side view of a double-sided adhesive composite sheet in the form of a roll.

[0017] FIG. 4 is a cross-sectional view of a composite construction board according to embodiments ofthe invention.

[0018] FIG. 5 is a cross-sectional view of a composite construction board including a construction board subcomponent with high-density and low-density layers according to embodiments ofthe invention.

[0019] FIG. 6 is a cross-sectional view of a composite construction board with high- density and low-density construction boards according to embodiments of the invention.

[0020] FIG. 7 is a cross-sectional view of a composite construction board with high- density and low-density construction boards according to embodiments of the invention.

[0021] FIG. 8 is a cross-sectional view of a composite construction board including a construction board subcomponent with offset foam layers according to embodiments ofthe invention.

[0022] FIG. 9 is a cross-sectional view of a composite construction board including a construction board subcomponent with offset foam layers according to embodiments ofthe invention.

[0023] FIG. 10 is a top elevational view of a composite construction board including a construction board subcomponent with offset foam layers according to embodiments of the invention

[0024] FIG. 11 is a cross-sectional view of a composite construction board including a construction board subcomponent with offset foam layers according to embodiments of the invention.

[0025] FIGS. 12A and 12 B are bottom elevational views of composite construction boards according to embodiments of the invention.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0026] Embodiments of the invention are based, at least in part, on the discovery of a flat or low-sloped roof system wherein one or more layers of construction boards or fragile insulation materials are adhered into the system with a double-sided adhesive sheet. While double-sided tapes have been used in the construction industry, the use of double-sided adhesive sheets with a carrier layer has yielded unexpected benefit when used to adhere construction boards and / or fragile insulation materials, particularly foamed construction boards. For example, when a double-sided adhesive sheet with a carrier layer is employed to secure construction boards and / or fragile insulation materials into the system, the adhesive sheet has been found to not be the point of failure when subjected to wind uplift testing. It is believed that the nature of the carrier advantageously allows the adhesive sheet to securely mate the foamed construction board and / or fragile insulation materials even though the contact surfaces of foamed construction boards are often irregular. Other embodiments are directed toward composite construction boards including a fragile insulating material and a double-sided adhesive component with a carrier layer. Also, where the double-sided adhesive sheet is applied as a continuous layer, the use of the double-sided adhesive sheet advantageously provides a vapor barrier layer for the roof system. Further, the present invention provides an efficient method for constructing roof systems by using the double-sided adhesive sheet for securing construction boards and / or fragile insulation materials including constructions boards with a variety of facer materials.ROOF SYSTEMS

[0027] A first aspect of the present invention can be described with reference to FIG. 1, which shows roof system 10 including roof deck 21, an optional first layer 31 of construction boards, a second layer 51 of construction boards, and a roofing membrane layer 61. In one or more embodiments, first layer 31 of construction boards is mechanically fastened to roof deck 21 via a mechanical attachment system, which may include fasteners 25, 25' and fastening plates 27, 27'. First layer 31 of construction boards includes individual construction boards 33, 33'. As a skilled person appreciates, first layer 31 of construction boards may include a plurality of construction boards arranged in a pattern that may be conventionally employed in the art, such as a staggered pattern. The skilled person appreciates that multiple fasters, and corresponding fastening plates, are used to secure each of the individual boards within first layer 31 of construction boards to roof deck 21. Similar to first layer 31 of construction boards, the skilled person appreciates that second layer 51 of construction boards may include a plurality of construction boards arranged in a pattern that may be conventionally employed in the art, such as a staggered pattern. As shown in FIG. 1, second layer 51 of construction boards includes individual construction boards 53, 53'.

[0028] In one or more embodiments, as also shown in FIG. 1, second layer 51 of construction boards may include one or more fragile insulation materials 55. In one or more optional embodiments, the at least one fragile insulation material 55 may be at least partially encased within the foam structure of second layer 51 of construction boards. It will be appreciated that the fragile insulation materials as presented throughout the various embodiments of the invention are optional and the skilled person can readily envisage embodiments without the fragile insulation materials even though the figures include the fragile insulation materials. Also, the skilled person will readily appreciate that first layer 31 of construction boards may, in addition to or in lieu of second layer 51 of construction boards, may include fragile insulation materials in a manner as described relative to first layer 31 of construction boards.

[0029] As also shown in FIG. 1, second layer 51 of construction boards is adhered to first layer 31 of construction boards through double-sided adhesive sheet 41, which may also be referred to as an adhesive sheet 41, and adhesive composite 41, or an adhesivesubcomponent 41. Adhesive sheet 41 includes a first pressure-sensitive adhesive layer 43, which may also be referred to as first adhesive layer 43, and a second pressure-sensitive adhesive layer 45, which maybe referred to as second adhesive layer 45. First adhesive layer 43 and second adhesive layer 45 sandwich a carrier layer 47, which may also be referred to as middle carrier layer 47 or simply carrier 47. As will be described in greater detail below, carrier layer 47 may include a foam or fabric. First adhesive layer 43 adhesively mates to first layer 31 of construction boards, and second adhesive layer 45 adhesively mates to second layer 51 of construction boards.

[0030] A second aspect ofthe invention can be described with reference to FIG. 2, which shows a double-sided adhesive sheet 81, which may also be referred to as an adhesive composite 81, or an adhesive subcomponent 81, adhering a layer 57 of fragile insulation materials to roof deck 21 or an intervening substrate layer (not shown). In one or more embodiments, an intervening layer of construction boards may be disposed between fragile insulation materials 55 and the roof deck 21. In one or more embodiments, this intervening layer of construction boards may include a layer of high-density foam boards, as described herein. In one or more embodiments, the intervening layer of construction boards may be mechanically fastened to roof deck 21, and then the layer 57 of fragile insulation materials may be secured to the layer of construction boards via the adhesive composite 81. Similar to adhesive sheet 41, adhesive sheet 81 includes a first pressure-sensitive adhesive layer 83, a second pressure-sensitive adhesive layer 85, and a carrier layer 87 sandwiched therebetween. As described in greater detail below, carrier layer 87 may include foam or fabric. Disposed above layer 57 of fragile insulation materials, relative to roof deck 21, is a layer 51 of construction boards. Layer 51, which includes construction boards 53, 53’, is adapted to protect the integrity of fragile insulation materials 55 of layer 57. For example, construction board 53, 53’ may include high-density foam boards as described herein. While the embodiments shown in FIGS. 1 and 2 include two layers of materials, the skilled person appreciates that the concepts can be extended to three or more layers of with the adhesive sheet adhering two or more ofthe layers together. As also shown in FIG. 2, and consistent with the description of FIG. 1, roof system 10 may include a roof deck 21, a layer 51 of construction boards, and a roofing membrane layer 61. Further, layer 51 of constructionboards can be adhered to layer 57 of fragile insulation materials through a double-sided adhesive sheet 41 including carrier layer 47 and pressure-sensitive layers 43 and 45.

[0031] Relative to the first and second aspects of the invention, and prior to being installed into the roof system, the adhesive sheet may be in the form of a roll with at least one release member protecting the adhesive layers. For example, as shown in FIG. 3, doublesided adhesive composite sheet 41, which is in the form of a roll, includes first pressuresensitive adhesive layer 43, second pressure-sensitive adhesive layer 45, and carrier layer 47. An optional first release member 44 protects first adhesive layer 43, and an optional second release member 46 protects second adhesive layer 45. In other embodiments, release member 44 is adapted to provide release on both planar surfaces thereof, which allows the adhesive sheet to be rolled with only one release member.COMPOSITE CONSTRUCTION BOARDS

[0032] Other aspects of the invention are directed toward composite construction boards. For example, a composite construction board of one or more embodiments may be described with reference to FIG. 4, which shows composite construction board 110, which may be referred to as composite assembly 110, or board assembly 110, including construction board subcomponent 120 and double-sided adhesive subcomponent 130. Construction board subcomponent 120, which may simply be referred to as construction board 120 or subcomponent 120, includes a rigid foam body 122, optional first facer 124 disposed on a first planar surface 125 of foam body 122, and an optional second facer 126 disposed on a second planar surface 127 of foam body 122. As the skilled person will appreciate, first and second facers 124,126 may be integrally attached to foam body 122 by virtue of the foam being mated to the facers during formation of the foam. In one or more embodiments, rigid foam body 122 may include at least one fragile insulating material 155. As shown, the at least one fragile insulation material 155 is at least partially encased within the foam structure of rigid foam body 122. Again, it will be appreciated that the fragile insulation materials are optional and / or they may be located in layers other than those shown in the figures.

