U.S. patent application number 09/735259 was filed with the patent office on 2002-02-07 for apparatus for applying tpo adhesive to a single-ply roofing membrane.
Invention is credited to Hubbard, Michael J., Kelly, Walter J., Verrocchi, Anthony, Weinert, Raymond J..
Application Number | 20020014312 09/735259 |
Document ID | / |
Family ID | 22727031 |
Filed Date | 2002-02-07 |
United States Patent
Application |
20020014312 |
Kind Code |
A1 |
Hubbard, Michael J. ; et
al. |
February 7, 2002 |
Apparatus for applying TPO adhesive to a single-ply roofing
membrane
Abstract
An apparatus and method of applying a bead of TPO or TPE
adhesive between a talc-free first roofing membrane and an
overlapping talc-free second roofing membrane. The apparatus
includes a movably supported chassis and an extruder attached to
the chassis having a nozzle including an outlet having at least one
opening for applying the TPO or TPE adhesive between the first
membrane and the overlapping second membrane to adhere the
overlapping second membrane to the first membrane.
Inventors: |
Hubbard, Michael J.;
(Holland, OH) ; Kelly, Walter J.; (Wadsworth,
OH) ; Verrocchi, Anthony; (Akron, OH) ;
Weinert, Raymond J.; (Macedonia, OH) |
Correspondence
Address: |
Robert F. Rywalski, Esq.
Omnova Solutions Inc.
175 Ghent Road
Fairlawn
OH
44333-3300
US
|
Family ID: |
22727031 |
Appl. No.: |
09/735259 |
Filed: |
December 12, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09735259 |
Dec 12, 2000 |
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09196850 |
Nov 20, 1998 |
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6253528 |
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Current U.S.
Class: |
156/578 ;
156/575; 52/746.11; 52/749.12 |
Current CPC
Class: |
Y10T 156/179 20150115;
E04D 15/04 20130101; Y10T 156/1798 20150115 |
Class at
Publication: |
156/578 ;
156/575; 52/746.11; 52/749.12 |
International
Class: |
E04D 015/07; E04G
021/16 |
Claims
What is claimed is:
1. An apparatus capable of applying a TPO or TPE adhesive between a
talc-free first membrane and an overlapping talc-free second
membrane, the apparatus comprising: a movably supported chassis;
and an extruder attached to said chassis having a nozzle including
an outlet having at least one opening for applying TPO or TPE
adhesive between the first membrane and the overlapping second
membrane to adhere the overlapping second membrane to the first
membrane.
2. The apparatus of claim 1 further comprising a press wheel
rotatably attached to said chassis and located rearward of said
nozzle relative to the direction of movement of the apparatus and
capable of simultaneously applying pressure to the second
membrane.
3. The apparatus of claim 2 wherein the press wheel is
bifurcated.
4. The apparatus of claim 3 wherein each portion of the bifurcated
press wheel is rotatable on a separate axle attached to the
chassis.
5. The apparatus of claim 3 wherein the press wheel is rotatable on
a single axle attached to said chassis.
6. The apparatus of claim 1 wherein the extruder includes an
open-end housing having an actuable piston member and a flexible
hose, the piston member including a heated platen to melt the
adhesive whereby the actuable piston member forces the melted
adhesive through the flexible hose between the first membrane and
the overlapping second membrane.
7. The apparatus of claim 6 wherein the open-end housing is
heated.
8. The apparatus of claim 1 wherein the extruder includes a heated
open-end housing having a flexible hose and an actuable piston
member including a platen, whereby the actuable piston member
forces the melted adhesive through the flexible hose between the
first membrane and the overlapping second membrane.
9. The apparatus of claim 1 wherein the extruder includes a helical
screw enclosed within a housing that is heated by electrical
resistance to melt the adhesive.
10. The apparatus of claim 9 wherein the housing is inclined at an
angle and attached to a feed bin wherein the adhesive is fed and
metered through the housing to the nozzle.
11. The apparatus of claim I wherein the TPO is an adhesive formed
of ethylene propylene rubber blended with polypropylene.
12. The process of claim 1 wherein the TPE is a thermoplastic
elastomer consisting of a highly crosslinked rubbery polymer in
combination with a thermoplastic polymer.
