CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 61/300,600, filed on February 2, 2010. The disclosure of the above application is incorporated herein by reference.

FIELD

[0002] The present invention relates to two-part non-foamable adhesives for use with roofing substrates, insulation boards, and roofing membranes, and more particularly to two-part non-foamable adhesives that have high renewable carbon content.

BACKGROUND

[0003] In many roofing applications, for example in large, flat commercial roof decks, the roofing substrate is a concrete, light weight concrete, wood, gypsum, wood fiber or steel roof deck . The roofing membrane is used to seal and protect the roof deck from environmental weather conditions and is placed over insulation boards, which provide insulative qualities. The insulation boards are typically secured to the roofing substrate or roof deck via an adhesive composition. A conventional adhesive composition used to adhere the insulation boards to the roof deck includes polyurethane. The polyurethane adhesives are oftentimes applied directly onto the roof deck, and the insulation boards are then laid onto the roof deck surface. Conventional polyurethane adhesives oftentimes include two separate parts that are mixed by an applicator just prior to being applied onto the surface of the roof deck. The two parts include an isocyanate blend and a polyol blend. Upon mixing, the isocyanate blend reacts or crosslinks with the polyol blend to form the polyurethane adhesive.

[0004] The roofing membrane may be made of various materials, such as polymeric materials including EPDM (ethylene propylene diene M-rubber), Mod Bit (Modified Bitumen), TPO (thermoplastic polyolefin), or polyvinyl chloride (PVC). The roofing membrane may be a composite material that includes EPDM or TPO, an example of which is Carlisle's FleeceBACK® EPDM and FleeceBACK® TPO. The roofing membrane is adhered overtop insulation boards or panels using an adhesive composition such as mopping asphalt (typically Type III or Type IV) or other conventional adhesive compositions that includes polyurethanes. There is room in the art for adhesive compositions in roofing applications that exhibit favorable properties, such as sufficient adhesive strength, shelf life, cure time, and tack that also have high renewable carbon content and/or renewable or environmentally favorable polyol and isocyanate content.

SUMMARY

[0005] The present invention provides adhesive compositions for use in adhering insulation panels to roofing substrates and roofing membranes to the insulation panels. The adhesive compositions include two components that are mixed prior to application on the roofing substrate. The first component can include a renewable polyol and catalyst. The renewable polyol is selected from any non-petroleum based polyol that is derived from a renewable source. The second component includes isocyanate, and may also include a polyol and a catalyst. The isocyanate and the polyol may each be any non-petroleum based isocyanate or polyol that is derived from a renewable source.

[0006] In one embodiment, the two-part adhesive for roofing applications includes a first composition comprising a renewable polyol present in an amount from about 15% to about 98% by weight of the first composition and a catalyst, and a second composition comprising a renewable isocyanate or renewable diisocyanate. The first composition is combined with the second composition to form a polyurethane adhesive.

[0007] In another embodiment the renewable polyol is a non-petroleum based polyol.

[0008] In yet another embodiment the renewable polyol is a soybean oil based polyol.

[0009] In yet another embodiment the renewable polyol is one of a Castor oil based polyol and polyols based upon the hydroxylation of a fatty acid based triglyceride.

[0010] In yet another embodiment the at least one catalyst is an organometallic catalyst selected to achieve a desired reaction profile between the first composition and the second composition when combined.

[0011] In yet another embodiment the renewable isocyanate or the renewable diisocyanate is present in an amount of about 100% by weight of the second composition. [0012] In yet another embodiment the renewable polyol is present in an amount from about 60% to about 98% by weight of the first composition.

[0013] In yet another embodiment the first composition further includes a non-renewable polyol present in an amount from about 0.1 % to about 15% by weight of the first composition.

[0014] In yet another embodiment the first composition further includes at least one tertiary amine.

[0015] In yet another embodiment the first composition further includes a filler or a viscosity modifier selected from the group consisting of fumed silica, clays, talc, CaCO3, fly ash, and microspheres.

[0016] In yet another embodiment the renewable isocyanate or the renewable diisocyanate is a non-petroleum based isocyanate or the diisocyanate.

[0017] In yet another embodiment the second composition further includes a polyol having at least one isocyanate-reactive functionality group.

[0018] In yet another embodiment the polyol of the second composition is a renewable polyol.

[0019] In yet another embodiment the renewable isocyanate or the renewable diisocyanate is present in an amount from about 40% to about 85% by weight of the second composition and the polyol of the second composition is present in an amount from about 60% to about 15% by weight of the second composition.

[0020] In yet another embodiment the second composition further includes a metal based polyurethane catalyst employed to expedite the reaction of the renewable polyol of the first composition with the renewable isocyanate or the renewable diisocyanate.

[0021] In yet another embodiment the second composition further includes a plasticizer selected from the group consisting of diisononyl phthalate, dioctyl phthalate, and di 2-ethylhexyl phthalate.

[0022] In yet another embodiment the second composition further includes a thixotropic agents.