[0033] Double-sided adhesive subcomponent 130, which may also be referred to as double-sided adhesive sheet 130, or adhesive subcomponent 130, includes a carrier layer132, a first pressure-sensitive adhesive layer 134 disposed on a first planar surface 135 of carrier layer 132, and a second pressure-sensitive adhesive layer 136 disposed on a second planar surface 137 of middle layer 132. A release member 140 is removably attached to first pressure-sensitive layer 134 opposite carrier layer 132. In one or more embodiments, first pressure-sensitive adhesive layer 134 is disposed on the entire first planar surface 135 of carrier layer 132. In one or more embodiments, second pressure-sensitive adhesive layer 136 is disposed on the entire second planar surface 137 of carrier layer 132. As shown in FIG. 4, double-sided adhesive subcomponent 130 is mated to first facer 124 through second pressure-sensitive adhesive layer 136 where first facer 124 is present, or it will be appreciated that subcomponent 130 will be mated to first planar surface 125 of foam body 120 where first facer 124 is not present.FIRST ALTERNATE COMPOSITE CONSTRUCTION BOARD

[0034] An alternative embodiment of composite boards can be described with reference to FIG. 5, which shows composite construction board 150 including composite construction board subcomponent 160 and double-sided adhesive subcomponent 170. Construction board subcomponent 160 includes a first rigid foam body 162 and second rigid foam body 164. First rigid foam body 162 includes first planar surface 163 and second planar surface 165. An optional first facer 166 is disposed on a first planar surface 163 of first rigid foam body 162. An optional second facer 168 is disposed on a second planar surface 165 of first rigid foam body 162. Second rigid foam body 164 includes first planar surface 167 and second planar surface 169. In one or more embodiments, facer 168, described above with respect to first rigid foam body 162, is disposed on first planar surface 167 of second rigid foam body 164. An optional second facer 171 is disposed on a second planar surface 169 of second rigid foam body 164. The skilled person will appreciate that the facers may be integrally attached to the foam body by virtue of the foam being mated to the facers during formation of the foam. In one or more embodiments, second rigid foam body 164 may include at least one fragile insulating material 155.

[0035] With reference again to FIG. 5. double-sided adhesive subcomponent 170 includes a carrier layer 172, a first pressure-sensitive adhesive layer 174 disposed on a first planar surface 175 of carrier layer 172, and a second pressure-sensitive adhesive layer 176disposed on a second planar surface 177 of carrier layer 172. A release member 180 is removably attached to second pressure-sensitive layer 176 opposite carrier layer 172. In one or more embodiments, first pressure-sensitive adhesive layer 174 is disposed on the entire first planar surface 175 of carrier layer 172. In one or more embodiments, second pressure-sensitive adhesive layer 176 is disposed on the entire second planar surface 177 of carrier layer 172. Double-sided adhesive subcomponent 170 is mated to facer 171 through first pressure-sensitive adhesive layer 174 where first facer 171 is present, or it will be appreciated that subcomponent 170 will be mated to planar surface 169 of foam body 164 where facer 171 is not present.

[0036] In one or more embodiments, first rigid foam body 162 is a high-density foam body (i.e. density of greater than 2.5 lbs. / ft3as described below) and second rigid foam body 164 is a low-density foam body (i.e. density of less than 2.5 lbs. / ft3as described below). In other embodiments, both first and second rigid foam bodies 162, 164 may be high-density foam, or in other embodiments both first and second rigid foam bodies 162, 164 maybe low- density foam. In yet other embodiments, the rigid foam layers can be reversed from what is shown in FIG. 5 so that foam body 162 is a low-density foam body and foam body 164 is a high-density foam body.SECOND ALTERNATE COMPOSITE CONSTRUCTION BOARD

[0037] Another alternative embodiment of the composite construction boards can be described with reference to FIG. 6, which shows composite construction board 190 including first construction board subcomponent 200, second construction board subcomponent 210, and double-sided adhesive subcomponent 220 disposed therebetween. First construction board subcomponent 200 includes a first rigid foam body 202 having firstplanar surface 203 and second planar surface 205. An optional first facer 206 is disposed on a first planar surface 203 of first rigid foam body 202. An optional second facer 208 is disposed on a second planar surface 205 of first rigid foam body 202. Second construction board subcomponent 210 includes a rigid foam body 212 having first planar surface 213 and second planar surface 215. An optional first facer 216 is disposed on firstplanar surface 213 of second rigid foam body 212. An optional second facer 218 is disposed on second planarsurface 215 of second rigid foam body 212. In one or more embodiments, second rigid foam body 212 may include at least one fragile insulating material 155.

[0038] Double-sided adhesive subcomponent 220 includes a carrier layer 222, a first pressure-sensitive adhesive layer 224 disposed on a first planar surface 225 of carrier layer 222, and a second pressure-sensitive adhesive layer 226 disposed on a second planar surface 227 of carrier layer 222. In one or more embodiments, first pressure-sensitive adhesive layer 224 is disposed on the entire first planar surface 225 of carrier layer 222. In one or more embodiments, second pressure-sensitive adhesive layer 226 is disposed on the entire second planar surface 227 of carrier layer 222. As discussed above with respect to the other embodiments, the skilled person will appreciate that the facers may be integrally attached to the foam body by virtue of the foam being mated to the facers during formation of the foam. Double-sided adhesive subcomponent 220 is mated to second facer 208 of first construction board subcomponent 200 through first pressure-sensitive adhesive layer 224 where first facer 224 is present. Double-sided adhesive subcomponent 220 is mated to first facer 216 of second construction board subcomponent 210 through second pressuresensitive adhesive layer 226 where first facer 216 is present.

[0039] In one or more embodiments, rigid foam body 202 of first construction board subcomponent 200 is a high-density foam body (i.e. density of greater than 2.5 lbs. / ft3as described below) and rigid foam body 212 of second construction board subcomponent 210 is a low-density foam body (i.e. density of less than 2.5 lbs. / ft3as described below). In other embodiments, both first and second rigid foam bodies 202, 212 may be high-density foam, or in other embodiments both first and second rigid foam bodies 202, 212 may be low- density foam. In yet other embodiments, the rigid foam layers can be reversed from what is shown in FIG. 6 so that foam body 202 is a low-density foam body and foam body 212 is a high-density foam body.THIRD ALTERNATE COMPOSITE CONSTRUCTION BOARD

[0040] Still another alternate embodiment of the composite construction boards can be described with reference to FIG. 7. Here, composite 190', which is similar to the composite shown in FIG. 6, may carry an additional double-sided adhesive component akin to that shown in FIGS. 4 and 5. Namely, composite 190' may include double-sided adhesivesubcomponent 320 including first adhesive layer 324, second adhesive layer 326, and carrier layer 322. Subcomponent 320 is adhesively mated to construction board subcomponent 210 (e.g. first adhesive layer 324 is adhesively mated to facer 218 of construction board subcomponent 210). A release member 340 may optionally be removably secured to second adhesive layer 326.FOURTH ALTERNATE COMPOSITE CONSTRUCTION BOARD

[0041] Yet another alternative embodiment of the composite construction boards can be described with reference to FIG. 8, which shows composite construction board 230 including first construction board subcomponent 200, second construction board subcomponent 210, and double-sided adhesive subcomponent 220. First construction board subcomponent 200 includes a first rigid foam body 202 having firstplanar surface 203 and second planar surface 205. An optional first facer 206 is disposed on a first planar surface 203 of first rigid foam body 202. An optional second facer 208 is disposed on a second planar surface 205 of first rigid foam body 202. Second construction board subcomponent 210 includes a second rigid foam body 212 having first planar surface 213 and second planar surface 215. An optional first facer 216 is disposed on first planar surface 213 of second rigid foam body 212. An optional second facer 218 is disposed on second planar surface 215 of second rigid foam body 212. The skilled person will appreciate that the facers may be integrally attached to the foam body by virtue of the foam being mated to the facers during formation of the foam. In one or more embodiments, second rigid foam body 212 may include at least one fragile insulating material 155.

[0042] Double-sided adhesive subcomponent 220 includes a carrier layer 222, a first pressure-sensitive adhesive layer 224 disposed on a first planar surface 225 of carrier layer 222, and a second pressure-sensitive adhesive layer 226 disposed on a second planar surface 227 of carrier layer 222. In one or more embodiments, first pressure-sensitive adhesive layer 224 is disposed on the entire first planar surface 225 of carrier layer 222. In one or more embodiments, second pressure-sensitive adhesive layer 226 is disposed on the entire second planar surface 227 of carrier layer 222. Double-sided adhesive subcomponent 220 is mated to second facer 208 of first construction board subcomponent 200 through first pressure-sensitive adhesive layer 224 where first facer 208 is present. And, double-sidedadhesive subcomponent 220 is mated to first facer 216 of second construction board subcomponent 210 through second pressure-sensitive adhesive layer 226 where first facer 216 is present.

