Patent Application
20210214946
The disclosure relates to roofing materials and roofing. In particular, the disclosure relates to rolled, self-adhering roofing materials having an architectural cap surface.
Conventional roofing systems may include a base roof layer. The base may be nailable roof ply or other material, or may include coverboard or insulation. Fasteners, and adhesive or primer may be disposed on the base. In some roofing systems a sheet overlaying the base roof layer. Many residential roofing systems and some commercial roofing systems include a surface layer or cap layer formed of shingles, whether cedar, asphalt, or other material. Shingles with asphalt surfaces and tar-adhesive backing are nailed into or otherwise adhered to a base roof layer such as play, typically over an intervening sheet or membrane.
Related art commercial roofing systems include rolled roofing or self-adhering roofing layers. Such products are well known and commercially available. Some commercially available products include a square, polyester reinforced cap sheet that are configured for installation on nailable or non-nailable substrates. The cap sheets may include a surface having granules configured and arranged for UV protection and ornamentation and appearance. These related art cap sheets do not overlay one another after installation to form a shingled effect suitable for residential application and consumer demand for a shingled architectural appearance for roofing.
Roof materials may be adhered to a roof base layer by mechanical fasteners, hot asphalt, cold adhesive, torch, or self-adhesive. Mechanical fasteners are suitable for base sheets underlying other protective layers. Hot asphalt is durable but requires trained personnel, specialized equipment, and carries risk of fire and noxious fumes. Cold adhesives minimize fire risks, but can take several months to cure. Torch application of a roofing layer carries risks and also requires specialized equipment and trained personnel. Self-adhering systems are known for their ease in installation, acceptable adhesion, and elimination of fire or fume risks.
A need has been recognized for a roof layer product having an architectural shingle appearance of any now known or later developed ornamental design, and having a profile and flexibility suitable for rolling for storage transport, and easy installation. The roofing apparatus and methods disclosed herein meet these needs.
A roof apparatus in accordance with embodiments is configured in accordance with now known or later developed methods to be suitable for residential or commercial roofing requirements. A roof apparatus is a layer of flexible roofing material selected from any suitable now known or later developed material with a back surface that faces a roof installed, and an outer surface that faces away from a roof installed. The outer surface includes a granule layer for UV protection and appeal. The back surface includes a portion having adhesive disposed thereon that, upon installation to a roof surface, adheres the roof apparatus to the roof with sufficient strength and seal. The adhesive portion may be in the form of a strip, multiple strips, or any other shape or pattern that is functional and cost-effective to produce. The adhesive may be selected for suitability from any now known or later developed material. A joint strip may be disposed on the outer surface. The joint strip may include adhesive suitable for adhering to and joining an adjacent, overlapping roof apparatus. The outer surface includes a granule layer having a granule color pattern, a granule pile height differential, or a combination thereof that provides the appearance of a architectural shingles or desirable dimension and layered appearance in residential applications and some commercial application.
A roof apparatus in accordance with an example embodiment includes a flexible planar material comprising a back surface on a first side, and an outer surface on a second side opposite the first side; and a granule layer disposed on the outer surface, the granule layer comprising a shingle design formed by a first plurality of granules and a second plurality of granules of the granule layer. One embodiment includes a joint strip disposed on the outer layer. The joint strip may include an adhesive. One embodiment includes the back surface having adhesive.
In an embodiment, the the flexible planar material and the granule layer together have flexibility suitable for rolling into a rolled configuration. In an embodiment, the first plurality of granules comprising a first color and the second plurality of granules comprising a second color, together forming a shingle pattern. In an embodiment, the first plurality of granules comprising a first pile height and the second plurality of granules comprising a second pile height, together forming a shingle pattern.
A method useful for forming a roof apparatus in accordance with an example embodiment includes providing a flexible planar material comprising a back surface on a first side, and an outer surface on a second side opposite the first side; and a granule layer disposed on the outer surface, the granule layer comprising a shingle design formed by a first plurality of granules and a second plurality of granules of the granule layer.
In an embodiment, methods include providing a granule layer wherein the first plurality of granules comprising a first color and the second plurality of granules comprising a second color, together forming a shingle pattern. The granules may be pre-colored before application. Alternatively, or additionally, the granule may colored after application by, for example, painting the granule layer disposed on the outer surface. In another embodiment, methods include providing a granule layer wherein the first plurality of granules comprising a first pile height and the second plurality of granules comprising a second pile height, together forming a shingle pattern.
Additional features and technical effects of the present disclosure will become readily apparent to those skilled in the art from the following detailed description wherein embodiments of the present disclosure are described simply by way of illustration of the best mode contemplated to carry out the present disclosure. In addition to the embodiments disclosed herein, other and different embodiments are within the spirit and scope of the disclosure, and its several details are capable of modifications in various respects.
