Process for preparing construction articles with cured pressure-sensitive adhesives

Abstract

An apparatus and related methods for constructing articles with cured pressure-sensitive adhesives comprising (i) a coater that applies a curable adhesive to a membrane; (ii) a cross-linking apparatus adapted to receive said membrane with said curable adhesive, said cross-linking apparatus comprising a light source positioned a first predetermined height above an aperture plate having an aperture therethrough, wherein said aperture plate is positioned a second predetermined height, said first predetermined height and said second predetermined height selected to define an exposure area of light emitted from said light source on to said curable adhesive to form a composite product; and (iii) a roll adapted to receive said composite product, said roll adapted to control a speed at which said membrane with said curable adhesive is exposed to light from said light source.

What is claimed is: 
     
         1 . An apparatus for constructing articles with cured pressure-sensitive adhesives comprising:
 (i) a coater that applies a curable adhesive to a membrane;   (ii) a cross-linking apparatus adapted to receive said membrane with said curable adhesive, said cross-linking apparatus comprising a light source positioned a first predetermined height above an aperture plate having an aperture therethrough, wherein said aperture plate is positioned a second predetermined height above said membrane, wherein said aperture opening defines an exposure area of light emitted from said light source on to said curable adhesive to form a composite product; and   (iii) a roll adapted to receive said composite product, said roll adapted to control a speed at which said membrane with said curable adhesive is exposed to light emitted from said light source.   
     
     
         2 . The apparatus according to  claim 1 , wherein said light source comprises an elliptical reflector positioned to direct light emitted from said light source through said aperture on to said curable adhesive. 
     
     
         3 . The apparatus according to  claim 2 , wherein said light source emits an amount of UV radiation, wherein at least 60% of the UV radiation rays have an intensity of at least 200 milliWatts/cm 2 . 
     
     
         4 . The apparatus according to  claim 3 , wherein said amount of UV radiation imparted to an upper surface of said curable adhesive is from about 75 to about 125 millijoule/cm 2 . 
     
     
         5 . The apparatus according to  claim 2 , wherein said first predetermined height and said second predetermined height are selected to further define said exposure area of light emitted from said light source on to said curable adhesive. 
     
     
         6 . The apparatus according to  claim 5 , wherein said exposure area is defined as a product of a length and a width of where light emitted from said light contacts said curable adhesive. 
     
     
         7 . The apparatus according to  claim 6 , wherein said exposure area includes a focal point area, wherein a ratio of said focal point area to said exposure area is at most 1:5. 
     
     
         8 . The apparatus according to  claim 1 , wherein said curable adhesive is subjected to light emitted from said light for about 0.12 to about 50 seconds. 
     
     
         9 . The apparatus according to  claim 1 , further comprising:
 a mandrel carrying a release member which is adapted to apply said release member on to said composite product.   
     
     
         10 . A method for constructing articles with cured pressure-sensitive adhesives, the method comprising:
 (i) applying a curable adhesive on to one side of a membrane;   (ii) feeding said membrane through a cross-linking apparatus having an exposure area; and   (iii) obtaining said exposure area by selectively positioning at least one of a light source and an aperture plate having an aperture therethrough with respect to each other and said curable adhesive so that light emitted from said light source passes through said aperture to optimally cure said curable adhesive.   
     
     
         11 . The method according to  claim 10 , further comprising:
 applying a release member on to said curable adhesive after passing through said exposure area.   
     
     
         12 . The method according to  claim 11 , further comprising:
 feeding said membrane through said cross-linking apparatus so that said curable adhesive is subjected to light emitted from said light for about 0.12 to about 50 seconds.   
     
     
         13 . The method according to  claim 11 , further comprising:
 heating said curable adhesive prior to applying to said membrane.   
     
     
         14 . The method according to  claim 11 , wherein said light is UV light having a wavelength of either about 220 nm to about 250 nm, or about 250 nm to about 260 nm. 
     
     
         15 . The method according to  claim 14 , further comprising:
 controlling an amount of radiation and an intensity of said UV light applied to said curable adhesive.