[0043] As also shown in FIG. 8, first construction board subcomponent 200 is offset from second construction board subcomponent 210 to thereby create a shiplap configuration including first shiplap area 240 where a portion of second pressure-sensitive adhesive layer 226 is exposed, and a second shiplap area 242 where a portion of first pressure-sensitive adhesive layer 224 is exposed. An optional release member (not shown) may be removably attached to the exposed area 244 of adhesive layer 226 in shiplap area 240, and an optional release member (not shown) maybe removably attached to the exposed area 246 of adhesive layer 224 in shiplap area 242.

[0044] As also shown in FIG. 8, double-sided adhesive subcomponent 220 contacts first construction board subcomponent 200 (i.e. adhesive layer 224 contact facer 208) across the entirety of facer 208 (e.g. across the entire width and length of subcomponent 200). Likewise, as shown in FIG. 8, double-sided adhesive component 220 contacts second construction board subcomponent 210 (i.e. adhesive layer 226 contact facer 216) across the entirety of facer 216 (e.g. across the entire width and length of subcomponent 210).

[0045] In other embodiments, as shown in FIG. 9, double-sided adhesive component 220 contacts the respective first and second construction board subcomponents 200, 210 to only partially contact the respective facers 208, 216 within the respective shiplap areas 240, 242. As a result, and with respect to shiplap area 240, double-sided adhesive subcomponent 220 is disposed relative to subcomponents 200, 220 to provide an exposed area of adhesive layer 226 within region 244 and an exposed area of facer 208 within region 245. Likewise, with respect to shiplap area 242, double-sided adhesive subcomponent 220 is disposed relative to subcomponents 200, 220 to provide an exposed area of adhesive layer 224 within region 246 and an exposed area of facer 216 within region 247. It will be appreciated that the amount of adhesive layer that is exposed can be readily adjusted, and it may be desirable to adjust the level of exposed adhesive layer to balance the ability to form a complete seal between adjacent boards when installed (e.g. partially overlap the exposed adhesive layers) and provide, for example, some exposed facer which could alleviate the need for a releasemember. That said, in one or more embodiments, a release member (not shown) may be disposed on the respective exposed adhesive layers with regions 244, 246.

[0046] In one or more embodiments, rigid foam body 202 of first construction board subcomponent 200 is a high-density foam body (i.e. density of greater than 2.5 lbs. / ft3as described below) and rigid foam body 212 of second construction board subcomponent 210 is a low-density foam body (i.e. density of less than 2.5 lbs. / ft3as described below). In other embodiments, both first and second rigid foam bodies 202, 212 may be high-density foam, or in other embodiments both first and second rigid foam bodies 202, 212 may be low- density foam. In yet other embodiments, the rigid foam layers can be reversed from what is shown in Figs. 8 and 9 so that foam body 202 is a low-density foam body and foam body 212 is a high-density foam body.

[0047] It will also be appreciated that in one or more embodiments, the shiplap configuration shown in FIGS. 8 and 9 may exist in two directions, as shown in FIG. 10. Specifically, as viewed from above, composite 230 includes construction board subcomponent 200, which has first facer 206 showing. Construction board subcomponent 200 is disposed over construction board subcomponent 210, which has first facer 216 partially showing, with adhesive subcomponent 220 disposed therebetween. Adhesive subcomponent has a portion of first adhesive layer 224 showing. The offset of the two construction board subcomponents creates shiplap regions 240, 242 in the width of composite 230, and shiplap regions 250, 252 in the length of composite 230.FIFTH ALTERNATE COMPOSITE CONSTRUCTION BOARD

[0048] Other alternate embodiments of the construction boards can be described with reference to FIG. 11. That is, composite 230 as shown in FIGS. 8-10 can be modified to carry an additional double-sided adhesive component akin to that shown in FIGS. 4 and 5. As shown in FIG. 11, composite 230' may include double-sided adhesive subcomponent 320 including first adhesive layer 324, second adhesive layer 326, and carrier layer 322. Subcomponent 320 is adhesively mated to construction board subcomponent 210 (e.g. first adhesive layer 324 of subcomponent 320 is adhesively mated to facer 218 of construction board subcomponent 210). A release member 340 may optionally be removably secured to second adhesive layer 326.

[0049] As noted above with respect to the various alternate embodiments of the construction boards, the adhesive subcomponent may be disposed over the entire surface of the layer to which it is attached. In alternate embodiments, the adhesive subcomponent is disposed on only a portion of construction board subcomponent to which it is attached. In this regard, reference can be made to FIG. 12A, which shows double-sided adhesive subcomponents 430, 430' disposed in strips extending the length of composite board 410 from a first longitudinal edge 412 to a second longitudinal edge 414. The strips, as shown, cover only a portion of the width, which is defined from a first lateral edge 416 to a second lateral edge 418. As also shown, double-sided adhesive subcomponent strips 430, 430' are disposed along lateral edges 416, 418. This configuration provides for exposure of, for example, first facer 424 between the double-sided adhesive subcomponent strips 430, 430'. An alternate embodimentis shown in FIG. 12B, where double-sided adhesive subcomponent strips 430, 430' are offset from one or both lateral edges 416, 418. This configuration may provide, for example, facer 424 being exposed between double-sided adhesive subcomponent strips 430, 430', and also allows facer 424 to be exposed along lateral edges 416, 418. In yet other alternative embodiments, double-sided adhesive component strips 430, 430' may be offset from one or both longitudinal edges 412, 414. As shown in FIG. 12B, strips 430, 430' do not extend to either of longitudinal edges 430, 430', which provides exposure of, for example, first facer 424 along the entirety of longitudinal edges 412, 414. The skilled person will be able to readily envisage other alternatives, such as where the example shown in FIG. 12A includes strips 430, 430' that do not extend to the edges 412, 414, or where strips 430, 430' do not extend to only one edge (e.g. edge 412) while fully extending to the opposed edge (e.g. edge 414).

[0050] The skilled person appreciates that the composite boards 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 double-sided adhesive subcomponent 430 is provided in strips (e.g. strips 430, 430'), 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 embodiments12 to about 18 inches (30.48 - 45.72 cm), and in other embodiments 14 to about 16 inches (35.56 - 40.64 cm).

[0051] In one or more embodiments, the construction boards of the present invention may be characterized by the degree to which the double-sided adhesive subcomponent covers the surface of the coverboard (e.g. the degree to which double-sided adhesive subcomponent(s) cover the facer of the construction board). This degree of coverage may be referred to as coverage rate, which may be quantified as a percentage of the surface (e.g. facer) covered by the double-sided adhesive subcomponent. 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%.PRESSURE SENSITIVE ADHESIVE LAYER

[0052] As described above, the adhesive sheet and adhesive subcomponent of the various embodiments of the invention include first and second pressure-sensitive adhesive layers disposed on opposite sides of a carrier layer. In one or more embodiments, the respective pressure-sensitive adhesive layers, which may also be referred to as adhesive layers, may have one or more of the same properties. For example, the respective pressuresensitive 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.

[0053] In one or more embodiments, the pressure-sensitive adhesive layers 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 layers is less than 500, in other embodiments less than 400, in other embodiments less than 300, in otherembodiments less than 200, and in other embodiments less than 150 pm. In one or more embodiments, the thickness of the pressure-sensitive adhesive layers 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 layers may be characterized bytheir 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.

[0055] 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 ofthe 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.

[0056] In one or more embodiments, the pressure-sensitive adhesive layers include, as major polymeric component, a rubber such as ethylene-propylene-diene rubber, ethylenepropylene 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 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 foam carrier layer or to a transfer film. As the skilled person appreciates, evaporation or removal ofthe 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 ofthe polymers within the adhesive layer.

[0058] 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 pressuresensitive adhesive compositions may include a variety of complementary constituents such as, but not limited to, tackifying resins, waxes, antioxidants, and plasticizers. Pressuresensitive 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 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 Nos. W0 2015 / 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 oneor 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 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).

[0063] 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.

[0064] 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.

[0065] Specific examples of polyacrylate elastomers that are useful in preparing the adhesive layers 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 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 inother embodiments greater than 99 wt % of the cured polyacrylate elastomer, based upon the total weight of the adhesive layers.

