Building roofs, including roofs of family dwellings, are often constructed with shingles, e.g., “composition” shingles. Composition material may include a tar-impregnated fibrous base, e.g., fiberglass, and may be coated with sand-like or similar materials. As a result of weathering and wear due to exposure to sunlight, heat, cold, and moisture, composition shingles (“tiles”) degrade, becoming brittle and porous. Brittle and/or porous shingles can cause moisture leaks, and may eventually become detached from the roof.
Improvements in roofing materials can increase roof life and effectiveness to shield a house from weather elements such as moisture (e.g., rain, snow, hail, etc.), sun, wind, ambient temperature, etc.
Methods and apparatus are presented to make a protective surface that forms at least part of a roof of a structure. The protective surface may be formed by applying a plural component polymer liquid to a roof substrate of a roof. In an embodiment, the non-aqueous based liquid includes a polyurea compound that, upon application, solidifies to produce a solid surface that adheres to the roof substrate. The plural component polymer liquid may have a fast hardening time, e.g., of the order of seconds to minutes after application, permitting a substantially uniform application to a sloped roof without thinning due to, e.g., drift of the liquid (e.g., as a result of gravitational force). Other embodiments are described.
Referring to
The substrate 102 may include underlayment, sheathing, shingles, other substrate materials, and the substrate 102 may comprise wood, tar-based covering, and/or other covering materials. The coating 104 may be a non-aqueous material, such as a polyurea compound and/or polyurethane-type material. The coating 104 may serve as a barrier membrane to protect the substrate 102 from moisture, sun, and other wear agents that may cause a breakdown of the roof, e.g., inability to protect contents of the building from e.g., moisture, sun, and other undesired external agents. In some embodiments, the coating 104 may be applied in new construction, e.g., directly over roof sheathing (e.g., plywood and/or oriented strand board). Additionally, the coating 104 may be applied to an existing roofing assembly to protect the existing roofing assembly from, e.g., weathering agents, e.g. rain, wind, snow etc.
The drip edge flashing 108, rake edge flashing 110 and other flashing (not shown, including but not limited to flashing applied to conjoining planes of a roofing surface, and protrusions such as chimneys, plumbing vents, other vents, and other protrusions) may be integrated with other portions of the roof. Integration of the flashing with the other portions of the roof may be accomplished by, e.g., inclusion of the coating 104 between the flashing 108 and the substrate 102, and application of plural component polymer material to the flashing after the coating 104 has been applied to the substrate 102 in a layered, or “sandwich-like” fashion, or by combinations thereof, and may be used, in some embodiments, as part of a sloped roof and/or as part of a substantially flat roof (e.g., non-sloped roof having a slope of less than 1/12 and/or less than 1/24).
Referring to
In the retrofit process, a membrane layer 208, e.g., plural component polymer material, may be applied as a liquid that may polymerize to form a solid water-repellant surface. In an embodiment, the membrane may be applied by, e.g., spraying the plural component polymer in liquid form onto exposed surfaces of the existing roof including the roof shingles 206, and onto flashing material including a drip edge flashing 212, which may be affixed (as part of the existing roof and prior to retrofit) to the roof shingles 206 and to the sheathing 202. In an embodiment, a rapidly hardening plural component polymer liquid may be applied to form the membrane, e.g., hardening (e.g., via polymerization) to occur in a time period (e.g., beginning at a time that the liquid leaves an application apparatus, e.g., spray gun) of several seconds to several minutes and less than approximately 10 minutes. By employing a rapidly hardening plural component polymer (e.g., a polyurea compound), the layer applied to the roof may tend to have a more uniform thickness over the extent of the membrane than, e.g. through use of a substance with a long hardening time (e.g., one hour or longer) because the plural component polymer that forms the membrane will harden before significant drift of the liquid occurs due to gravitational effects that would otherwise result in non-uniformity of membrane depth.