13. The process of claim 12 wherein the crosslinked rubbery phase
is a polymer comprised of ethylene-propylene-diene termonomer and
the thermoplastic polymer is a polyolefin.
14. A process of adhering a first membrane and an overlapping
second membrane by applying a TPO or TPE adhesive, the process
comprising the steps of: providing a first membrane; providing a
second membrane over the first membrane so as to overlap portions
of the first membrane; providing an apparatus including a movably
supported chassis and an extruder attached to the chassis including
a nozzle having an outlet; positioning the outlet between the first
and second membranes; and forcing TPO or TPE adhesive through the
outlet to apply the TPO or TPE adhesive to hold the overlapping
portions of the first and second membranes together.
15. The process of claim 14 wherein the first and second membranes
are single ply sheets of ethylene-propylene diene terpolymer.
16. The process of claim 14 wherein the TPO is an adhesive formed
of ethylene propylene rubber blended with polypropylene.
17. The process of claim 14 wherein the TPE is a thermoplastic
elastomer consisting of a highly crosslinked rubbery polymer in
combination with a thermoplastic polymer.
18. The process of claim 17 wherein the crosslinked rubbery phase
is a polymer comprised of ethylene-propylene-diene termonomer and
the thermoplastic polymer is a polyolefin.
Description
FIELD OF THE INVENTION
[0001] This invention relates to an apparatus for applying TPO or
TPE based solid phase adhesive to a single-ply roofing membrane.
More particularly, this invention relates to an apparatus for
applying the adhesive layer between overlapping talc-free roofing
membranes of a membrane roofing system to form a seam and a method
of using the same.
BACKGROUND OF THE INVENTION
[0002] A roof system generally includes a roof deck that is
considered the structural supporting surface of a building
extending between surrounding exterior walls of the building. The
roof deck may be constructed from plywood, metal decking or
concrete or any other suitable material. Depending upon the
construction, the roof deck may extend over the surrounding
exterior walls or the roof deck may stop short of the exterior
walls thereby forming a parapet wall, i.e., a low retaining wall at
the edge of the roof deck. If desired, the roofing system may also
include an insulation barrier formed from polyisocyanurate or any
other suitable material applied over the roof deck.
[0003] To make the roof system weather resistant, a single-ply
membrane roof may be installed over the roof deck. A single-ply
membrane roof refers to a water impermeable single sheet of
polymeric material such as thermoplastic olefins, chlorinated
polyethylene, polyvinyl chloride, chlorosulfonated polyethylene or
ethylene propylene diene rubber (EPDM). The membrane roof may be
mechanically fastened over the roof deck using a variety of
different methods well known in the art.
[0004] When applying the membrane roof to the roof deck, it is
usually necessary to splice together roofing membranes to form a
single continuous field of the membrane roof An example of this
would be cured EPDM sheets. It will be appreciated that the splice
or seam area is subjected to both short term and long term stresses
such as those caused by roof movement, heavy winds, freeze thaw
cycling and thermal cycling. Such stresses may manifest themselves
in shear forces or peel forces, i.e., the seam peels back under
severe stress conditions or may cause a partially open seam under
less severe conditions.
[0005] In view of the foregoing problem, it has been necessary to
apply an adhesive to splice the cured EPDM roofing membranes
together. The adhesive for splicing cured EPDM roofing membranes
together must be capable of being simply and/or economically
applied in the field to provide an acceptable adhesive bond. The
applied adhesive must provide sufficient seam peel and shear
strength such that the spliced EPDM roofing membranes resist both
the short term and long term stresses. Moreover, the applied
adhesive must be resistant to oxidation, hydrolysis and chemical
attack from pooled water.
[0006] In accordance with one object of the present invention, an
apparatus is provided for continuously applying TPO or TPE adhesive
between talc-free overlapping edges of roofing membranes (e.g. EPDM
sheets). In accordance with another object of the present
invention, an apparatus is provided for continuously applying a TPO
(thermoplastic olefin) or TPE (thermoplastic elastomer) adhesive
between overlapping edges of EPDM roofing membranes. It is another
object of the present invention to provide an applicator for
applying a TPQ or TPE adhesive between overlapping single-ply EPDM
roof membranes to form a seam in the field. Yet another object of
the present invention is to provide an applicator and method for
applying a TPO or TPE adhesive that is simple to use and economical
to manufacture.