[0069] 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.

[0070] 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.

[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.Carrier LayerNON-RIGID FOAM LAYER

[0072] In one or more embodiments, the carrier layer of the various embodiments disclosed herein 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.

[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 thermoplasticelastomer. 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 layers to 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 layers. 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 / ft33 (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).

[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 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 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 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 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 (344.5 kPa). 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 50to 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 layers. 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 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.

[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 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).

[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%.FABRIC CARRIER LAYER

[0083] In one or more embodiments, the carrier layer of the various embodiments disclosed herein includes 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 forroofing 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.

[0084] 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.

[0085] 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.

[0086] 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 70to 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.

[0087] 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.

[0088] 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

[0089] 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.

[0090] In one or more embodiments, expandable graphite includes intercalated graphite in which an intercallant material is included between the graphite layers of graphitecrystal 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.

[0091] 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).

[0092] In one or more embodiments, the expandable graphite maybe characterized as having a mean or average size in the range from about 30 pm to about 1.5 mm, in other embodiments from about 50 pm to about 1.0 mm, and in other embodiments from about 180 to about 850 pm. In one or more embodiments, the expandable graphite may be characterized as having a mean or average size of at least 30 pm, in other embodiments at least 44 pm, in other embodiments at least 180 pm, and in other embodiments at least 300 pm. 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 pm, in other embodiments at most 600 pm, in yet other embodiments at most 500 pm, and in still other embodiments at most 400 pm. Useful expandable graphite includes Graphite Grade #1721 (Asbury Carbons), which has a nominal size of greater than 300 pm.

[0093] 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.

[0094] In one or more embodiments, the expandable graphite maybe 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.

[0095] In one or more embodiments, the expandable graphite maybe 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%.

[0096] In one or more embodiments, the expandable graphite maybe characterized as having an expansion ratio (cc / g) in the range from about 10:1 to about 500:1, in other embodiments atleast20:l to about450:l, in other embodiments atleast30:l 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.

[0097] 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 includesthat 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.

[0098] In one or more embodiments, the expandable graphite maybe 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.

[0099] 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.

[0100] Practice of this invention is not limited by the selection of any particular method for adding the intumescent material to the carrier layer. In one or more embodiments, the intumescent material can be included when the material of the carrier layer is produced. Adding the intumescent material during manufacture of the 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 carrier layer could include employing a low temperature foam as the carrier layer. In one or more embodiments, particularly where the 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 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 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 carrier layer to a deleterious degree. In one or more embodiments, particularly where the carrier layer is a fabric carrier layer, the intumescent material may be applied by coating the 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.

[0101] In one or more embodiments, the 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 carrier layer. In these or other embodiments, the 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 carrier layer. In one or more embodiments, the carrier layer includes from about 2 to about 50, in otherembodiments 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 carrier layer.FRAGILE INSULATING MATERIAL

[0102] Practice of the present invention is not necessarily limited by the selection of the fragile insulation material, which may also be referred to as fragile insulating material, fragile insulating devices, or fragile insulation devices, as used in the various embodiments described above. In one or more embodiments, the fragile insulation materials offer greater insulating properties than the closed-cell foams that encase the fragile insulation materials. In one or more embodiments, the fragile insulation materials have a lower thermal conductivity than closed-cell foams that encase the fragile insulation materials. In one or more embodiments, the fragile insulation materials include a friable component.

[0103] In one or more embodiments, the fragile insulation materials are or include cellular or open cell structures wherein the cellular walls of the cellular structure include one or more of silica (e.g. fumed or precipitated silica), alumina, titania, magnesia, chromia, tin dioxide, glass wool, fiberglass, polymeric materials, and carbon. In one or more embodiments, the cellular structure may include aluminosilicates such as, but not limited to, perlite.

[0104] In one or more embodiments, the fragile insulation material may include an aerogel. Specific examples include carbon aerogels, silica aerogels, and alumina aerogels.

[0105] In one or more embodiments, the fragile insulation material includes a vacuum insulation panel (VIP). Vacuum insulation panels are known and generally include substantially gas-tight enclosures surrounding a rigid core wherein air therein has been evacuated. The enclosures may include membrane walls that prevent air from entering the panel. The core may include a rigid, highly-porous material that supports the membrane walls against atmospheric pressure once the air is evacuated.

[0106] Examples of vacuum insulation panels include those that include a cellular core that may include silica (e.g. fumed or precipitated silica), alumina, titania, magnesia, chromia, tin dioxide, glass wool, fiberglass, carbon, aluminosilicates (e.g. perlite), and open-cell polymeric materials, including polymeric fibers, such as open-cell polystyrene or open-cellpolyurethane. In these or other embodiments, the core may include an aerogel such as carbon aerogels, silica aerogels, and alumina aerogels.

[0107] Some specific examples of vacuum insulation panels are also described in U.S. Publication Nos. 2013 / 0216854; 2013 / 0216791; 2013 / 0142972; 2013 / 0139948; 2012 / 0009376; 2009 / 0126600; 2008 / 0236052; 2004 / 0058119; 2003 / 0159404; and 2003 / 0082357 which are incorporated herein by reference.

[0108] In other embodiments, the fragile insulation materials include modified atmospheric insulation (MAI) panels. MAIs are produced with steam, in lieu of a porous silica core as typically found in a VIP, which, as it cools and condenses, leaves a vacuum. The manufacturing process may advantageously be devoid of sealing the device under very low pressure. Devices of this nature, and methods for their manufacture, are disclosed in U.S. Publication Nos. 2014 / 0360044 and 2014 / 0366480, which are incorporated herein by reference.ROOF DECK

[0109] The roof deck referenced above in the various embodiments is not limited and therefore the roofing systems of this invention can include a variety of roof decks. Exemplary roof decks include concrete pads, steel decks, wood beams, and foamed concrete decks.CONSTRUCTION BOARDS

[0110] Generally, practice of the invention is not necessarily limited by the selection of particular construction boards that are used to form the layers of the composite construction boards or roof system. Those skilled in the art understand the various construction boards that are used within a roofing system. For example, useful construction boards may include, but are not limited to, foam boards (e.g. polystyrene or polyisocyanurate board stock), fiber boards (e.g. OSB boards), masonite boards, gypsum boards (e.g. DensDeck), and perlite boards. As the skilled person appreciates, fiber boards, masonite boards, gypsum boards, perlite boards, and high-density foam boards, which may be adapted to protect the integrity of fragile insulation materials used herein, are often referred to as cover boards, while low- density boards are often referred to as insulation boards.

[0111] In one or more embodiments, the construction boards are polyisocyanurate foam boards, which may also be referred to as ISO boards or polyisocyanurate board stock.In one or more embodiments, these foam boards generally include a foam body with optional facers on the opposed planar surfaces of the foam body.

[0112] The skilled person appreciates that the foam body of the foam construction boards (i.e. the polyisocyanurate and / or polyurethane foam) can be manufactured 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 any event, the reaction that ensues produces a foam that, according to one or more kinetic and / or thermodynamic properties, develops over a period of time. Unless otherwise specified, therefore, the term developing foam will be understood to refer to the mixture of the polyurethane and / or polyisocyanurate reactants as they exist prior to cure, which is when the reaction mixture is appreciably immobile (e.g., is no longer flowable).

[0113] The skilled person also understands that the foam body of the foam construction boards may be a cellular structure that may include an interconnected network of solid struts or plates 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.

[0114] In one or more embodiments, the foam body of the foam construction boards may be characterized by a desired ISO index. As the skilled person understands, ISO index correlates to PIR / PUR ratio and can determined by IR spectroscopy using standard foams of known index (note that ratio of 3 PIR / PUR provides an ISO Index of 300), of greater than 150, in other embodiments greater than 180, in other embodiments greater than 200, in other embodiments greater than 220, in other embodiments greater than 240, in otherembodiments greater than 260, in other embodiments greater than 270, in other embodiments greater than 285, in other embodiments greater than 300, in other embodiments greater than 315, and in other embodiments greater than 325. In these or other embodiments, the foam maybe characterized by an ISO index of less than 350, in other embodiments less than 300, in other embodiments less than 275, in other embodiments less than 250, in other embodiments less than 225, and in other embodiments less than 200.

[0115] In one or more embodiments, one layer of construction boards includes polyisocyanurate foam board characterized by a relatively low density (i.e. low-density foam boards), and one layer of construction boards includes polyisocyanurate foam board characterized by a relatively high density (i.e. high-density foam boards).