In an embodiment, after the membrane layer 208 is applied to the existing roof outer surface, a drip edge flashing 214 and a rake edge flashing 216 (shown in
According to an embodiment, a portion of the plural component polymer may be sprayed onto the existent roof structure prior to installing the drip edge flashing 214 and the rake edge flashing 216 (e.g., plural component polymer applied beneath each of the drip edge flashing 214 and the rake edge flashing 216). After application of the plural component polymer to the existent roof structure, the drip edge flashing 214 and the rake edge flashing 216 may be affixed, and additional plural component polymer 209 may be applied to coat the drip edge flashing 214 and rake edge flashing 216. The additional plural component polymer application 209 may further extend to cover a portion of the membrane layer 208, which can result in the drip edge flashing 214 and the rake edge flashing 216 being integrated within the (extended) membrane 208 and the membrane 209 and including the mechanical fasteners 210 that attach flashing (drip edge flashing 214 and rake edge flashing 216) to the sheathing 202. Sandwiching at least a portion of the flashing between the membrane 208 and the membrane 209 may serve to anchor the membrane 208 to the roof assembly to prevent lifting by, e.g., wind or other weather elements. Integration of the flashing (drip edge flashing 214 and rake edge flashing 216) between the membrane 208 and the membrane 209 may serve to protect the flashing from deterioration due to, e.g., moisture and/or other weathering agents. In some embodiments, use of the “sandwich” technique to install flashing may be applicable to sloped roofs and to non-sloped roofs.
Referring to
One or more panels 310 may be affixed to the roof shingles via, e.g., mechanical fasteners 318 and/or adhesive. In an embodiment, the panels 310 may be constructed from a polystyrene foam, or another solid plastic material, and the panels 310 may be shaped prior to installation over the roof shingles. For example, the panels 310 may be shaped to resemble one or more roof shingles, or another conventional roofing system such as standing seam metal roofing, tile, slate etc. Shaping of the panels 310 may increase marketability of a retrofit of the roof, because the shaped panels may provide the retrofitted roof with an appearance of a conventional shingle roof or other conventional roof shape. Similarity of the appearance of the retrofitted roof to a conventional shingle roof may significantly enhance marketability of the retrofitted roof, where the roof is retrofitted according to embodiments presented herein. Pre-formed shaped panels (made from, e.g., polystyrene or other material) may be used in formation of sloped roofs and non-sloped roofs, in some embodiments.
At least a portion of an outer surface of the panels 310 may be coated with a first membrane layer 320, which may be is situated at least between the panels 310 and flashing 312 that may be affixed to the portion of the panels 310 and optionally to the shingles 308 and the roof deck 304 by, e.g. mechanical fasteners 314. A first layer 320 of membrane formed from a plural component polymer (e.g., polyurea) may encase the flashing 312 and may promote adhesion of the flashing 312 to a second layer of membrane 322 (formed from the plural component polymer (e.g., polyurea), forming a structure that includes flashing 312 and membrane 322. Mechanical fastening of the flashing 312 to the roof deck 304 can serve to anchor the membrane layers 320 and 322 to the roof deck 304, with the flashing 312 sandwiched between the membrane layers 320 and 322. This sandwiching of the flashing 312 between the membrane layers 320 and 322 may prevent deterioration of the flashing 312 due to weathering agents that might otherwise directly contact the flashing. Additionally, the flashing and membrane in combination may prevent water and/or other weathering elements from reaching any portion of the roof assembly that is beneath the membrane/flashing combination that includes the membrane layers 322 and 320, flashing 312 and fasteners 314. The first membrane layer 320 may partially or completely coat the flashing 312, and may extend to at least the portion of other surfaces of the panels 310. In an embodiment, the first membrane layer 320 may be applied to the flashing 312 prior to affixing the flashing to the panels 310. In another embodiment, the first membrane layer 320 may be applied portions (e.g., outer surface of the panels 310), after which the flashing 312 may be affixed to the panels 310.
After the flashing 312 is affixed to the panels 310, the second membrane layer 322 may be applied to exposed portions of the panels 310 and to exposed portions of the flashing 312. In an embodiment, the second membrane layer 322 may be applied in a liquid form that hardens to form a barrier to protect underlying components from weathering agents such as moisture, sun, etc. The first membrane layer and the second membrane layer may be a non-aqueous material such as a polyurethane, polyurea, or other plural component polymer compound that may be applied in liquid form and that hardens to form the second membrane layer 322. In an embodiment, the second membrane layer may be formed from a quickly hardening (e.g., quickly polymerizing) material, e.g., having a hardening time of less than approximately 10 minutes from time of application, and in some embodiments, having a respective hardening time of less than approximately 2 minutes, and in some embodiments, having an effective respective hardening time of less than approximately 30 seconds.
