FIELD OF INVENTION
The present disclosure relates to a roof kit and systems, and methods using a roof kit and systems.
BACKGROUND OF THE INVENTION
The disclosed subject matter provides a roof kit and systems, and methods using a roof kit and systems.
BRIEF SUMMARY
In embodiments, the disclosure may provide a system for adhering and sealing flanges to a roof. The system may comprise a mastic asphalt concrete layer with a top surface and a bottom surface. The layer may not be thicker than 0.375 inches in embodiments. A bottom removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the bottom removable sealant layer may be adhered to the bottom surface of the mastic asphalt concrete substrate. At least one of the top and bottom surfaces of the bottom removable sealant layer may be larger in surface area than the bottom surface of the mastic asphalt concrete layer. A top removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the top removable sealant layer may be adhered to the top surface of the mastic asphalt concrete substrate. At least one of the top and bottom surfaces of the top removable sealant layer may be larger in surface area than the top surface of the mastic asphalt concrete layer.
In embodiments, the disclosure may provide a system. The system may comprise a flange comprising a top surface and a bottom surface. A bottom mastic asphalt concrete layer may comprise a top surface and a bottom surface. At least one of the top and bottom surfaces of the bottom mastic asphalt concrete layer may be adhered to the bottom surface of the flange. A top mastic asphalt concrete layer may comprise a top surface and a bottom surface. At least one of the top and bottom surfaces of the top mastic asphalt concrete layer may be adhered to the top surface of the flange. A bottom removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the bottom removable sealant layer may be adhered to the bottom surface of the mastic asphalt concrete substrate. At least one of the top and bottom surfaces of the bottom removable sealant layer may be larger in surface area than the bottom surface of the mastic asphalt concrete layer. The top removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the top removable sealant layer may be adhered to the top surface of the mastic asphalt concrete substrate. At least one of the top and bottom surfaces of the top removable sealant layer may be larger in surface area than the top surface of the mastic asphalt concrete layer.
In embodiments, the disclosure may provide an apparatus. The apparatus may comprise a flange comprising a flange top surface and a flange bottom surface. The flange bottom surface may be disposed in opposition to the flange top surface in spaced relationship therewith. An aperture may be defined through the flange from the flange top surface to the flange bottom surface. A bottom mastic asphalt concrete layer may comprise a top surface and a bottom surface. At least one of the top and bottom surfaces of the bottom mastic asphalt concrete layer may be adhered to the bottom surface of the flange. A top mastic asphalt concrete layer may comprise a top surface and a bottom surface. At least one of the top and bottom surfaces of the top mastic asphalt concrete layer may be adhered to the top surface of the flange. A bottom removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the bottom removable sealant layer may be adhered to the bottom surface of the mastic asphalt concrete substrate. The at least one of the top and bottom surfaces of the bottom removable sealant layer may be larger in surface area than the bottom surface of the mastic asphalt concrete layer. A top removable sealant layer may comprise a top and bottom surface. At least one of the top and bottom surfaces of the top removable sealant layer may be adhered to the top surface of the mastic asphalt concrete substrate. The at least one of the top and bottom surfaces of the top removable sealant layer may be larger in surface area than the top surface of the mastic asphalt concrete layer.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed characteristic of the disclosed subject matter will be set forth in any claims that are filed later. The disclosed subject matter itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a perspective view of an embodiment of a system including a flanged roof apparatus.
FIG. 2 is a perspective view of a flanged roof apparatus in an embodiment.
FIG. 3 is a bottom view of an embodiment of a flanged roof apparatus.
FIG. 4 is a top view of an embodiment of a flanged roof apparatus.
FIG. 5 is a side view of an embodiment of a flanged roof apparatus.
FIG. 6 is an elevated perspective of a flanged roof apparatus shown in FIG. 5.
FIG. 7 is an enlarged partial side view of the area generally indicated at reference 7 in FIG. 5 in accordance with one embodiment.
FIG. 8 is a bottom view of an embodiment of a flanged roof apparatus shown generally in FIG. 3 and having a removable sealant layer thereof removed to show mastic coverage of a bottom surface.