The disclosure is shown by way of example in the figures of the accompanying drawings, in which like reference numerals refer to like elements.
In the following description, for the purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of exemplary embodiments. It should be apparent, however, that exemplary embodiments may be practiced without these specific details or with an equivalent arrangement. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring exemplary embodiments. In addition, unless otherwise indicated, all numbers expressing quantities, ratios, and numerical properties of ingredients, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”
Embodiments of roof apparatus, systems and methods are disclosed that provide a roof layer product having an architectural shingle appearance of any now known or later developed ornamental design, and having a profile and flexibility suitable for rolling for storage transport, and easy installation.
A roof apparatus in accordance with embodiments is configured in accordance with now known or later developed methods to be suitable for residential or commercial roofing requirements. A roof apparatus is a layer of flexible roofing material selected from any suitable now known or later developed material with a back surface that faces a roof installed, and an outer surface that faces away from a roof installed. The outer surface includes a granule layer for UV protection and appeal. The back surface includes a portion having adhesive disposed thereon that, upon installation to a roof surface, adheres the roof apparatus to the roof with sufficient strength and seal. The adhesive portion may be in the form of a strip, multiple strips, or any other shape or pattern that is functional and cost-effective to produce. The adhesive may be selected for suitability from any now known or later developed material.
In an embodiment, a joint strip may be disposed on the outer surface. The joint strip may include adhesive suitable for adhering to and joining an adjacent, overlapping roof apparatus. The outer surface includes granule layer having a granule color pattern, a granule pile height differential, or a combination thereof that provides the appearance of a architectural shingles or desirable dimension and layered appearance in residential applications and some commercial application. In other embodiments, no joint strip may be included and no means for joining adjacent, overlapping roof apparatus. In other embodiments, alternative devices and methods, now known or later developed, suitable for joining adjacent, overlapping roof apparatus.
A related art roofing apparatus is shown in
The shingle 100 may be arranged in a shingled configuration on a sloped roof. For example, the shingle 100 may be sized for use as a shingle. The back 101 of the shingle 100 may include an adhesive strip, and the roofing apparatus may be installed on a roof in an overlapping fashion with numerous other shingles. Each of the shingles is nailed into the roof, each being separately fitted and secured.
Other related roofing material is known to reduce materials, costs, and installation time. In particular, rolled roofing materials are known and include a rolled or spooled strip of adhesive-backed roofing material. Some rolled roofing products known in the related art include an outer granule layer for protection and aesthetics. Such products are not, however, useful for arrangement in a shingled configuration and are conventionally used in commercial roofing applications requiring covering for substantially flat, not angled, roofs.
The outer surface 221 includes a granule layer 233 as shown in
By way of the example, the roofing apparatus 200 includes a shingle pattern 237 formed by using different color granules. In particular, the first plurality of granules 233a is a first color, and the second plurality of granules 233b is a second color, darker than the first color. The combined effect of the color difference and granule configuration is shingle appearance, or the appearance of a shingle effect and thus an easily stored, transported, and installed roofing system without the drawbacks of a shingled roof system.
The outer surface 441 includes a granule layer 441 as shown in
By way of the example, the roofing apparatus 400 includes a shingle pattern 443 formed by using different color granules. In particular, the first plurality of granules 441a is a first color, and the second plurality of granules 441b is a second color, darker than the first color. The combined effect of the color difference and granule configuration is shingle appearance, or the appearance of a shingle effect and thus an easily stored, transported, and installed roofing system without the drawbacks of a shingled roof system.
The first and second colors may be applied before the granules are applied to the outer surface. Alternatively, the first and second colors may be applied after the granules are applied to the outer surface.
In another alternative embodiment, the first plurality of granules may be applied to a first pile height, and the second plurality of granules may be applied to a second pile height. A pile height of the granules is a height reached by a granule or stack of granules on the outer surface after application. The second pile height may be, for example, lower than the first pile height, and arranged in a shingle pattern. The effect of the height difference between pattern lines and granule configuration is shingle appearance, or the appearance of a shingle effect and thus an easily stored, transported, and installed roofing system without the drawbacks of a shingled roof system.
Embodiments are shown by way of example, and not by way of limitation in the figures and drawings. While the invention has been described in connection with a number of embodiments and implementations, the invention is not so limited but covers various obvious modifications and equivalent arrangements, which fall within the purview of the appended claims. Although features of the invention are expressed in certain combinations among the claims, it is contemplated that these features can be arranged in any combination and order.