After application of the second membrane layer 322, optionally a third membrane layer (e.g., an ultraviolet blocking layer) 324 may be applied to the second membrane layer, e.g., as a liquid substance that hardens to form an ultraviolet-protecting surface that filters out or reflects ultraviolet light that may impinge on an outer surface of the ultraviolet blocking layer 324. The third membrane layer 324 may be a polyurethane compound that can filter ultraviolet light and that effectively withstands weathering effects, e.g., moisture, heat, etc. over a multi-year life span that may be expected of the retrofit. The third membrane layer 324 may also contain color pigments to color the roof surface, which may provide may provide color (dark or light) that reflects or absorbs heat, and may enhance the roof aesthetically. The reflective or absorptive properties of the third membrane layer 324 may result in energy savings and may improve comfort in the interior of the building, e.g., attic temperature. Use of multiple layers, e.g., polyurea, polyurethane, and/or other plural component polymer layers, may be applicable to sloped roofs and to non-sloped roofs, in some embodiments. Note that the embodiments described herein are not limiting.
Turning to
Advancing to block 406, a first membrane layer (e.g., a plural component polymer compound, e.g., polyurea) may be applied, in liquid form, to a perimeter strip of the substrate roof. In an embodiment, the application may be through a spray technique, described herein. In an embodiment, the plural component polymer compound may have a relatively short hardening time (e.g., of the order of one or more second, up to approximately 10 minutes). In an embodiment, the perimeter strip includes an outer strip of the substrate roof that is at least as wide as a flashing strip to be affixed to the substrate roof at perimeter portions of the substrate roof and may include including dormers and regions surrounding protrusions, e.g. vents, chimneys etc. In an embodiment, the perimeter strip has a longitudinal extent that is at least twice a longitudinal extent of the flashing strip, so that when the flashing strip is affixed to the perimeter strip of the substrate roof the first membrane layer extends beyond the longitudinal extent of the flashing strip, providing a moisture barrier between the substrate roof and the flashing strip and allowing the flashing to be encased between two layers of the sprayed membrane material.
Moving to block 408, the flashing strip may be affixed to the substrate roof at the perimeter strip, e.g. rake edges, drip edges, dormer edges etc., through use of mechanical fastening techniques. Each section of flashing is to contact the first membrane and may be fastened to the underlying roof via mechanical fasteners that pierce the first membrane to the substrate roof and roof decking.
Proceeding to block 410, a second membrane layer (e.g., a plural component polymer compound, e.g., polyurea) may be applied, in liquid form, to outer surfaces of the substrate roof and affixed flashing, e.g., via a spraying technique. The second membrane layer may harden to form a retrofitted roof outer surface that protects the underlying layers (e.g., substrate roof and flashing) from degradation due to, e.g., weathering agents, etc. Continuing to block 412, the second membrane may optionally be coated with a top coat (e.g., a plural component polymer compound, e.g., polyurethane) to protect the second membrane and substrate roof from, e.g., effects of ultraviolet light, and to provide reflectivity and color choice to enhance aesthetics of the retrofitted roof. In an embodiment, one or more to the membrane layers may have brief hardening times that counteract a tendency to non-uniformity of layer thickness due to liquid drift, e.g., as a result of gravitational effects. The method ends at 414. The method may apply to sloped roofs and also to non-sloped roofs, in various embodiments.
Turning to
A membrane layer 512 that can serve as an outer layer of the roof may be formed from, e.g., a non-aqueous plural component polymer membrane, e.g., polyurea or another non-aqueous plural component polymer plastic. The membrane layer 512 may be applied as a liquid to the substrate, and may subsequently harden to form an outer layer that is resistant to weathering agents such as moisture (e.g., rain, snow, ice, hail, etc.), and that is resistant to some weathering agents such as sun, wind, etc. The membrane layer may include a secondary outer layer 514 that can be a color filter material to protect against, e.g., detrimental effects of ultra-violet light and/or other weathering agents. The secondary outer layer 514 may be applied as a liquid and that hardens to form a protective outer layer. For example, the secondary outer layer 514 may be sprayed on as a liquid that can harden, e.g., by polymerization, or by a chemical process, e.g., through chemical reaction with atmosphere (e.g., oxygen). In one embodiment, the secondary outer layer 514 may be a polyurethane compound. Use of several polymer layers may be applicable to non-sloped roofs and to sloped roofs, in some embodiments.