SUMMARY OF THE INVENTION
[0007] Briefly, the present invention relates to an apparatus
capable of applying a TPO or TPE adhesive between a talc-free first
membrane and an overlapping talc-free second membrane. The
apparatus includes a movably supported chassis and an extruder
attached to the chassis having a nozzle including an outlet having
at least one opening for applying the TPO or TPE adhesive between
the first membrane and the overlapping second membrane to adhere
the overlapping second membrane to the first membrane.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] Further features and other objects and advantages of this
invention will become clear from the following detailed description
made with reference to the drawings in which:
[0009] FIG. 1 is a perspective view of one embodiment of a TPO or
TPE hot melt applicator; and
[0010] FIG. 2 is a perspective view of another embodiment of a TPO
or TPE hot melt applicator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0011] In the following description, like reference characters
designate like or corresponding parts. Also in the following
description, it is to be understood that such terms as "forward",
"rearward", and the like, are words of convenience and are not to
be construed as limiting terms apart from the invention as claimed.
The present invention is directed to an applicator 10 for applying
TPO or TPE adhesive between overlapping first and second membranes
12 and 14 to form a continuous sheet of a single-ply membrane that
may be installed over a roof deck 16 or other roofing
structure.
[0012] As used herein, "TPO" refers to adhesive formed of ethylene
propylene rubber blended with polypropylene and TPE refers to a
thermoplastic elastomer consisting of a highly crosslinked rubbery
polymer in combination with a thermoplastic polymer. The
crosslinked rubbery phase may be a polymer comprised of
ethylene-propylene-diene termonomer and the thermoplastic polymer
may be a polyolefin. In addition, the first membrane 12 and the
second membrane 14 refer to water impermeable single-ply sheets of
ethylene propylene diene terpolymer (EPDM). An important aspect of
the present invention is that the roofing membranes of EPDM are
"clean" sheets, i.e.; the sheets do not include talc or other
treatments typically applied thereto in well known manufacturing
operations of EPDM roofing membranes. The roofing membranes may be
of any suitable length and width as desired subject to
manufacturing and performance considerations. For a more detailed
description of the manufacturing process of EPDM roofing membranes,
reference is made to U.S. Pat. Nos. 4,337,112 and 4,343,667,
incorporated herein by reference.
[0013] Referring to the figures, the apparatus 10 includes a
chassis 18 that is movably supported by wheels. In a preferred
embodiment, the chassis 18 is movably supported by a set of two
spaced rear wheels 20 and 22 and a set of two spaced forward wheels
24 and 26. The rear wheels 20 and 22 and forward wheels 24 and 26
are mounted to the underside of the chassis 18 adjacent to each
corner of the chassis using most any suitable means well known in
the art. The chassis 18 is preferably of a one-piece frame member
construction. The frame member may be formed of most any suitable
material such as cast aluminum and the like.
[0014] Referring to FIG. 1, extending generally upward from the
chassis 18 is a guide handle 28 at the end of which is a grip 30.
In a preferred embodiment, the guide handle 28 is an aluminum rod
and is mounted to a threaded boss on the chassis 18. The chassis 18
may be motor driven by a heavy duty electrical motor 32 of a type
well known in the art. The motor 32 drives at least one wheel for
movably transporting the chassis 18. The motor 32 is operatively
coupled to at least one of the wheels through a gear transmission
that is selectively engaged or disengaged with a drive axle by a
transmission lever. The motor 32, thus, operates to drive at least
one of the wheels and to move the apparatus 10 in the forward
direction. As the apparatus 10 moves forward, it is guided by
manipulation of the guide handle 28.
[0015] Attached to the chassis 18 is an extruder 34 for
continuously extruding the TPO or TPE adhesive. The extruder 34 is
operatively connected to a nozzle 36 including an outlet 38 having
at least one rectangular opening 40 to apply a thin wide bead of
adhesive for selective distribution of the TPO or TPE adhesive
between the overlapping membranes 12 and 14.