[0116] In one or more embodiments, the foam boards that include polyisocyanurate foam characterized by a relatively low density have a density, defined according to ASTM C 303-21, of less than 2.5 pounds per cubic foot (12.2 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, foam characterized by a relatively low density has a density that is greater than 1.50 pounds per cubic foot (7.32 kg / m2) and in other embodiments greater than 1.55 pounds per cubic foot (7.57 kg / m2).

[0117] In one or more embodiments, the foam boards that include polyisocyanurate foam characterized by a relatively high density have a density, defined according to ASTM C 303-21, of greater than 2.5 pounds per cubic foot (12.2 kg / m2), 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 density of this high density boards may be 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 otherembodiments 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).

[0118] In one or more embodiments, the foam body may have a thickness of greater than 0.25 (0.64 cm), in other embodiments greater than 0.50 (1.27 cm), in other embodiments greater than 1.0 (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 (15.24 cm), in other embodiments less than 5.0 (12.7 cm), in other embodiments less than 3.0 (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 (0.64 - 15.24 cm), in other embodiments from about0.50 to about 5.0 (1.27 - 12.7 cm), and in other embodiments from about 1.5 to about 4.0 inches (3.81 - 10.16 cm).

[0119] As described above, the foam boards may include facers. The skilled person appreciates that these facers may be disposed on opposed planar surfaces of the boards. The facers can be the same or different and may include a variety of materials or compositions. Useful facers include aluminum foil, cellulosic fiber mats, reinforced cellulosic fiber mats, craft paper, coated glass fiber mats, uncoated glass fiber mats, chopped glass mats, and combinations thereof. Useful facer materials are known as described in U.S. Patent Nos. 6,774,071; 6,355,701; RE 36674; 6,044,604; and 5,891,563, which are incorporated herein by reference.

[0120] The thickness of the facer may vary; for example, it may be from about 0.01 to about 1.0 inches thick (0.025 - 2.54 cm) or in other embodiments from about 0.015 to about 0.050 inchesthick (0.04 - 0.13 cm), or in other embodiments from about 0.015 to about 0.030 inches thick (0.04 - 0.07 cm).

[0121] In other embodiments, the facers may be generally solid, rigid material such as wood, particle, or fiber board. In one or more embodiments, the facer is a wood board such as plywood, luan board, or oriented-strand board (OSB). In other embodiments, the facer board is a particle or fiber board such as fiber boards, masonite board, wall board, gypsum board, gypsum products such as DensDeck, perlite boards, and high-density foam boards. The thickness of the rigid facer can vary; for example, the thickness of the rigid facer can befrom about 0.2 to about 1.5 inches (0.51 - 3.8 cm), or in other embodiments from about 0.25 to about 1.0 inches (0.64 - 2.54 cm).

[0122] In one or more embodiments, facers are optional. Therefore, in one or more embodiments, the construction board may be facerless. The ability to produce facerless construction boards is known as described in U.S. Patent No. 6,117,375, which is incorporated herein by reference.RELEASE MEMBER

[0123] The release liner employed in various embodiments disclosed herein, which may also be referred to as release members, includes a polymeric film or extrudate. This polymeric 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 includes a cellulosic substrate having a polymeric film or coating applied thereon, which film or coating may be referred to as a polymeric layer.

[0124] In one or more embodiments, the nature and construction of the release member will facilitate transport, storage and delivery of the devices for composites that include the pressure-sensitive adhesive layers. For example, where the double-sided adhesive sheet includes a single release member, then both planar surfaces of the release member will be adapted to removably adhere or attach to the adhesive layers; in other words, the adhesive layers, which are positioned opposite the foamed carrier layer, are removably adhered to the respective surfaces of the release members, which are adapted to release from the adhesive layers.

[0125] 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 referencedfilms and materials may be coated with a release agent, (e.g., silicone). In one or more embodiments, the release liner includes a static dissipative material. For example, the release liner may include carbon black or metal particles dispersed within a polymeric matrix.

[0126] 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.MANUFACTURE OF DOUBLE-SIDED ADHESIVE SHEET

[0127] The double-sided adhesive sheets employed in the various embodiments of the present invention can be manufactured by employing conventional techniques. F or example, a liquid composition including the adhesive material can be applied to respective planar surfaces of the carrier material. These compositions can include solvent-borne and waterborne compositions. The skilled person can readily determine the appropriate thickness at which to apply the composition, and then conventional techniques can be employed to evaporate the solvent. Once evaporated, the residue forms the pressure-sensitive adhesive layer. The pressure-sensitive adhesive layers can then optionally undergo further processing such as curing to chemically crosslink the polymers within the layer. In alternate embodiments, the adhesive composition can be applied to the respective layers of the carrier by extrusion (i.e., the adhesive materials are melt extruded onto the carrier). Once applied to the carrier, the adhesive composition can undergo further processing such as chemical crosslinking by, for example, UV curing. In other embodiments, the adhesive composition, either as a melt extrudate or as a liquid composition, can be applied to a release member to form a transfer film composite. The composition can be dried and / or chemically crosslinked to provide the adhesive layer, which is removably attached to the release member. The adhesive layer can then be mated to the carrier (i.e., it is laminated to the carrier) to form the double-sided adhesive sheet.METHOD OF MANUFACTURING COMPOSITE CONSTRUCTION BOARDS

[0128] In one or more embodiments, the composite construction boards of the present invention may be fabricated by mating a construction board to a double-sided adhesivecomponent, where the construction boards and the double-sided adhesive components are consistent with the teachings provided herein.

[0129] The construction board may be provided by preparing a construction board by using conventional techniques. The boards of one or more embodiments of this invention can be manufactured by using known techniques such as known techniques for producing polyurethane or polyisocyanurate insulation. Generally, the process includes 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.

[0130] The mixture of the A-side and the B-side stream is then deposited on to a facer that, within a continuous process, is continuously conveyed below the mix head in which the A-side and B-side streams are mixed. After the mixture is deposited on to the first facer, a second facer material is then applied over the mixture, which is in the form of a rising or expanding foam at this point. In other words, the mixture is sandwiched between two facer materials that are being continuously conveyed. This sandwiched structure is then typically conveyed into a laminator where the polyurethane / polyisocyanurate reaction is accelerated through the application of heat. Processes for the manufacture of polyurethane or polyisocyanurate insulation boards are known in the art as described in U.S. Patent Nos. 7,838,568; 7,612,120; 7,387,753; 6,117,375; 6,044,604; 5,891,563; 5,573,092; and U.S. Publication Nos. 2004 / 0109983, 2003 / 0082365, 2003 / 0153656, 2003 / 0032351, and 2002 / 0013379, which are incorporated herein by reference.

[0131] In those embodiments that include a composite board with multiple foam layers, such as those described with reference to FIG. 6, the skilled person appreciates that the composite boards be manufactured by employing known techniques including those techniques that include forming a first foam layer on a first facer, mating a second facer to the developing foam, and then forming a second foam layer on the second facer, followed by mating a third facer to the second foam layer. These techniques are described, for example,in U.S. Publication No. 2014 / 0011008, which is incorporated herein by reference. The skilled person will also appreciate how to manufacture construction boards including fragile insulation materials, which methods include depositing developing foam on and / or around one or more fragile insulation materials such as may occur in the manufacture of board stock. Known techniques for manufacturing these composites are disclosed in U.S. Publication Nos. 2017 / 0015027, 2022 / 0001642, and 2013 / 0089696, which are incorporated herein by reference.

[0132] The double-sided adhesive component, which may also be referred to as an adhesive sheet, maybe 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 sheet 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 foam carrier layer will have the characteristics outlined above with respect to the composite. Useful double-sided adhesive components are described in co-pending PCT / EP2024 / 058094 which is incorporated herein by reference.

[0133] 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.

[0134] 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 pm. 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 pm. In one or more embodiments, the double-sided 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.

[0135] 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.

[0136] 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 doublesided 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.

[0137] In one or more embodiments, the double-sided adhesive sheet may be characterized by tensile strength measured perpendicular to the planar surface of the foamed layer, which may also be referred to as the Z-direction tensile strength. The skilled person appreciates that Z-direction tensile strength of the foamed 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 C209-20 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 foamed 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 embodimentsgreater 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 foamed 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).

[0138] 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 foamed 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.

[0139] 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.

[0140] In one or more embodiments, with the construction board and the double-side adhesive component provided, the next step of the process includes mating the double-sided adhesive component to the construction board. This can be accomplished by employingstandard techniques. For example, 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 that can be mated to the construction board (e.g., to a facer of the construction board) while leaving the release liner in place on the opposite pressure-sensitive layer.