FIG. 9 is a top view of an embodiment of a flanged roof apparatus shown generally in FIG. 4 and having a removable sealant layer thereof removed to show mastic coverage of a top surface.
FIG. 10 is a side cutaway view of the flanged roof apparatus in accordance with an embodiment.
FIG. 11 is a top view of an embodiment of a kit comprising a mastic asphalt concrete layer, a top removable sealant layer, and bottom removable sealant layer.
FIG. 12 is a top view of an embodiment of a perforated kit comprising a mastic asphalt concrete layer, a top removable sealant layer, and a bottom removable sealant layer.
FIG. 13 is a layered view of an embodiment of a kit comprising two mastic asphalt concrete layers, four removable sealant layers, and a flange.
FIG. 14 is a layered view of an embodiment of a kit comprising two mastic asphalt concrete layers and a flange.
FIG. 15 is a flow chart of a method according to an embodiment, and the method using flanged roof apparatus as herein disclosed.
DETAILED DESCRIPTION OF EMBODIMENTS
Reference now should be made to the drawings, in which the same reference numbers are used throughout the different figures to designate the same components. It will be understood that, although the terms first, second, third, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Thus, a first element discussed below could be termed a second element without departing from the teachings of the present disclosure.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” or “includes” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
FIG. 1 is a perspective view of an embodiment of a system 10 including flanged roof apparatus 100. As shown in the particular embodiment shown in FIG. 1, system 10 may include a roof system 20 as illustrated. System 10 may include an underlayer 30 of roofing felt or other suitable underlayer material applied on roof structural surface 35 of a building to prevent moisture from penetrating to or contacting a roof structural surface 35 or other roof structure (not shown) beneath the underlayer 30. One of skill will understand that, for example, the roof structural surface 35 may be inclined to shed precipitation that is caused to flow from top to bottom by the incline of the roof structural surface 35. System 10 may include a plurality of shingles 40 mounted on and supported by roof structural surface 35 generally atop underlayer 30. It will be understood that the plurality of shingles 40 may be installed in a layered arrangement to prevent moisture from contacting underlayer 30 and to flow atop overlapped layered upper surfaces of shingles 40. System 10 may include flanged roof apparatus 100 as further described herein.
Referring to FIG. 1, in an embodiment a system 10 may include flanged roof apparatus 100 as described herein. It will be understood that system 10 in an embodiment may include a roof system 20 having flanged roof apparatus 100.
In an embodiment, apparatus 100 may include a flange 110 and stack 120 extending in angular relationship to flange 110. Flange 110 may be formed of a continuous member such as, for example, a continuous sheet member 130. One of ordinary skill will understand that continuous sheet member 130 may be formed to define and include a substantially planar peripheral portion 140 and a shaped, non-planar neck region 150 adjoining the peripheral portion 140 and protruding therefrom. It will be understood that stack 120 may be tubular and may include a continuous tubular wall 160 defining an aperture 170 through flange 110. Stack 120 may include an upper end 180 defining a respective aperture upper end portion 190. Stack 120 may include a stack lower end 200 disposed in spaced opposing relationship to a stack upper end 180 and defining a respective aperture lower end portion 210. It will be understood that aperture upper end portion 190 thus is located in proximity to a flange top surface 220 (see FIG. 7) of flange 110 and opposite from a flange bottom surface 230 (see FIG. 7) of flange 110. It will be understood that aperture lower end portion 200 thus is located in proximity to the flange bottom surface 230 of flange 110 and opposite from the flange top surface 220 of flange 110. In an embodiment shown in FIG. 2, apparatus 100 may include aperture 170 defined through the flange 110 and extending from the flange top surface 220 to