Patent Application
20180274252
Roofing membranes, as used, for example, in commercial roofing applications, commonly include a roofing felt or fibrous sheet impregnated or laminated with one or more thermosoftening materials (e.g., asphalt or other bituminous materials, acrylic or other thermoplastic materials, etc.) to provide a waterproof barrier for the roof. In some applications, the installed roofing membranes may absorb moisture (e.g., through the cut edges or surface imperfections of the membranes) that, when exposed to heat, expand as water vapor to form blisters in the membranes. These blisters can grow and form cracks in the membrane, compromising the waterproofing properties of the roofing material. A common method for repairing blistered portions of roofing materials is to cut out the blistered section of the membrane and adhere a small sheet of roofing membrane (i.e., a patch) over the hole in the roofing material. These types of repairs are time consuming and produce additional potential leak paths between the patch and the original roofing material.
The present application contemplates devices and methods for repairing blistered portions of a membrane, such as, for example, a laminated roofing membrane.
In an exemplary embodiment of the present application, a method of repairing a blistered portion of a membrane is contemplated. In the exemplary method, a heated air dispensing device is provided, having an elongated nozzle including at least one outlet aperture. The blistered portion of the membrane is pierced to form an opening sized to receive the elongated nozzle. The elongated nozzle is inserted through the opening and into an interior cavity of the blistered portion, with the interior cavity being at least partially defined by a thermosoftening material. The heated air dispensing device is operated to dispense heated air through the at least one outlet aperture into the interior cavity of the blistered portion to at least partially melt the thermosoftening material. A force is applied to an exterior surface of the blistered portion to flatten the blistered portion, thereby substantially eliminating the interior cavity.
In another exemplary embodiment of the present application, a method of repairing a blistered portion of a membrane is contemplated. In the exemplary method, a glue dispensing device is provided, having an elongated nozzle including at least one outlet aperture. The blistered portion of the membrane is pierced to form an opening sized to receive the elongated nozzle. The elongated nozzle is inserted through the opening and into an interior cavity of the blistered portion. The glue dispensing device is operated to dispense glue through the at least one outlet aperture into the interior cavity of the blistered portion. A force is applied to an exterior surface of the blistered portion to flatten the blistered portion, to adhere opposed interior surfaces of the interior cavity together with the glue, thereby substantially eliminating the interior cavity.
In another exemplary embodiment of the present application, a heated air dispensing device includes a housing, an air pumping mechanism disposed in the housing, an air heating mechanism positioned to heat air pumped through the air pumping mechanism, and an elongated nozzle in fluid communication with the air pumping mechanism and including a neck portion extending along an insertion axis to an end portion having a pair of opposed laterally oriented apertures for directing heated air laterally outward from the insertion axis.
In another exemplary embodiment of the present application, a hot glue dispensing device includes a housing, a glue pumping mechanism disposed in the housing, a glue heating mechanism positioned to heat glue pumped from the glue pumping mechanism, and an elongated nozzle in fluid communication with the glue pumping mechanism and having a neck portion extending along an insertion axis to an end portion having a pair of opposed laterally oriented apertures for directing heated glue laterally outward from the insertion axis.
In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to provide examples of the principles of this invention.
As described herein, when one or more components are described as being assembled, connected, joined, affixed, coupled, attached, or otherwise interconnected, such interconnection may be direct as between the components or may be indirect such as through the use of one or more intermediary components. Also as described herein, reference to a “member,” “component,” or “portion” shall not be limited to a single structural member, component, or element but can include an assembly of components, members or elements.
The Detailed Description merely describes exemplary embodiments and is not intended to limit the scope of the claims in any way. Indeed, the invention as claimed and described is broader than and unlimited by the exemplary embodiments, and the terms used in the claims have their full ordinary meaning. For example, while the specific embodiments described herein relate to devices and methods for the repair of blistered portions of a thermosoftening (e.g., asphalt-coated) roofing membrane, the inventive devices and methods described herein may additionally or alternatively be applied to other types of membranes (e.g., wall covering, flooring), other membrane materials (e.g., rubber, acrylic), and other types of repairs (e.g., cracks, delamination).
The present application contemplates, in part, devices and methods for repairing a blistered portion of a membrane, for example, to prevent blister growth, cracking, and further damage, and associated leakage therethrough. According to an exemplary aspect of the present application, a blistered portion of a membrane may be repaired by heating and compressing the blistered portion, such that softened/melted membrane materials on the interior surfaces of the blister cavity may be rebonded to flatten and substantially eliminate the blister. In an exemplary embodiment, heated air (or other such heated gas) is injected into the interior cavity of the blister through an opening formed in the blistered portion, thereby softening or at least partially melting a thermosoftening material (e.g., asphalt or other bituminous material, acrylic, etc.) at least partially defining the interior cavity. A force is then applied to the exterior surface of the blistered portion, causing the softened/melted material to bond together to flatten and substantially eliminate the blister.