[0023] In yet another embodiment the second composition further includes fumed silica.

[0024] In yet another embodiment the second composition further includes an anti-foaming agent or a de-foaming agent.

[0025] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

DETAILED DESCRIPTION

[0026] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.

[0027] A roofing membrane is used to seal and protect the roof deck from environmental weather conditions and is placed over insulation boards. The roofing membrane may be made of various materials, such as polymeric materials including EPDM (ethylene propylene diene M-rubber), TPO (thermoplastic polyolefin), polyvinyl chloride (PVC), or Mod Bit (Modified Bitumens). The roofing membrane may be a composite material that includes EPDM or TPO, such as Carlisle's FleeceBACK®, and other suitable membranes. The roofing membrane is adhered overtop insulation boards or panels using an adhesive composition such as mopping asphalt (typically Type III or Type IV) or other suitable materials such as polyurethanes. There is room in the art for adhesive compositions in roofing applications that have high renewable carbon content and also exhibit favorable properties, such as sufficient adhesive strength, shelf life, cure time, and tack. A two-part adhesive composition according to the principles of the present invention is provided for securing a first component to a roofing substrate. The roofing component or membrane may be made of various materials, such as polymeric materials including EPDM (ethylene propylene diene M-rubber), TPO (thermoplastic polyolefin), polyvinyl chloride (PVC), Mod Bit (Modified Bitumens) or may be a composite material that includes EPDM or TPO, such as FleeceBACK®, and other suitable membranes. However, it should be appreciated that other components and other roofing substrates may employ the two-part adhesive composition without departing from the scope of the present invention.

[0028] The two-part adhesive composition is generally formed by combining two separate compositions or blends prior to application on the roofing substrate. The two parts include a "B side" or resin side and an "A side" or prepolymer side. Each of the sides is packaged separately and is mixed by an applicator prior to applying on the roofing substrate.

[0029] Due to the finite nature of petrochemical resources, increasing emphasis is now placed on the development of polymers from renewable resources abundantly available in nature. In particular, agricultural processing by products such as soy proteins from oil processing are of increasing significance since these are eco-friendly materials based on easily renewable natural resources. The two-part adhesive composition of the present invention is typically non-foaming, with a medium to high level of renewable carbon content, providing for increased environmentally friendly adhesives solutions. Varying degrees of renewable carbon content may be present in either the "A side" or prepolymer side, the "B side" or resin side, or both the "A side" (prepolymer side) and "B side" resin side, depending on the amount of renewable and recyclable content desired.

[0030] The two-part non-foamable adhesive composition of the present invention generally offers characteristics and advantages over a foamable adhesive. These include better moisture vapor transition (MVT) and lesser moisture uptake. Other advantages include generally higher physical properties such as tensile, elongation, tear, and compressive strengths. In general, non- foamable adhesives are used for membrane and other applications such as Weather-Tite® Lockin' Pocket Inter-Locking Pitch Pocket System.

[0031] The B side blend generally includes a renewable polyol, and at least one catalyst. The renewable polyol is selected from any non-petroleum based polyol that is derived from a renewable source, i.e., is a natural polyol. In a preferred example of the present invention, the renewable polyol is a soybean oil based polyol. Alternatively, the renewable polyol includes Castor oil based polyols and polyols based upon the hydroxylation of a fatty acid based triglyceride. Exemplary renewable polyols suitable with the composition of the present invention are commercially available from Urethane Soy Systems Company under the designation SOYOL including SOYOL R2-052-G and R2- 052-C. Other exemplary renewable polyols commercially available from the G. R. O'Shea Company under the designation POLYCIN. Further examples are available under the designation Agrol 2.0 and Agrol 3.0 from BioBased Technologies, LLC and BiOH 210 and 600 from Cargill and Renave di and trifunctional polyols from Dow. Chemical derivatives and combinations of renewable polyols may also be employed in the composition without departing from the scope of the present invention. The renewable polyol comprises from about 5% to about 100% by weight of the B side of the composition. In addition, the B side composition may include a nonrenewable polyol in addition to the renewable polyol. An exemplary nonrenewable polyol is ARCOL PPG 2000, commercially available from Bayer MaterialScience. The nonrenewable polyol comprises from about 0% to about 70% by weight of the composition.

[0032] The catalysts are selected from any organometallic catalysts in order to achieve the desired reaction profile between the resin and isocyanate components. In some instances, tertiary amines may be used, however, since they also promote the generation of carbon dioxide in the presence of water, precautions must be taken. In a preferred example of the present invention, an exemplary organometallic catalyst used in the B side blend is Vertellus Cotin 227, commercially available from G.R. O'Shea Company. Another exemplary organometallic catalyst is Reaxis C218, commercially available from Reaxis Inc. While Vertellus Cotin 227 is used in this example, other organometallic catalysts and their derivatives could be used in this application. In addition, chemical derivatives and combinations of catalysts may also be employed in the composition without departing from the scope of the present invention. The B component may also contain fillers and viscosity modifiers such as fumed silica, clays, talc, CaCO3, fly ash, microspheres, and the like.