As shown in the cross-sectional view, the roof may include a plurality of layers including a roof sheathing 506 (e.g., plywood, oriented strand board (OSB)), roof underlayment 508 (e.g., tar, felt, flexible plastic sheathing, etc.), roof shingles 510, non-aqueous hardened membrane layer (e.g., polyurea) 512, and optionally colored UV-filter layer 514 (e.g., polyurethane). Flashing (not shown) may be installed after the membrane layer 512 is applied, and the flashing may be integrated into the membrane as described above.
Turning to
Turning to
Turning to
Turning to
Turning to
Turning to
A second structure 1120 has another roof including a membrane layer according to embodiments such as shown in
Fewer vents can translate to energy savings due to less heat needed in cold weather, and less air conditioning needed in warm weather. A water-resistant membrane thus permits a reduction in building envelope venting, with consequent energy savings.
Embodiments presented herein may be applicable to sloped roof systems, and to non-sloped roof systems. While the present invention has been described with respect to a limited number of embodiments, those skilled in the art will appreciate numerous modifications and variations therefrom. It is intended that the appended claims cover all such modifications and variations as fall within the scope of the present invention.
This application is a continuation of U.S. patent application Ser. No. 13/802,799, filed Mar. 14, 2013, which is hereby incorporated by reference herein in its entirety.
Number | Name | Date | Kind |
---|---|---|---|
3763605 | Freeman | Oct 1973 | A |
4557081 | Kelly | Dec 1985 | A |
4746365 | Babcock | May 1988 | A |
5171818 | Wilson | Dec 1992 | A |
5251411 | Kelley | Oct 1993 | A |
5253461 | Janoski | Oct 1993 | A |
5740647 | Kelly | Apr 1998 | A |
6209283 | Folkersen | Apr 2001 | B1 |
6679018 | Georgeau | Jan 2004 | B2 |
6742313 | Ritland | Jun 2004 | B2 |
6751923 | Nunley | Jun 2004 | B1 |
6871472 | Folkersen | Mar 2005 | B2 |
7454876 | Kelly | Nov 2008 | B2 |
7622187 | Clarke | Nov 2009 | B2 |
7658052 | Kelly | Feb 2010 | B2 |
7779595 | Polk, Jr. | Aug 2010 | B2 |
7793479 | Kelly | Sep 2010 | B2 |
7793480 | Gembala | Sep 2010 | B2 |
7805900 | Kelly | Oct 2010 | B2 |
8407958 | Kelly | Apr 2013 | B2 |
8413914 | Davis | Apr 2013 | B2 |
8479467 | Johnson | Jul 2013 | B2 |
8689510 | Krumvieda | Apr 2014 | B1 |
9067383 | Dubey | Jun 2015 | B2 |
20030005658 | Folkersen | Jan 2003 | A1 |
20030145546 | Georgeau | Aug 2003 | A1 |
20040016201 | Folkersen | Jan 2004 | A1 |
20040025462 | Meier | Feb 2004 | A1 |
20050218547 | Roche | Oct 2005 | A1 |
20050244626 | Leslie | Nov 2005 | A1 |
20060010808 | Kelly | Jan 2006 | A1 |
20060053717 | Kelly | Mar 2006 | A1 |
20060240243 | Leslie | Oct 2006 | A1 |
20070043197 | Posey | Feb 2007 | A1 |
20070066786 | Hanson | Mar 2007 | A1 |
20070261346 | Kelly | Nov 2007 | A1 |
20090241450 | Italiane | Oct 2009 | A1 |
20100011691 | Anaya | Jan 2010 | A1 |
20100086697 | Pjatikin | Apr 2010 | A1 |
20140037855 | Otero Martinez | Feb 2014 | A1 |
20140109500 | Bacon | Apr 2014 | A1 |
Number | Date | Country |
---|---|---|
1046361 | Jan 1979 | CA |