To facilitate the supply of heated air into the interior cavity 17 of the blistered portion 15, the device 100 may be provided with an elongated nozzle 140 connected with an exhaust port 114 of the housing 110, and in fluid communication with the air pumping mechanism 120. As shown, the elongated nozzle 140 may include a neck portion 142 extending along an insertion axis X to an end portion 144 defining at least one outlet aperture 146, 147 for dispensing the heated air supplied through the nozzle 140. While the nozzle may be provided as a flexible extension, in one embodiment, at least the neck portion 142 of the nozzle is substantially rigid to facilitate extension and redirection of the nozzle 140 within the blister cavity. The neck portion 142 may be provided in a length sufficient to reach interior edge portions 17a, 17b of the blister cavity 17, for example, from an opening 19 in the upper layer 13 at the blistered portion 15. In an exemplary embodiment, the neck portion 142 is between about 12 inches and about 24 inches, or between about 16 inches and about 18 inches.
To facilitate extension of the nozzle along an insertion axis substantially parallel to and adjacent to the roofing deck D, an offset or branch portion 141 of the nozzle 140 may extend between the housing 110 and the nozzle neck portion 142 at an angle a with respect to the insertion axis X, thus allowing a user to stand or squat on the roofing deck D while operating the device 100. The branch portion 141 may be formed as a rigid bent extension of the neck portion 142. Alternatively, the branch portion may be flexible to facilitate adjustment of the angle of the branch portion 141 with respect to the insertion axis X. As shown a guide handle 150 may extend laterally from the branch portion 141 of the nozzle 140 to assist the user in supporting and orienting the nozzle.
To insert the end portion 144 and at least a portion of the neck portion 142 of the nozzle 140 into the blister cavity, an opening 19 is formed in the upper layer 13 at the blistered portion 15. While a separate tool (not shown) may be utilized to cut the opening 19 in the upper layer, in the illustrated embodiment, the end portion 144 of the elongated nozzle 140 includes a pointed tip 145 capable of puncturing or piercing the upper layer 13 at the blistered portion 15, thereby generating an opening 19 sized for insertion of the nozzle neck portion 142 therethrough. The pointed tip may be provided in many different shapes, including, for example, conical, spear shaped, wedge shaped, diamond shaped, or triangular. In the illustrated embodiment, as shown in
The outlet aperture or apertures in the nozzle end portion may be provided in a variety of quantities, sizes, shapes and orientations. In one embodiment, a plurality of outlet apertures are disposed on opposed lateral side surfaces of the end portion, such that heated air supplied through the inserted nozzle is directed substantially horizontally between opposed upper and lower interior surfaces 16, 18 of the interior cavity 17, and such that the apertures are less likely to be clogged or obstructed by the softening interior material within the blister. Lateral orientation of the outlet apertures on the inserted nozzle end portion may be facilitated by positioning these apertures laterally with respect to the nozzle branch portion 141, as the nozzle branch portion will extend along a plane that is substantially vertical or perpendicular to the membrane 10 when the nozzle neck portion 142 is inserted through the blister opening and positioned to be substantially parallel to and adjacent to the roofing deck.
In the illustrated embodiment of
In another embodiment, as shown in
In an exemplary method of repairing a blistered portion 15 of a membrane 10, the blistered portion of the membrane is pierced or punctured by the pointed tip 145 of the nozzle end portion 144 to form an opening 19 sized to receive at least a portion of the neck portion 142 of the elongated nozzle 140. The end portion 144 is inserted through the opening and into an interior cavity 17 of the blistered portion 15, with the interior cavity being at least partially defined by a meltable or softenable material. The heated air dispensing device 100 is operated (e.g., using a pump control element 115) to dispense heated air through the outlet apertures 146a, 146b, 147a, 147b into the interior cavity 17 of the blistered portion 15 to at least partially melt or soften the thermosoftening material forming the blister cavity. The nozzle end portion 144 is moved within the blister cavity to apply heated air substantially uniformly within the cavity, for example, by positioning the outlet apertures at a plurality of edge positions 17a, 17b of the interior cavity 17. The dry, heated air from the nozzle may also evacuate any moist air present in the blistered portion of the membrane. Additionally, the heated air passing through the nozzle 140 may be effective to heat the exterior surfaces of the nozzle, such that the heated surfaces of the blister inserted portion of the nozzle may also at least partially melt or soften the thermosoftening material within the blistered portion of the membrane.