the flange bottom surface 230 to define a passage. It will be understood that such a passage may be aligned with a hole or perforation in the roof structure for penetration of a vent line or other tubular member such as, for example, a plumbing vent line (not shown). In an embodiment, apparatus 100 may include stack 120 having stack upper end 180, the stack upper end 180 defining a respective aperture upper end portion 190 of the aperture 170, In an embodiment, the stack 120 may have a stack lower end 200 joined in closed relationship with the flange 110 at the non-planar neck region 150 thereof. In an embodiment, at least one of the stack lower end 200 and non-planar neck region 150 may define the respective aperture lower end portion 200 of the aperture 170. In an embodiment as shown in FIG. 2, apparatus 100 may include the stack 120 protruding upward from the flange 110 at flange top surface 220 and in opposed relationship to the flange bottom surface 230. In an embodiment as shown in FIG. 2, the flange 110 may have a flange upper end portion 260 and a flange lower end portion 270 joined in continuous relationship about the stack 120 at the stack lower end 200. It is noted that the stack lower end 200 may extend to at least the top surface of the flange 110. In an embodiment as shown in FIG. 2, the flange 110 may be inclined relative to the stack 120, such that an acute angle (α) is defined between the stack 120 and the flange upper end portion 260, and such that an obtuse angle (β) defined between the stack 120 and the flange lower end portion 270. It will be understood that in an embodiment as illustrated in FIG. 2, apparatus 100 may be configured for use in a roof system 10 that is inclined, such that when installed the acute angle (α) and flange upper end portion 260 are located above obtuse angle (β) and flange lower end portion 270.
FIG. 3 is a bottom view of flanged roof apparatus 100 in an embodiment and taken generally along 3-3 in FIG. 2. In the embodiment shown in FIG. 3, apparatus 100 may include a bottom mastic asphalt concrete layer 300 comprising a top surface 310 and a bottom surface 320 (structurally similar to FIG. 7), wherein at least one of the top and bottom surfaces 310,320 of the bottom mastic asphalt concrete layer 300 may be adhered to the bottom surface of the flange 110. Shown in FIG. 7 is an enlarged partial side view of the area generally indicated at reference 7 in FIG. 5 that may show structural setups similar to other embodiments of the disclosure. As shown in FIG. 3, in an embodiment apparatus 100 may include a bottom mastic asphalt concrete layer 300. FIG. 8 is a bottom view of the flanged roof apparatus 100 shown generally in FIG. 3 and having a removable sealant layer 340 thereof removed to show mastic coverage of a bottom surface 230. Referring to FIGS. 5 and 7, a bottom removable sealant layer 330 may include a top surface 360 and a bottom surface 370, at least one of the top and bottom surfaces 360,370 of the bottom removable sealant layer 330 adhered to the bottom surface 320 of the bottom mastic asphalt concrete layer 300. FIG. 6 is an elevated perspective of a flanged roof apparatus 100 shown in FIG. 5. The apparatus 100 is shown from a straight-on top view angle in order to better depict the angle of the non-planar neck region 150. In an embodiment such as in FIGS. 5, 7 and 8, at least one of the top and bottom surfaces 360,370 of the bottom removable sealant layer 330 may be larger in surface area (not shown) than the bottom surface 320 of the bottom mastic asphalt concrete layer 300. The larger surface area may provide a tab area where an individual may engage in order to peel off the bottom sealant layer 330 from the bottom mastic asphalt concrete layer 300. In an embodiment as shown in FIGS. 5, 7 and 8, apparatus 100 may include the top surface 310 and bottom surface 320 of the bottom removable sealant layer 330 comprising a wax layer. In an embodiment as shown in FIGS. 5, 7 and 8, apparatus 100 may include the bottom removable sealant layer 330 comprising an indicator. In embodiments, the indicator may show direction on how apparatus 100 may be installed. In embodiments, the indicator may be ink or an indentation. In an embodiment as shown in FIG. 8, apparatus 100 may include the bottom removable sealant layer 330 comprising at least one inscription.