2000120192 | Apr 2000 | JP |
2001064881 | Mar 2001 | JP |
125546 | Mar 2013 | RU |
WO-2009132967 | Nov 2009 | WO |
Entry |
---|
“ExpandoThane, Roof Coating, Water Proofing”, https://sprayez.com/product/expandothane-roof-coating-water-proofing/ (Year: 2021). |
“Expando Thane Seamless Roof System”, https://img1.wsimg.com/blobby/go/3b8c68a6-8dfa-49a1-b9d0-948b02f52c5c/downloads/expandothane-sales-book(2).pdf?ver=1622041530354 (Year: 2021). |
“ExpandoThane Technical Data Sheet”, https://superiorseamlessroofing.com/wp-content/uploads/2018/09/Expandothane-Technical-Data-Sheet-2018-Superior-Seamless-Roofing.pdf (Year: 2021). |
“New Polyurea Coating for Roofing and Waterproofing”, Tom Hay, sprayfoam.com; Feb. 9, 2010; https://www.sprayfoam.com/foam-news/new-polyurea-coating-for-roofing-and-waterproofing/1278 (Year: 2010). |
“Polyurea Spray Coatings: The Technology and Latest Developments” Oct. 10, 2002; https://www.pcimag.com/articles/84126-polyurea-spray-coatings-the-technology-and-latest-developments (Year: 2002). |
“Expando Thane Safety Data Sheet”, Jun. 7, 2015; https://sprayez.com/wp-content/uploads/2018/11/Safety-Data-Sheet-Expandothane-Polyurea-Materia-by-SprayEZ-Spray-Coating-Material.pdf (Year: 2015). |
www.expandothane.com; https://web.archive.org/web/20110907090335/http://expandothane.com/node/1; Sep. 7, 2011 (Year: 2011). |
Soythane Corporation, soythane.com website, ca. May 2011, as archived by archive.org. https://web.archive.org/web/20110522023144/http://soythane.com. |
Soythane Corporation, sprayez.com website, ca. Feb. 2014, as archived by archive.org. https://web.archive.org/web/20140209060337/http://sprayez.com. |
Edward M. Petrie, MS Polymers in “Hybrid” Sealants, www.adhesives.org, (c) 2010, pp. 1-8, EMP Solutions, The Adhesive and Sealant Council, Inc., Bethesda, MD USA. |
Art Webb, Applying Plural Component Spray, Webinar Series, (c) 2012, pp. 1-50, The Society for Protective Coatings, Pittsburgh, PA USA. |
Graco, Fast-Set Plural-Component Equipment and Accessories, OEM Equipment Literature, © 2002-2009, pp. 1-24, Rev. E 7/09, Graco Inc., Minneapolis, MN USA. |
Nace International, Introduction to Thick-Film Polyurethanes, Polyureas, and Blends, Technical Committee Report, (c) 1998, pp. 1-9, Item No. 24197 NACE International Publication 6A198, NACE International, Houston, TX USA. |
Dudley J. Primeaux II, Application of 100% Solids, Plural Component Aliphatic Polyurea Spray Elastomer Systems, Journal of Protective Coatings & Linings (JPCL) Magazine, (c) 2001, pp. 26-32, Mar. 2001 Edition, The Technology Publishing Network, Pittsburgh PA USA. |
Dudley J. Primeaux II, Polyurea vs Polyurethane & Polyurethane/Polyurea: What's the Difference?, Presentation Polyurea Development Association (PDA) Conference, (c) 2004, pp. 1-20, Primeaux Associates LLC, Elgin, TX USA. |
Specialty Products, Inc., About Polyurea, Polyurea Education, (c) 2015, pp. 1-3, specialty-products.com/about-polyurea/, Specialty Products, Inc., Lakewood, WA USA. |
Number | Date | Country | |
---|---|---|---|
20170081856 A1 | Mar 2017 | US |
Number | Date | Country | |
---|---|---|---|
Parent | 13802799 | Mar 2013 | US |
Child | 15370389 | US |