Once the interior cavity has been sufficiently and uniformly heated, the nozzle end portion 144 is withdrawn from the blistered portion 15 of the membrane 10, and a force F is applied to an exterior surface 13 of the blistered portion 15 to flatten the blistered portion (
According to another exemplary aspect of the present application, a blistered portion of a membrane may be repaired by injecting a glue or sealant material into the interior cavity of the blistered portion, and compressing the blistered portion, such that interior surfaces of the blister cavity may be bonded together by the glue to flatten and substantially eliminate the blister. In an exemplary embodiment, glue is injected into the interior cavity of the blister through an opening formed in the blistered portion. A force is then applied to the exterior surface of the blistered portion, causing the injected glue to bond with the blistered material to flatten and substantially eliminate the blister. Many different suitable glues and sealants may be utilized, including, for example, glues that may be dispensed and applied at ambient temperatures, such as a two-part urethane adhesive. In other embodiments, a hot glue dispensing device may be configured to dispense a heated glue into a blistered portion of a membrane. Exemplary hot glues may include, for example, PolyTec Polyamide hot melt glue sticks.
To facilitate the supply of glue into the interior cavity 17 of the blistered portion 15, the device 200 may be provided with an elongated heated nozzle 240 connected with an outlet port 214 of the housing 210, and in fluid communication with the glue pumping mechanism 220. As shown, the elongated nozzle 240 may include a neck portion 242 extending along an insertion axis X to an end portion 244 defining at least one outlet aperture 246, 247 for dispensing the glue supplied through the nozzle 240. While the nozzle may be provided as a flexible extension, in one embodiment, at least the neck portion 242 of the nozzle is substantially rigid to facilitate extension and redirection of the nozzle 240 within the blister cavity 17. The neck portion 242 may be provided in a length sufficient to reach interior edge portions 17a, 17b of the blister cavity 17, for example, from an opening 19 in the upper layer 13 at the blistered portion 15. In an exemplary embodiment, the neck portion 242 is between about 12 inches and about 24 inches, or between about 16 inches and about 18 inches.
To facilitate extension of the nozzle along an insertion axis substantially parallel to and adjacent to the roofing deck D, an offset or branch portion 241 of the nozzle 240 may extend between the housing 210 and the nozzle neck portion 242 at an angle a with respect to the insertion axis X (e.g., an angle between about 45° and about 60°), thus allowing a user to more easily stand or squat on the roofing deck D while operating the device 200. The branch portion 241 may be formed as a rigid bent extension of the neck portion 242. Alternatively, the branch portion may be flexible to facilitate adjustment of the angle of the branch portion 241 with respect to the insertion axis X. As shown a guide handle 250 may extend laterally from the branch portion 241 of the nozzle 240 to assist the user in supporting and orienting the nozzle.
The secondary glue heating mechanism may be disposed in the housing, and may for example, include an electrical heating coil, or other such heat source. Additionally or alternatively, the secondary glue heating mechanism 230 may be disposed along the nozzle 240 to ensure a heated condition of the glue as it is dispensed. In the illustrated embodiment, as shown in
In another embodiment, heated air may be supplied through an annular space between a glue conduit and an outer tube, to heat the glue to a desired temperature (e.g., to a temperature of about 400° F. to about 450° F. or any other suitable heated temperature). While the heated air may be circulated through the annular space and evacuated through a rear portion of the device, in one embodiment, the dry heated air is exhausted through the inserted end portion of the nozzle, into the blistered portion of the membrane when the device is in use, for example, to dry or evacuate any moisture present in the blistered portion of the membrane to facilitate stronger adhesion of the repaired blistered portion, and reduced likelihood of further blistering.
Referring back to
The outlet aperture or apertures in the nozzle end portion may be provided in a variety of quantities, sizes, shapes and orientations. In one embodiment, a plurality of outlet apertures are disposed on opposed lateral side surfaces of the end portion, such that glue supplied through the inserted nozzle is directed substantially horizontally between opposed upper and lower interior surfaces 16, 18 of the interior cavity 17, and such that the apertures are less likely to be clogged or obstructed by the interior material within the blister. Lateral orientation of the outlet apertures on the inserted nozzle end portion may be facilitated by positioning these apertures laterally with respect to the nozzle branch portion 241, as the nozzle branch portion will extend along a plane that is substantially vertical or perpendicular to the membrane 10 when the nozzle neck portion 242 is inserted through the blister opening and positioned to be substantially parallel to and adjacent to the roofing deck D.