FIG. 4 is a top view of flanged roof apparatus 100 in an embodiment. In the embodiment shown in FIG. 4, apparatus 100 may include a top mastic asphalt concrete layer 400 comprising a top surface 410 and a bottom surface 420 (structurally similar to FIG. 7), at least one of the top and bottom surfaces 410,420 of the top mastic asphalt concrete layer 400 may be adhered to the top surface 220 of the flange 110. Shown in FIG. 7 is an enlarged partial side view of the area generally indicated at reference 7 in FIG. 5, and FIG. 9 is a top view of the flanged roof apparatus 100 shown generally in FIG. 4 and having a top removable sealant layer 430 thereof removed to show mastic coverage of a top surface 220. As shown in FIG. 7 in an embodiment found in FIG. 9, the top removable sealant layer 430 may include a top and bottom surface 450,460 wherein at least one of the top and bottom surfaces 450,460 of the top removable sealant layer 430 may be adhered to the top surface 410 of the top mastic asphalt concrete layer 400, the at least one of the top and bottom surfaces 450,460 of the top removable sealant layer 430 may be larger in surface area than the top surface 410 of the top mastic asphalt concrete layer 400. The larger surface area may provide a tab area where an individual may engage in order to peel off the bottom sealant layer 330 from the bottom mastic asphalt concrete layer 300. Referring to FIGS. 7 and 9, in an embodiment, apparatus 100 may include the top surface 450 and bottom surface 460 of the top removable sealant layer 440 comprising a wax layer. In an embodiment as shown in FIGS. 4, 7 and 9, apparatus 100 may include the top removable sealant layer 430 comprising an indicator. In embodiments, the indicator may show direction on how apparatus 100 may be installed. In an embodiment as shown in FIGS. 7 and 9, apparatus 100 may include the top removable sealant layer 430 comprising at least one inscription.
Embodiments such as those found in FIGS. 3 and 4 may be installed on a flat roof. The non-planar neck region 150 shown may not be constructed at an angle.
In embodiments, removable sealant layer 340 and/or removable sealant layer 430 may extend a minimum of one-half an inch from the edges of the bottom mastic asphalt concrete layer 300 and/or top mastic asphalt concrete layer 400.
FIG. 10 is a side cutaway view of the flanged roof apparatus in accordance with an embodiment. This embodiment may show a side view of an uninstalled apparatus 100. This depiction more clearly shows the relationship between the aperture lower end portion 210, and other components of the apparatus. The removable sealant layer 340 and bottom mastic asphalt concrete layer 300 may cover the lower end of the aperture lower end portion 210. Perforated lines 490 may exist around the perimeter of the aperture lower end portion 210 on the removable sealant layer 340 and bottom mastic asphalt concrete layer 300 in order to provide an aperture for the stack lower end 200. An aperture may also be cut manually into the removable sealant layer 340 and bottom mastic asphalt concrete layer 300.
FIG. 11 is a top view of a mastic asphalt concrete layer 475, a top removable sealant layer 455, and bottom removable sealant layer 465. This embodiment may be referred to as a kit 470 for adhering flanges to a roof. The kit 470 may comprise a mastic asphalt concrete layer 475 comprising a top surface and a bottom surface 485,495 (structurally similar to embodiment in FIG. 7). The mastic asphalt concrete layer 475 may not thicker than 0.375 inches in embodiments. The kit 470 may further comprise a bottom removable sealant layer 465 comprising a top and bottom surface 435,445. At least one of the top and bottom surfaces 435,445 of the bottom removable sealant layer 465 may be adhered to the bottom surface 495 of the mastic asphalt concrete substrate 475. At least one of the top and bottom surfaces 435,445 of the bottom removable sealant layer 465 may be larger in surface area than the bottom surface 495 of the mastic asphalt concrete layer 475. The bottom removable sealant layer 465 may be removable to expose a portion of the bottom surface 495 of the mastic asphalt concrete layer 475.
The kit 470 may further comprise a top removable sealant layer 455 comprising a top and bottom surface 450,460. At least one of the top and bottom surfaces 450,460 of the top removable sealant layer 455 may be adhered to the top surface 485 of the mastic asphalt concrete layer 475. The at least one of the top and bottom surfaces 435,445 of the top removable sealant layer 455 may be larger in surface area than the top surface 485 of the mastic asphalt concrete layer 475. The bottom removable sealant layer 465 may be removable to expose a portion of the bottom surface 495 of the mastic asphalt concrete layer 475.