[0141] In those embodiments where the double-sided adhesive component secures two construction boards together, for example in the embodiments shown in FIGS. 6 and 7, the process for fabricating the construction board may include mating the double-side adhesive component to a first board, removing the release liner, and then mating the opposite layer of pressure-sensitive adhesive to the second boardROOFING MEMBRANE LAYER

[0142] Practice of this invention is likewise not limited by the selection of any particular roofing membrane, which may also be referred to herein as protective membranes. As the skilled person appreciates, roofing membranes provide weather-protective layer to the roofing system. In other words, these membranes are configured to resist environmental conditions experienced on the surface of the roof including water in the form of rain or snow and solar radiation, particularly UV radiation. Useful membranes include those that are known as single-ply roofing membranes. Useful roofing membranes include polymeric membranes. Useful polymeric membranes include both thermoplastic and thermoset materials. For example, and as is known in the art, membrane prepared from polyfethylene- co-propylene-co-diene) terpolymer rubber or poly(ethylene-co-propylene) copolymer rubber can be used. Roofing membranes made from these materials are well known in the art as described in U.S. Patent Nos. 6,632,509; 6,615,892; 5,700,538; 5,703,154; 5,804,661; 5,854,327; 5,093,206; and 5,468,550, which are incorporated herein by reference. Other useful polymeric membranes include those made from various thermoplastic polymers or polymer composites. For example, thermoplastic olefin (i.e. TPO), thermoplastic vulcanizate (i.e. TPV), or polyvinylchloride (PVC) materials can be used. The use of these materials for roofing membranes is known in the art as described in U.S. Patent Nos. 6,502,360; 6,743,864; 6,543,199; 5,725,711; 5,516,829; 5,512,118; and 5,486,249, which areincorporated herein by reference. In one or more embodiments, the membranes include those defined by ASTM D4637 / 4637M-15 and / or ASTM D6878 / 6878M-21-21.

[0143] Still in other embodiments, the protective membrane can include bituminous or asphalt membranes. In one embodiment, these asphalt membranes derive from asphalt sheeting that is applied to the roof. These asphalt roofing membranes are known in the art as described in U.S. Patent Nos. 6,579,921; 6,110,846; and 6,764,733, which are incorporated herein by reference. In other embodiments, the protective membrane can derive from the application of hot asphalt to the roof.

[0144] Other layers or elements of the roofing systems are not excluded by the practice of this invention. For example, and as is known in the art, another layer of material can be applied on top of the protective membrane. Often these materials are applied to further protect the protective membranes from exposure to electromagnetic radiation, particularly that radiation in the form of UV light. In certain instances, ballast material is applied over the protective membrane. In many instances, this ballast material simply includes aggregate in the form of rock, stone, or gravel; U.S. Patent No. 6,487,830 is incorporated herein in this regard.METHOD OF ASSEMBLING ROOF SYSTEM

[0145] As suggested above, the methods of this invention employ double-sided adhesive sheet to secure one or more layers of construction boards and / or fragile insulation materials into a roof system. In particular embodiments, a layer of construction boards and / or fragile insulation materials is adhered to a substrate, which may include, without limitation, a roof deck or a layer of construction boards. These methods generally include contacting a first adhesive layer of the double-sided adhesive sheet to the substrate (e.g. to a first layer of construction boards). Then, individual boards that form a first or second layer of construction boards is contacted to an exposed opposite adhesive layer of the doublesided adhesive sheet. The methods may include removing a release member where necessary. For example, if the double-sided adhesive sheet includes release members removably mated to each adhesive layer of the adhesive sheet, then a first release member is removed to secure the adhesive sheet to the substrate (e.g., to a first layer of construction boards). Likewise, if the opposed adhesive layer includes a release member, then theopposed release member is removed in order to expose the adhesive layer before placing the individual boards of the subsequent layer of construction boards into contact with the opposed adhesive layer.

[0146] Methods of one or more embodiments of the invention can be described in greater detail as follows. According to one or more embodiments, an installation process includes providing a double-sided adhesive sheet, and providing a first layer of construction boards and / or fragile insulation materials, which layer of construction boards and / or fragile insulation materials may be secured to the roof deck. In one or more embodiments, the first layer of construction boards may be mechanically affixed to the roof deck. The method is continued by positioning the double-sided adhesive sheet on a desired exposed surface of the first layer of construction boards and / or fragile insulation materials. This step of positioning may include unwinding a roll of the double-sided adhesive sheet. In one or more embodiments, the double-sided adhesive sheet is then secured to the first layer of construction boards. The step ofunwinding may include adhering the double-sided adhesive sheet while the roll is being unrolled. Where the adhesive sheet includes a release member removably secured to the adhesive layer adjacent to the substrate (e.g., first layer of construction boards), the process may include a step of removing the lower release member so that the adhesive layer can be contacted and adhered to the substrate (e.g., first layer of construction boards). The skilled person will appreciate that where the composite includes a single release member, the release member can be removably adhered to the opposite adhesive layer of the adhesive sheet, and therefore the act of unrolling the composite allows the adhesive layer to be directly contacted to the substrate without the need to remove the release member. With the adhesive layer exposed, the step of contacting and adhering the adhesive sheet to the substrate (e.g., first layer of construction boards) may include applying force to the upper surface of the adhesive sheet to thereby increase adhesion between the adhesive sheet and the underlying construction board. It will be appreciated that these installation methods include the application of multiple, adjacent strips or sheets of the double-sided adhesive sheet to the substrate. In one or more embodiments, the edges of these respective sheets are abutted to one another. In other embodiments, the edges of therespective sheets are overlapped. In yet other embodiments, a gap (e.g. 0.1 - 20 cm) is provided between adjacent sheets.

[0147] The process continues with optionally removing an upper release member, if present, to thereby expose the upper planar surface of the adhesive layer. Once exposed, the process continues with placing a layer of construction boards into contact with the upper surface of the adhesive sheet (i.e., the upper adhesive layer of the adhesive sheet). The adhesion between the second layer of construction boards and the adhesive sheet, as well as the adhesion between the adhesive sheet and the first layer of construction boards, can be enhanced by a step of applying force (e.g., pressure) to the second layer of construction boards after placing the construction boards in contact with the adhesive sheet.

[0148] In one or more embodiments, the methods of this invention employ an applicator for installing the double-sided adhesive sheet for securing one or more layers of construction boards into a roof system. The applicator can include a dispenser for a roll of the double-sided adhesive sheet. Since certain rolls of the double-sided adhesive sheet can have relatively wide lengths (e.g., 24 inches, 30 inches, 48 inches), the use of an applicator can facilitate easier handling of the roll by a single worker. The applicator may have sufficient width in order to handle the widths of the roll of the double-sided adhesive sheet.

[0149] In one or more embodiments, the applicator can be portable in order to perform on-roof installation of the double-sided adhesive sheet from a roll. An exemplary form for a portable version is a "walk-behind” applicator. In other embodiments, the applicator can be fixedly positioned, such as with a manufacturing bench, in order to perform factory installation of the double-sided adhesive sheet.

[0150] The applicator may allow for continuous application of a roll of the double-sided adhesive sheet to a substrate. The applicator may allow for removal of the at least one release member. The applicator may allow for quick change of the roll and quick application of the double-sided adhesive sheet from the roll to substrates on a roof deck or to boards in a pre-applied fashion. The applicator may allow a user to correct alignment as needed, which provides the ability for continuous and smooth application of the double-sided adhesive sheet from a roll.

[0151] The applicator may include a sufficient distance from where the double-sided adhesive sheet releases off the roll to a roller which presses the released double-sided adhesive sheet to the substrate. An intermediate roller can be placed for assistance in guiding the released double-sided adhesive sheet to the substrate. The intermediate roller can also allow for the slight corrections to align the released double-sided adhesive sheet in a straight line. The intermediate roller can be positioned relatively close to the substrate to allow for critical sight of alignment. The position of the intermediate roller may also prevent premature contact of the released double-sided adhesive sheet with the substrate. The released double-sided adhesive sheet may be located correctly before contacting the intended substrate.

[0152] Further exemplary applicators or details thereof may be disclosed in U.S. Publication Nos. 2011 / 0229265, 2007 / 0125474, and 2006 / 0226168, and U.S. Patent Nos. 11,821,154; 11,591,177; 11,512,481; 9,546,068; 8,347,932; 7,763,136; 7,028,941; 6,571,849; 6,508,287; and 5,772,359. Other commercially available applicators may also be suitable.