In the illustrated embodiment, the nozzle end portion 244 includes a first pair of opposed laterally oriented apertures 246a, 246b disposed on opposed lateral sides of a cylindrical portion 243 of the nozzle end portion 244, and a second pair of opposed laterally oriented apertures 247a, 247b disposed on opposed side surfaces of the conical pointed tip 245. By locating the second pair of opposed laterally oriented apertures 247a, 247b on the conical tip 245 of the end portion, these apertures are angled for directing glue laterally outward and axially forward with respect to the insertion axis X, while the first pair of opposed laterally oriented apertures 247a, 247b are oriented to direct glue primarily laterally outward with respect to the insertion axis X. The apertures 246a, 246b, 247a, 247b may, but need not, substantially match the apertures of the embodiment of
In an exemplary method of repairing a blistered portion 15 of a membrane 10, the blistered portion of the membrane is pierced or punctured by the pointed tip 245 of the nozzle end portion 244 to form an opening 19 sized to receive at least a portion of the neck portion 242 of the elongated nozzle 240. The end portion 244 is inserted through the opening and into an interior cavity 17 of the blistered portion 15. The glue dispensing device 200 is operated (e.g., using a pump control element 215) to pump hot glue g through the outlet apertures 146a, 146b, 147a, 147b into the interior cavity 17 of the blistered portion 15 to dispense glue g into the blister cavity. The nozzle end portion 244 is moved within the blister cavity to dispense glue substantially uniformly within the cavity, for example, by positioning the outlet apertures at a plurality of edge positions 17a, 17b of the interior cavity. Once the interior cavity has been provided with a sufficient amount of glue, the nozzle end portion 244 is withdrawn from the blistered portion 15 of the membrane 10, and a force F is applied to an exterior surface 14 of the blistered portion to flatten the blistered portion (
The heated air dispensing devices and hot glue dispensing devices of the present application may utilize additional features and configurations in accordance with inventive aspects of the present application.
While many different attachment arrangements may be utilized, in the illustrated embodiment, a branch or supply tube 307 is attached to the outlet port 314 by a split collar 308 held in coupling engagement with the supply tube 307 and outlet port 314 by fasteners 309, to facilitate disassembly and reassembly of the nozzle attachment assembly 301 with the dispenser 305 (e.g., for ease of cleaning, replacement, and storage).
To facilitate handling and operation of the dispensing apparatus 300, the nozzle attachment assembly may be provided with two laterally extending handles 350, 360 attached to a handle support frame 351 that is attached (e.g., welded) to the supply tube 307. In the illustrated embodiment, a heat cage 352 is attached to the first handle 350 to surround the handle support frame 351, to protect the user from contact with the handle support frame 351, which may become extremely hot during use. An adjustable foot support 353 is adjustably connected (e.g., by threaded connection) to the handle support frame 351, to support the nozzle attachment assembly 301 when the dispensing apparatus is placed down on a roof or other surface, to space the heated portions of the nozzle attachment assembly apart from the roof surface.
In the illustrated embodiment, the nozzle 340 is configured to be disassembled from and reassembled with the supply tube 307, for example, for ease of cleaning, replacement, and storage. While many different attachment arrangements may be utilized, in the illustrated embodiment, as shown in
While various inventive aspects, concepts and features of the inventions may be described and illustrated herein as embodied in combination in the exemplary embodiments, these various aspects, concepts and features may be used in many alternative embodiments, either individually or in various combinations and sub-combinations thereof. Unless expressly excluded herein all such combinations and sub-combinations are intended to be within the scope of the present inventions. Still further, while various alternative embodiments as to the various aspects, concepts and features of the inventions—such as alternative materials, structures, configurations, methods, circuits, devices and components, hardware, alternatives as to form, fit and function, and so on—may be described herein, such descriptions are not intended to be a complete or exhaustive list of available alternative embodiments, whether presently known or later developed. Those skilled in the art may readily adopt one or more of the inventive aspects, concepts or features into additional embodiments and uses within the scope of the present inventions even if such embodiments are not expressly disclosed herein. Additionally, even though some features, concepts or aspects of the inventions may be described herein as being a preferred arrangement or method, such description is not intended to suggest that such feature is required or necessary unless expressly so stated. Still further, exemplary or representative values and ranges may be included to assist in understanding the present disclosure, however, such values and ranges are not to be construed in a limiting sense and are intended to be critical values or ranges only if so expressly stated. Moreover, while various aspects, features and concepts may be expressly identified herein as being inventive or forming part of an invention, such identification is not intended to be exclusive, but rather there may be inventive aspects, concepts and features that are fully described herein without being expressly identified as such or as part of a specific invention. Descriptions of exemplary methods or processes are not limited to inclusion of all steps as being required in all cases, nor is the order that the steps are presented to be construed as required or necessary unless expressly so stated.
While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicant to restrict or in any way limit the scope of the invention to such detail. Additional advantages and modifications will readily appear to those skilled in the art. For example, the specific locations of the component connections and interplacements can be modified. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus, and illustrative examples shown and described. Accordingly, departures can be made from such details without departing from the spirit or scope of the applicant's general inventive concept.
This application claims priority to and all benefit of U.S. Provisional Patent Application Ser. No. 62/476,084, filed Mar. 24, 2017, titled ROOFING BLISTER REPAIR DEVICES AND METHODS, the entire disclosure of which is fully incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62476084 | Mar 2017 | US |