In embodiments, one or both of the top and bottom removable sealant layers 455,465 may be one half an inch greater 355 in surface area (on all sides of the kit) than the mastic asphalt concrete layer 475.
FIG. 12 is a top view of a perforated kit 480 comprising a mastic asphalt concrete layer 475, a top removable sealant layer 455, and a bottom removable sealant layer 465. At least one of the mastic asphalt concrete layer 475, top removable sealant layer 455, and bottom removable sealant layer 465 may comprise a perforated line 490 penetrating the entire layer(s) where the perforated line 490 exists. The perforated line 490 may allow a perforated kit 480 to be easier to work with since shaping the mastic asphalt concrete layer 475 to specific dimensions may be time consuming without a perforated line 490. In embodiments, the perforated line 490 may follow the shape of a general roofing setup. For example, perforated line 490 may be splayed on the mastic asphalt concrete layer 475 and top and bottom removable sealant layers 455,465 in a shape to allow the mastic asphalt concrete layer 475 to be placed around an element, such as the non-planar neck region 150 found in FIG. 2.
In embodiments, the perforated kit 480 of may comprise at least one perforated line 490 may extend a length of the mastic asphalt concrete layer 475, bottom removable sealant layer 465, and top removable sealant layer 455. The perforated line 490 may comprise at least two perforations. The at least two perforations may extend the distance of the width of the bottom mastic asphalt concrete layer 475, bottom removable sealant layer 465, and top removable sealant layer 455.
In embodiments, the perforated line 490 may exist as a dotted line 491 on one or more sealant layers 455,465.
In embodiments, at least one perforated line 490 may exist on any of the system embodiments found in this disclosure. In embodiments, at least one dotted line 491 may exist on any of the system embodiments found in this disclosure. In embodiments, at least one perforated line 490 and at least one dotted line 491 may exist on any of the system embodiments found in this disclosure.
In embodiments, the mastic asphalt concrete layer 475 may be reinforced with fibrous material.
In embodiments, the system may be an article of manufacture.
In embodiments of a kit 470, perforated kit 480, system, system 10, and/or roof system 20, at least one orifice (not shown) may penetrate through at least one of the one or more mastic asphalt concrete layers 300,400,475, flange 110, and one or more of the top and bottom removable sealant layers 330,440,455,465 (depending on the embodiment). The orifice may provide a space to allow a fastener, such as but not limited to a nail and a screw, to penetrate any of the aforementioned layers/objects.
In embodiments, at least two of any of the top and bottom surfaces of the bottom removable sealant layers and the top and bottom surfaces of the top removable sealant layers found in a kit 470, perforated kit 480, system, system 10, and/or roof system 20 may comprise a wax layer 492.
In embodiments, at least one of any of the bottom removable sealant layers and top removable sealant layers found in a kit 470, perforated kit 480, system, system 10, and/or roof system 20 may comprise at least one indicator. In embodiments, the indicator may show direction on how apparatus 100 may be installed. In embodiments, the indicator may be ink or an indentation.
In embodiments, at least one of any of the bottom removable sealant layers and top removable sealant layers found in a kit 470, perforated kit 480, system, system 10, and/or roof system 20 may comprise at least one inscription.
In embodiments, a kit 470 or perforated kit 480 may comprise a flange having a top and bottom surface. In embodiments, the top surface may be adjacent the bottom surface of the top removable sealant layer. In embodiments, the bottom surface may be adjacent the top surface of the bottom removable sealant layer.
It may be appreciated by one of skill in the art that the mastic asphalt concrete found in the disclosure may be self-adhering. The mastic may essentially be “sticky”.
In embodiments, the mastic asphalt concrete may comprise an adhesive material.
In embodiments, the top and/or bottom surfaces of any of the mastic asphalt concrete layers such as 300,400 found in this disclosure may comprise an adhesive layer that may cover a portion of the top and/or bottom surfaces of any of the mastic asphalt concrete layers such as 300,400 found in this disclosure.