[0033] The A side component includes isocyanate, and may include polyols, catalysts, plasticizers and thixotropic agents. The isocyanate includes compounds having at least one isocyanate functionality group of NCO. Exemplary isocyanates suitable with the composition of the present invention are commercially available from BASF under the designation LUPRANATE M10, from Dow under the designation of Isonate 143L, and from Evonik under the designation Vestanat IPDI.

[0034] Alternatively, the A side isocyanate can also be a renewable isocyanate, such as a biomass sourced difurfuryl diisocyanate, or other renewable diisocyanate. An exemplary renewable diisocyanate is DDI 1410® available from Cognis Corporation. A formula with over 99% renewable content can now be formed by combining the A side, containing the renewable isocyanate with the B side, composed almost entirely of a renewable polyol.

[0035] The A side may also include a polyol. The polyol which may be included in the A side may be any compound conventionally used in the production of polyurethanes having at least one isocyanate-reactive functionality. One exemplary polyol suitable with the composition of the present invention includes a polypropylene glycol commercially available from BASF under the designation PLURACOL P2010. Renewable polyols may also be used as an A side component. For example, the renewable polyol can be a 35-70 OH# polyol, such as SOYOL R2-052-G and R2-052-C, commercially available from Urethane Soy Systems. Other exemplary renewable polyols include Priplast 3190, Polycin 35, and BiOH Polyol 500, or other exemplary renewable polyols commercially available from the G. R. O'Shea Company under the designation POLYCIN. Further examples are available under the designation Agrol 2.0 and Agrol 3.0 from BioBased Technologies, LLC and BiOH 210 and 600 from Cargill and Renave di and trifunctional polyols from Dow. Chemical derivatives and combinations of polyols may also be employed in the composition without departing from the scope of the present invention. The polyol comprises from about 0% to about 60% by weight of the A side of the composition.

[0036] The catalyst employed includes any metal based polyurethane catalyst employed to expedite the reaction of the polyol with the isocyanate. An example of a catalyst includes Vertellus Cotin 227 commercially available from G.R. O'Shea Company. Chemical derivatives and combinations of metal based polyurethane catalysts and certain amine based catalysts may also be employed in the composition without departing from the scope of the present invention. The catalyst comprises from about 0% to about 0.5% by weight of the A side of the composition.

[0037] The thixotropic agent employed includes fumed silicas. An example of fumed silica is Cabosil TS720 from Cabot Industries. The plasticizer employed includes diisononyl phthalate, dioctyl phthalate, and di 2-ethylhexyl phthalate.

[0038] In order that the invention may be more readily understood, reference is made to the following examples which are intended to illustrate various embodiments of the two-part adhesive composition of the present invention, but not limit the scope thereof:

Example 1 :

^* At least one of the starred values is typically non-zero.

Example 2:

^* At least one of the starred values is typically non-zero.

Example 3: Example 4:

Example 8:

[0039] It should be appreciated that the exemplary trade name materials referenced are for illustration purposes only, and that suitable equivalent manufacturers may be employed. In addition, the A side and B side components may include other additives without departing from the scope of the present invention. As noted above, the A side and B side components are preferably mixed by an applicator prior to being extruded or otherwise applied to the roofing substrate. During mixing, and after mixing, the A side components and B side components react to form a polyurethane adhesive composition having suitable physical properties. In a preferred embodiment, each of the A side and B side contain a dye of two separate colors which, upon mixing, creates a new color indicative of proper blending of the A and B sides. For example, the A side may contain a red dye and the B side may contain a white dye and upon mixing the composition has a pink color. It should be appreciated that other colors may be employed without departing from the scope of the present invention.

[0040] The two-part adhesive composition exhibits a VOC content of 0 tested according to EPA Method 24 and SCAQMD Method 304-91 . [0041] In addition, the composition of the present invention was tested against equivalent products, the results of which are summarized below:

^* Modified

[0042] As shown above, the present composition exhibits comparable peel adhesion strength as well as superior tensile strength with a much higher green content. The tensile strength test method was based on ASTM D-412 wherein foam was shot on polyethylene sheet in several isolated beads. Before the foam was tack free, but after it had reached its maximum foam height, in other words, had finished foaming, the bead was compressed with a second polyethylene sheet. The foam was kept compressed for several hours to prevent the bead from curling on the edges. The samples were prepared following ASTM D-412. The testing procedure of ASTM D-142 was followed, except the speed of 10 inches per minute was used in place of the standard 20 inches per minute. The samples were tested after conditioning at room temperature for one week. [0043] The composition may be applied to substrates in environmental temperatures ranging from approximately 40 degrees Fahrenheit to approximately 100 degrees Fahrenheit. The two-part adhesive composition exhibits a set time of 5-30 minutes.

[0044] The description of the invention is merely exemplary in nature and variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.