Patent Application
20210285221
The present disclosure relates to an underlayment assembly and a method of installing thereof.
One aspect of the invention provides a method of installing an underlayment assembly for roofing application. The method includes one or more of the features listed below:
The method of underlayment assembly installation further includes one or more of the additional features listed below:
Another aspect of the invention provides an underlayment assembly for roofing application. The underlayment assembly includes one or more of the features listed below:
The underlayment assembly further includes one or more of the additional features listed below beacon device provides one or more of the features listed below:
The foregoing underlayment assembly and installation method, and or beacon device may further include one or more of the additional features that are defined in the original claims such that the system, method, system or beacon device may include two or more features that are defined in different claims.
Hereinafter, embodiments of the present invention will be described with reference to the drawings. These embodiments are provided for better understanding of the present invention, and the present invention is not limited only to the embodiments. Changes and modifications apparent from the embodiments still fall in the scope of the present invention. Meanwhile, the original claims constitute part of the detailed description of this application.
In embodiments, the underlayment assembly 100 is for installing over a roof deck. In an installation process, the underlayment assembly 100 is place over a roof deck, and then the liners 124 are removed such that the adhesive layers 124, 134 to a surface of the roof deck. Processes of underlayment installation will be also described in detail referring to the drawings.
Referring to
In embodiments, the base substrate 110 is a sheet comprising an asphalt material. In embodiments, the base substrate 110 includes at least one of a fiberglass-based modified asphalt material, a styrene butadiene styrene (SBS) modified asphalt material, an asphalt saturated felt and an asphalt saturated recycle paper material. In embodiments, the base substrate 110 includes one or more coating material impregnated into a fiberglass sheet. In embodiments, the base substrate 100 can be made using one or more materials other than the mentioned above. In certain embodiments, the base substrate 100 is a sheet of FONTANA® VulcaSeal ACRILAY® SBS Modified Asphalt Fiberglass Reinforced Base Sheet. FONTANA® is a registered trademark of Fontana Paper Mills, Inc. ACRILAY® is a registered trademark to Fontana Paper Mills, Inc.
The base substrate 110 may have a thickness of about 60 mil (0.06 inches). In embodiments, the base substrate 100 has a thickness in a desirable range between 50 and 70 mils (between 0.05 inches and 0.07 inches). In other embodiments, the base substrate 100 has a thickness less than 50 mil or greater than 70 mil.
The base substrate 100 may have a width of about 36 inches. In embodiments, the base substrate 100 has a desirable width in a range between 30 and 40 inches. In other embodiments, the base substrate 100 has a width less than 30 inches or greater than 400 inches.
The base substrate 100 may have a length of about 72 feet. In embodiments, the base substrate 100 has a desirable length in a range between 30 and 80 feet. In other embodiments, the base substrate 100 has a length less than 40 feet or greater than 80 feet.
The underlayment assembly 100 includes one or more layers of adhesive material disposed over the base substrate 110. Referring to
In embodiments, the adhesive layer 124, 134 includes an acrylic adhesive material. In embodiments, the adhesive layer includes at least one of acrylic adhesive, cyanoacrylate adhesive, epoxy adhesive, and urethane adhesive. In certain embodiments, the adhesive layer is provided using one or more materials other than the listed above. In certain embodiments, the adhesive layer includes at least one of 3M® Acrylic Adhesive 100MP, 3M® Acrylic Adhesive 200MP, 3M® Acrylic Adhesive 300MP and 3M® Acrylic Adhesive 350.
The adhesive layer 124, 134 may have a thickness of about 5.0 mils (0.127 mm). In embodiments, the adhesive layer has a desirable thickness in a range between 5.0 and 8.0 mils (between 0.005 inches and 0.008 inches). In other embodiments, the adhesive layer has a thickness less than 4.0 mil or greater than 8.0 mil.
The adhesive layer 124, 134 may have a width of about 6 inches. In embodiments, the adhesive layer has a desirable width in a range between 5 and 7 inches. In embodiments, the adhesive layer has a width less than 5 inches or greater than 7 inches.
The underlayment assembly 100 includes a liner disposed over the adhesive layer 124, 134. Referring to
In embodiments, the liner 123, 133 is a polymer liner. In embodiments, the liner 123, 133 includes is a polyethylene terephthalate (PET) plastic liner. In embodiments, the liner includes at least one of PET, polypropylene (PP), polyethylene. In certain embodiments, the liner is a paper liner having a polymer coating. In embodiments, the liner can be made using one or more materials other than the mentioned above.
In embodiments, the liner 123, 133 is an opaque liner to prevent potential degradation of the adhesive layer by lights. In embodiments, the liner includes at least one of pigment, ultraviolet stabilizer and a light-blocking material.
The liner 123, 133 may have a thickness of about 4.2 mils (0.10668 mm). In embodiments, the liner has a thickness in a desirable range between 4.0 mils and 7.0 mils. In other embodiments, the liner has a thickness less than 4.0 mils or greater than 7.0 mils.
The handle portion 123, 133 have a width, from the side edge 142, 143 along the lateral direction, of about 2 inches. In embodiments, the handle portion 123, 133 has a desirable width in a range between 1 and 3 inches. In other embodiments, the handle portion 123, 133 has a width less than 1 inch or greater than 3 inches.