FIG. 13 is a layered view of an embodiment of a kit comprising two mastic asphalt concrete layers, four removable sealant layers, and a flange. The dotted lines may show where the mastic asphalt concrete layer 475 may be placed on the bottom of the flange 110 once the top removable sealant layer 455 and bottom removable sealant layer 465 are removed. The dotted lines may further show where the mastic asphalt concrete layer 475 may be placed on the bottom of the flange 110 once the top removable sealant layer 455 and bottom removable sealant layer 465 are removed. It is shown that the aperture lower end portion 210 may penetrate through the mastic asphalt concrete layer 475.
FIG. 14 is a layered view of an embodiment of a kit comprising two mastic asphalt concrete layers and a flange. The dotted lines may show where the mastic asphalt concrete layer 475 may be placed on the bottom of the flange 110. The dotted lines may further show where the mastic asphalt concrete layer 475 may be placed on the bottom of the flange 110. It is shown that the aperture lower end portion 210 may penetrate through the mastic asphalt concrete layer 475.
In embodiments, the flange 110 may be a flange other than a general flange. In embodiments, flange 110 may be flanges such as, but not limited to a water heater stack vent jack, a static attic square vent, a turbin attic vent, a chimney stack vent, a conduit, a flasing, a skylight, a solar tube, and a whirlybird roof vent. It is noted that components of the disclosure may be appropriately altered to account for different flanges used in certain embodiments.
In embodiments, a kit 470, perforated kit 480, system, system 10, and/or roof system 20 may be packaged in a thin plastic polymer or polymeric case in order to contain melting of the mastic asphalt concrete found in embodiments.
In embodiments, at least two of the top and bottom surfaces 360,370 of the bottom removable sealant layer 330 and the top and bottom surfaces 450,460 of the top removable sealant layer 430 may comprise permanent adhesive properties.
In embodiments, any of the apparatuses may include a permanent sealant layer. In embodiments, any of the apparatuses may include an asphalt based sealant layer. In embodiments, any of the apparatuses may include a mastic asphalt based sealant layer. In embodiments, any of the apparatuses may include a mastic asphalt concrete sealant layer. In embodiments, any of the aforementioned layers may be referred to as an “adhesive layer.”
For the purposes of this disclosure, the term “roof perforation may refer to a section of the aperture lower end portion 210.
Illustrated in FIG. 15 is a flow chart of a method 500 according to an embodiment. Method 500 may use a flanged roof apparatus 100 as disclosed herein. In an embodiment, method 500 may include or provide a method for installing a roof system having or using a flanged roof apparatus 100 as disclosed herein. In an embodiment as illustrated in FIG. 15, method 500 may include aligning 510 a flanged roof apparatus 100 with a roof perforation. It will be understood that as used herein, roof perforation may include a vent line or tubular member extending through a roof structure or substructure (such as that included in roof system 20) to which shingles 40 are to be applied. In an embodiment as illustrated in FIG. 15, method 500 may include bottom exposing 520 a bottom mastic asphalt concrete layer 300, such as by removing a bottom removable sealant layer 340 therefrom. In an embodiment as illustrated in FIG. 15, method 500 may include bottom sealing 530 a bottom mastic asphalt concrete layer 300 to roof structure in abutting relationship therewith. In an embodiment as illustrated in FIG. 15, method 500 may include bottom confirming 540 the formation of a bottom sealing relationship between a bottom mastic asphalt concrete layer 300 and roof structure in abutting relationship therewith. In an embodiment as illustrated in FIG. 15, method 500 may include top exposing 550 a top mastic asphalt concrete layer 400, such as by removing a top removable sealant layer 430 therefrom. In an embodiment as illustrated in FIG. 15, method 500 may include top sealing 560 a top mastic asphalt concrete layer 400 to shingles 40 in abutting relationship therewith. In an embodiment as illustrated in FIG. 15, method 500 may include top confirming 570 the formation of a top sealing relationship between a top mastic asphalt concrete layer 400 and shingles 40 in abutting relationship therewith.
Patent Application
20160237688