[0153] As indicated above with reference to FIGS. 1 and 2, in one or more embodiments, the first layer of construction boards can be mechanically affixed to the roof deck. This can be accomplished by using known techniques whereby, for example, a board is positioned in place and a plurality of mechanical fastener assemblies, which often include a fastener and a fastening plate, are used to secure the board to the roof deck. In other embodiments, the first layer of construction boards are adhesively secured to the roof deck.

[0154] In one or more embodiments, the double-sided adhesive sheet used to adhere the first and second layers of construction boards. For example, according to embodiments of the invention, the double-side adhesive sheet disclosed herein can be employed to secure the first layer of construction boards to the roof deck.INSTALLATION OF COMPOSITE BOARDS

[0155] 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, theconstruction boards can be adhered without the use of adhesives or primers, which may include volatile organic compounds.

[0156] According to one or more embodiments, the composite construction boards can be pre-fabricated 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.

[0157] In one or more embodiments, the roof 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 layer of pressure-sensitive adhesive, and then securing the composite construction board to the roof surface.ATTACHING MEMBRANE TO SYSTEM

[0158] In one or more embodiments, a plurality of membrane panels are secured to the uppermost layer of construction boards and seamed together to form the weather-protective layer of the roof system. In one or more embodiments, the membrane panels are mechanically affixed to the roof system (e.g., mechanically fastened through the layers of construction board to the roof deck). In other embodiments, the membrane panels are adhesively secured to the uppermost layer of construction boards. In particular embodiments, the membrane panels carry a layer of pressure-sensitive adhesive that is used to adhesively mate the membrane panels to the uppermost layer of construction boards. The membrane panels can then be seamed using conventional techniques. For example, it is common to seam rubber membranes by using adhesive tapes or a pressure-sensitive adhesive that is pre-applied to the lap portion of the membrane (which may include the same pressure-sensitive adhesive used to secure the membrane to the roof deck). For thermoplastic membranes, it is typically useful to heat weld the membranes together and thereby form a seam.

[0159] In one or more embodiments, the double-sided adhesive sheet used to adhere the first and second layers of construction boards can be employed to secure the membranepanes to the uppermost layer of construction boards. The membrane panels can then be seamed using conventional techniques.

[0160] 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 flat or low-sloped roof system comprising:(i) a roof deck;(ii) a first layer including a first layer of construction boards secured directly or indirectly to the roof deck;(iii) a second layer of construction boards adhered to the first layer, the second layer of construction boards including at least one fragile insulating material; and(iv) a roofing membrane forming a water-proof protective layer over the roof system, where the second layer of construction board is adhered to the first layer through a double-sided adhesive sheet including first and second layers of pressure-sensitive adhesive sandwiching a carrier layer.

2. A flat or low-sloped roof system comprising:(i) a roof deck;(ii) a first layer including a layer of one or more fragile insulation materials adhered to the roof deck;(iii) a second layer of construction boards adhered to the first layer; and(iv) a roofing membrane forming a water-proof protective layer over the roof system, where the second layer of construction board is adhered to the first layer through a double-sided adhesive sheet including first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, and where the layer of one or more fragile insulation materials is adhered to the roof deck through a double-sided adhesive sheet including first and second layers of pressuresensitive adhesive sandwiching a carrier layer.

3. The roof system of claim 1, where said first layer of construction boards includes a plurality of construction boards including foamed polyisocyanurate.

4. The roof system of any of the preceding claims, where said second layer of construction boards includes a plurality of construction boards including foamed polyisocyanurate.

5. The roof system of any of the preceding claims, where the foamed polyisocyanurate within said first layer of construction boards has a density of less than 48 kg / m3(3.0 lbs / ft3).

6. The roof system of any of the preceding claims, where the foamed polyisocyanurate within said second layer of construction boards has a density of greater than 48 kg / m3(3.0 lbs / ft3).

7. The roof system of any of the preceding claims, where the carrier layer is a foamed carrier layer.

8. The roof system of any of the preceding claims, where the foamed carrier layer is a foamed thermoplastic resin.

9. The roof system of any of the preceding claims, where the foamed thermoplastic resin is a foamed polyolefin.

10. The roof system of any of the preceding claims, where the foamed carrier layer is a foamed acrylic resin.

11. The roof system of any of the preceding claims, where the foamed carrier layer is a foamed elastomer.

12. The roof system of any of the preceding claims, where the foamed carrier layer is a foamed ethylene vinyl acetate resin.

13. The roof system of any of the preceding claims, where the foamed carrier layer is a foamed polyurethane.

14. The roof system of any of the preceding claims, where the foamed carrier layer has a thickness of about 500 to about 10,000 pm.

15. The roof system of any of the preceding claims, where the foamed carrier layer is a closed-cell foam.

16. The roof system of any of the preceding claims, where the foamed carrier layer is an open-cell foam.

17. The roof system of any of the preceding claims, where the foamed carrier layer has a density of from about 12.8 kg / m3to about 160 kg / m3(about 0.8 to about 10 lbs per ft3).

18. The roof system of any of the preceding claims, where the foamed carrier layer, prior to sandwiching between the pressure-sensitive adhesive layers, has a tensile strength, in the machine direction, of about 207 to about 689 kPa (about 30 to about 100 psi).

19. The roof system of any of the preceding claims, where the foamed carrier layer has a firmness of about 0.689 to about 103.35 kPa (about 0.1 to about 15 psi).

20. The roof system of any of the preceding claims, where the foamed carrier layer has a Shore A hardness of about 0 to about 10.

21. The roof system of any of the preceding claims, where the foamed carrier layer has a deflection strength at 25 % deflection of from about 6.89 to about 206.84 kPa (about 1 to about 30 psi).

22. The roof system of any of the preceding claims, where the first and second pressureadhesive layers have a thickness of from about 25 to about 500 pm.

23. The roof system of any of the preceding claims, where the double-sided adhesive sheet is characterized by a Z-direction tensile strength of from about 20.68 to about 310.26 kPa (about 3 to about 45 psi).

24. The roof system of any of the preceding claims, where the double-sided adhesive sheet is characterized by a dead load shear at 22 °C of at least 60 minutes.

25. The roof system of any of the preceding claims, where the double-sided adhesive sheet is characterized as being non-permeable, semi-impermeable, or semi- permeable.

26. The roof system of any of the preceding claims, where the carrier layer is a fabric carrier layer.

27. The roof system of any of the preceding claims, where the fabric carrier layer is fleece.

28. The roof system of any of the preceding claims, where the first layer of construction board is adhered to the roof deck through a double-sided adhesive sheetthat includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer.

29. A method of installing construction boards on a roof, the method comprising:(i) providing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a foamed carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet;(ii) providing a first layer of construction boards secured to a roof deck;(iii) positioning the double-sided adhesive sheet on a desired exposed surface of the first layer of construction boards;(iv) contacting and adhering the bottom surface of the double-sided adhesive sheet to the first layer of construction boards; and(v) placing a second layer of construction boards into contact with the upper surface of the double-sided adhesive sheet, where the second layer of construction boards includes at least one fragile insulating material.

30. A method of installing fragile insulating materials on a roof, the method comprising:(i) providing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a foamed carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet;(ii) positioning the double-sided adhesive sheet on a desired exposed surface of a roof deck;(iii) contacting and adhering the bottom surface of the adhesive sheet to the roof deck;(iv) placing a layer of fragile insulating materials into contact with the upper surface of the adhesive sheet;(v) providing a second amount of the double-sided adhesive sheet;(vi) positioning the second amount of the double-sided adhesive sheet on a desired exposed surface of the layer of fragile insulating materials;(vii) contacting and adhering the bottom surface of the second amount of the double-sided adhesive sheet to the layer of fragile insulating materials;(viii) placing a second layer of construction boards into contact with the upper surface of the second amount of the double-sided adhesive sheet.

31. The method of claim 29, where the first layer of construction boards is mechanically secured to the roof deck.

32. The method of any of claims 29-31, where the first layer of construction boards is adhesively secured to the roof deck.

33. The method of any of claims 29-32, where, prior to said step of contacting and adhering the adhesive sheet to the first layer, removing a release member from the bottom surface of the adhesive sheet.

34. The method of any of claims 29-33, where said step of providing a double-sided adhesive sheet includes providing the double-sided adhesive sheet in the form of a roll, and, prior to said positioning the double-sided adhesive sheet, unwinding the roll.

35. The method of any of claims 29-34, where, prior to placing a second layer of construction boards into contact with the upper surface of the adhesive sheet, removing an upper release member removably secured to the upper surface of the adhesive sheet to thereby expose the upper planar surface of the adhesive layer.