In embodiments, the underlayment assembly 100 includes one or more guidelines indicating location of the adhesive layer 124, 134. Referring to
In embodiments, the underlayment assembly 100 is produced by applying, to the base substrate 110, an adhesive tape including a liner and an adhesive layer disposed over the liner. In embodiments, a process to produce the underlayment assembly 100 includes: (1) preparing an adhesive tape that includes a liner 122 and an adhesive layer 124 disposed over the liner, (2) subsequently, placing the adhesive tape over the base substrate 110 at a low temperature (for example, 70° F. to 100° F.) such that the adhesive layer 124 contacts a surface 116 of the base substrate 110, and (3) subsequently, applying heat to the adhesive tape and the base substrate such that the adhesive layer sticks to the surface 116. In embodiments, the adhesive layer is heated over a predetermined temperature (for example, 200° F., 300° F. and 300° F.) such that at least a portion of the adhesive layer 124 is melt-bonded to the surface 116.
In embodiments, adhesive tapes that can be used for producing the underlayment assembly 100 includes at least one of 3M® adhesive tape 9786 (5.5 mils thick adhesive 300MP, 4.2 mils thick poly-coated kraft paper liner), 3M® adhesive tape 6038 (8.0 mils thick adhesive 300MP, 4.2 mils thick poly-coated kraft paper liner), 3M® adhesive tape 468MP (5.2 mils thick adhesive 200MP, 4.2 mils thick poly-coated kraft paper liner), and 3M® adhesive tape 9775 (5.2 mils thick adhesive 300MP, 7.0 mils thick poly-coated kraft paper liner). In embodiments, adhesive tapes other than the mentioned above can be used.
In embodiments, an adhesive tape to produce underlayment assembly 100 can be selected based on results of a peel adhesion strength test in accordance with American Society for Testing and Materials (ASTM) D3654 standard. The following tables show peel adhesion strength of underlayment (UL) assemblies using different adhesive tapes when attached to an oriented strand board (OSB).
According to the results of peel adhesion strength tests shown in Tables 1-3, the tape 6038 using the adhesive 300MP shows an outstanding performance. Based on the outstanding performance, in embodiments, an adhesive tape using the adhesive 300MP can be selected over tapes using the adhesives 200MP or other. In certain embodiments, however, an adhesive tape using the adhesive 200MP can be selected over tapes based on data of one or more tests other than the peel adhesion strength test.
In embodiments, an adhesive tape to produce underlayment assembly 100 can be based on a shear adhesion test conducted in accordance with American Society for Testing and Materials (ASTM) D3654 standard. The following tables show shear adhesion strength of underlayment assemblies using different adhesive tapes when attached to an oriented strand board (OSB).
According to the results of shear adhesion strength tests shown in Tables 4-6, the tape 468MP using the adhesive 200MP shows an outstanding performance. Based on the outstanding performance, in certain embodiments, an adhesive tape using the adhesive 200MP can be selected over other adhesive tapes the adhesive 300MP. In certain embodiments, however, an adhesive tape using the adhesive 300MP can be selected over other adhesive tapes using the adhesive 200MP in view of other test results (peel adhesion) as far as it meet a predetermined requirement for the shear adhesion strength (for example, over 75 for 20 min dwell condition).
In embodiments, it is advantageous when an adhesive tape has a liner thicker than its adhesive layer. A thick liner can prevent a break during handling and installing the underlayment assembly 100. In this perspective, 3M® Adhesive tape 9775MP can be selected over the other adhesive tapes listed.
Referring to
In embodiments, it is advantageous not to apply an adhesive primer (or adhesive promotor) to the roof deck 310 or the adhesive layer 124, 134. According to the test results show in the Tables 4-6, using 3M® primer WP2000 in combination with the adhesive MP 300 or MP 200 may degrade the shear adhesion performance. According to the test results, using a water based adhesive 3M® 1000NF adhesive may degrade the shear adhesion performance, particularly when combined with the 300MP adhesive. Not using an adhesive primer would be beneficial as it simplifies an underlayment installation process. In certain embodiments, however, an adhesive primer or additional promoter can be used in an underlayment installation.
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
In the double-layer installation shown
In the first layer 810 and the second layer 820, two immediately neighboring underlayment substrate (for example, 812 and 814 of the first layer 810, and 824 and 826 of the second layer 820) overlap each other.
A third set of underlayment extensions 832, 834 are installed to extend along a direction substantially parallel to the bottom edge of the forth roof deck 360. The third set of underlayment extensions 832, 834 extends over an interface 334 (valley) between the first roof deck 310 and the fourth roof deck 360.
In embodiments, the underlayment assembly can be installed in a wide range of application temperatures (40° F.-240° F.) without the use of a torch in cold climates or sloppy viscous asphalt in hot conditions.
While the present invention has been described with reference to one or more preferred embodiments, which embodiments have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, such embodiments are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention. The scope of the invention, therefore, shall be defined solely by the following claims. Further, it will be apparent to those of skill in the art that numerous changes may be made in such details without departing from the spirit and the principles of the invention.