36. The method of any of claims 29-35, further comprising applying force to the second layer of construction boards after placing the construction boards in contact with the adhesive sheet.

37. The method of any of claims 29-36, further comprising installing an additional layer of construction boards over the second layer of construction boards and / or installing a membrane system over the second layer of construction boards or the additional layer of construction boards.

38. The method of any of claims 29-37, where the first layer of construction boards is adhesively secured to the roof deck by employing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesiveforming a bottom surface of the adhesive sheet and the second layer of pressuresensitive adhesive forming an upper surface of the adhesive sheet.

39. The method of any of claims 29-38, where said first layer of construction boards includes a plurality of construction boards including foamed polyisocyanurate.

40. The method of any of claims 29-39, where said second layer of construction boards includes a plurality of construction boards including foamed polyisocyanurate.

41. The method of any of claims 29-40, where the foamed polyisocyanurate within said first layer of construction boards has a density of less than 48 kg / m3(3.0 lbs / ft3).

42. The method of any of claims 29-41, where the foamed polyisocyanurate within said second layer of construction boards has a density of greater than 48 kg / m3(3.0 lbs / ft3).

43. The method of any of claims 29-42, where the carrier layer is a foamed carrier layer which is a foamed thermoplastic resin.

44. The method of any of claims 29-43, where the foamed thermoplastic resin is a foamed polyolefin.

45. The method of any of claims 29-44, where the foamed carrier layer is a foamed acrylic resin.

46. The method of any of claims 29-45, where the foamed carrier layer is a foamed elastomer.

47. The method of any of claims 29-46, where the foamed carrier layer is a foamed ethylene vinyl acetate resin.

48. The method of any of claims 29-47, where the foamed carrier layer is a foamed polyurethane.

49. The method of any of claims 29-48, where the foamed carrier layer has a thickness of about 500 to about 10,000 pm.

50. The method of any of claims 29-49, where the foamed carrier layer is a closed cell foam.

51. The method of any of claims 29-50, where the foamed carrier layer is an open-cell foam.

52. The method of any of claims 29-51, where the foamed carrier layer has a density of from about 12.8 kg / m3to about 160 kg / m3(about 0.8 to about 10 lbs per ft3).

53. The method of any of claims 29-52, where the foamed carrier layer, prior to sandwiching between the pressure-sensitive adhesive layers, has a tensile strength, in the machine direction, of about 207 to about 689 kPa (about 30 to about 100 psi).

54. The method of any of claims 29-53, where the foamed carrier layer has a firmness of about 0.689 to about 103.35 kPa (about 0.1 to about 15 psi).

55. The method of any of claims 29-54, where the foamed carrier layer has a Shore A hardness of about 0 to about 10.

56. The method of any of claims 29-55, where the foamed carrier layer has a deflection strength at 25 % deflection of from about 6.89 to about 206.84 kPa (about 1 to about 30 psi).

57. The method of any of claims 29-56, where the first and second pressure-adhesive layers have a thickness of from about 25 to about 500 pm.

58. The method of any of claims 29-57, where the double-sided adhesive sheet is characterized by a Z-direction tensile strength of from about 20.68 to about 310.26 kPa (about 3 to about 45 psi).

59. The method of any of claims 29-58, where the double-sided adhesive sheet is characterized by a dead load shear at 22 °C of at least 60 minutes.

60. The method of any of claims 29-59, where the double-sided adhesive sheet is characterized as being non-permeable, semi-impermeable, or semi-permeable.

61. The method of any of claims 29-60, where the carrier layer is a fabric carrier layer.

62. The method of any of claims 29-61, where the fabric carrier layer is fleece.

63. The method of any of claims 29-62, where said step of providing a first layer of construction boards secured to a roof deck includes adhering the first layer of construction board to the roof deck through a double-sided adhesive sheet that includes firstand second layers of pressure-sensitive adhesive sandwiching a foamed carrier layer.

64. A method of installing construction boards on a roof, the method comprising:(i) providing a double-sided adhesive sheet, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a foamed carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet;(ii) positioning the double-sided adhesive sheet on a desired area of a roof deck;(iii) contacting and adhering the bottom surface of the adhesive sheet to the roof deck;(iv) providing a plurality of fragile insulating materials; and(v) contacting and adhering the plurality of fragile insulating materials to the upper surface of the double-sided adhesive sheet to thereby form a layer of fragile insulating materials adhered to the roof deck.

65. The use of a double-sided adhesive sheet to secure construction boards into a roofing system by securing a plurality of construction boards to a layer of construction boards, where the adhesive sheet includes first and second layers of pressuresensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet, where the plurality of construction boards includes at least one fragile insulating material.

66. The use of a double-sided adhesive sheet to secure construction boards into a roofing system by securing a plurality of fragile insulating materials to a roof deck, where the adhesive sheet includes first and second layers of pressure-sensitive adhesive sandwiching a carrier layer, the first layer of pressure-sensitive adhesive forming a bottom surface of the adhesive sheet and the second layer of pressure-sensitive adhesive forming an upper surface of the adhesive sheet.

67. A double-sided adhesive sheet as provided in any of the preceding claims.

68. A composite construction board comprising:(i) a construction board subcomponent including at least one fragile insulating material; and(ii) a double-sided adhesive subcomponent.

69. The composite construction board of claim 68, further comprising a release member.

70. The composite construction board of any of claims 68-69, where said double-sided adhesive subcomponent includes a middle layer which is either a non-rigid foam layer or a fabric layer, and first and second pressure-sensitive adhesive layers disposed on opposite sides of said middle layer.

71. The composite construction board of any of claims 68-70, where said firstand second pressure-sensitive adhesive layers include a cured polyacrylate.

72. The composite construction board of any of claims 68-71, where said firstand second pressure-sensitive adhesive layers have a thickness of from about 51 to about 381 pm.

73. The composite construction board of any of claims 68-72, where the first and second pressure-sensitive adhesive layers have a Tg of less than 0°C.

74. The composite construction board of any of claims 68-73, where said construction board subcomponent includes polyisocyanurate foam.

75. The composite construction board of any of claims 68-74, where said polyisocyanurate foam has a density of less than 2.5 pounds per cubic foot and an ISO index of at least 120.

76. The composite construction board of any of claims 68-75, where said polyisocyanurate foam layer includes a density greater than 2.5 pounds per cubic foot and an ISO index ofat least 270.

77. The composite construction board of any of claims 68-76, where the construction board subcomponent includes first and second polyisocyanurate foam layers.

78. The composite construction board of any of claims 68-77, where the first polyisocyanurate foam layer has a density of less than 3.0 lbs / ft3.

79. The composite construction board of any of claims 68-78, where the second polyisocyanurate foam layer has a density of greater than 3.0 lbs / ft3.

80. The composite construction board of any of claims 68-79, where the non-rigid foam layer is a foamed thermoplastic resin.

81. The composite construction board of any of claims 68-80, where the foamed thermoplastic resin is a foamed polyolefin.

82. The composite construction board of any of claims 68-81, where the non-rigid foam layer is a foamed acrylic resin.

83. The composite construction board of any of claims 68-82, where the non-rigid foam layer is a foamed elastomer.

84. The composite construction board of any of claims 68-83, where non-rigid foam layer is a foamed ethylene vinyl acetate resin.

85. The composite construction board of any of claims 68-84, where the non-rigid foam layer is a foamed polyurethane.

86. The composite construction board of any of claims 68-85, where the non-rigid foam layer has a thickness of about 500 to about 10,000 pm.

87. The composite construction board of any of claims 68-86, where the non-rigid foam layer is a closed cell foam.

88. The composite construction board of any of claims 68-87, where the non-rigid foam layer has a density of from about 0.8 to about 10 lbs per ft3.

89. The composite construction board of any of claims 68-88, where the non-rigid foam layer prior to sandwiching between the pressure-sensitive adhesive layers, has a tensile strength of about 30 to about 100 psi.

90. The composite construction board of any of claims 68-89, where the fabric layer is fleece.

91. The composite construction board of any of claims 68-90, where the middle layer includes intumescent material.

92. The composite construction board of any of claims 68-91, where foam of said construction board subcomponent at least partially encases said at least one insulating material.

93. A roof system including the composite construction board of any of claims 68-92.

94. A method of installing the composite construction boards of any of claims 68-92 on a roof, the method comprising positioning the composite construction board on a roof surface, removing the release liner; and securing the composite construction board to the roof through one of said pressure-sensitive adhesive layers.

Images