[0016] In one embodiment, the extruder 34 includes a helical screw
42. The helical screw 42 is enclosed within a housing 44 that is
heated by electrical resistance to melt the TPQ or TPE adhesive to
a desired temperature. The housing 44 is inclined at an angle and
attached to a feed bin 46 wherein TPO or TPE adhesive is fed and
metered through the housing to the nozzle 36. A control panel 48 is
mounted to the chassis 18 for adjusting the speed and temperature
of the apparatus 10. For example, the temperature of the housing,
as produced by the heating element may be controlled by a
thermostat, rheostat, or a potentiometer and the like operatively
connected to a control knob of the control panel 48.
[0017] In a preferred embodiment, as shown in FIG. 1, the apparatus
10 may also include a press wheel 50. Depending upon the
application conditions, the press wheel 50 may be bifurcated or the
press wheel may be formed as a single wheel. It will be appreciated
that the press wheel 50 may be bifurcated to allow a roof membrane
fastener of a type well known in the art to pass between the press
wheel and to simultaneously press the first membrane 12 and the
second membrane 14 against the roof deck 16 on both sides of the
roof membrane fastener. The press wheel 50 is located rearward of
the nozzle 36 relative to the direction of movement of the
apparatus 10 and in front of the outlet 38 of the nozzle to press
the first membrane 12 and the second membrane 14 firmly against the
roof deck 16 and against each other after the adhesive has been
applied. As a further aid in maintaining as much pressure on the
roof membranes 12 and 14 as possible, one or more weights may be
affixed to the chassis over the press wheel 50. The press wheel 50
may be rotatable on a single axle operatively attached to the
chassis 18 or rotatable on separate axles operatively attached to
the chassis.
[0018] In yet another embodiment, the extruder 34 includes an
open-end housing 52 having an actuatable piston member 54. The
piston member 54 is sized to match the internal diameter of the
open-end of the housing 52 and movable axially within the housing.
The piston member 54 includes a heated plunger or platen to melt
the polymer. In an alternate embodiment, the entire reservoir and
hose can be heated to melt the polymer. The plunger or platen is
attached to the piston member 54 and forces the melted adhesive
through a heater hose and between the sheets forming the seam. The
thickness of the applied adhesive layer should be about 0.1 to 30
mils, preferably about 2 to 10 mils. The width of the adhesive
should be sufficient to provide dimensional stability to the
overlapped sheets.
[0019] Attached to the top surface of the piston member 54 is a
notched bar 56. The notched bar 56 is operatively attached to a
motor 32 as well known in the art to incrementally force the piston
member downward within the housing 52 thereby forcing the TPO or
TPE adhesive Out of the housing and through the flexible hose to
the nozzle 36.
[0020] The apparatus contains a heated moveable plunger or platen
to melt the polymer. The plunger or platen is attached to the
piston and forces the molten adhesive through a heated hose and it
is dispensed in the area between the sheets forming a seam. The
thickness of the final adhesive layer should be about 0.1 to 30
mils, more preferred is 2 to 10 mils. The width of the adhesive
should be sufficient to provide dimensional stability to the
overlapped sheets. Alternatively, the entire reservoir and hose can
be heated to melt the polymer.
[0021] The first membrane 12 is typically placed on the roof deck
16 first. It will be appreciated that the first membrane 12 may
have at least one roof membrane fastener 18 secured through the
first membrane and to the roof deck to mechanically fasten the
membrane to the roof deck. The roof membrane fastener 18 may be of
most any suitable size and type depending upon membrane roof system
performance requirements. For example, the roof membrane fastener
18 may be of a type well known in the art such as a batten bar or
seam disc size and the like and may vary from about 1 inch to about
4 inches or more in width. The second membrane 14 is then
positioned in overlapping relation over a portion of a marginal
edge of the first membrane 12. After the first and second membranes
12 and 14 have been laid in an overlapping relation, the nozzle 36
of the apparatus 10 is inserted between the first and second
membranes 12 and 14. The nozzle 36 is then conveyed along and
between the first and second membranes 12 and 14. The nozzle 36
applies a thin, wide bead of TPO or TPE adhesive through the outlet
38 to adhere the overlapping portions of the first and second
membranes 12 and 14 together. It will be appreciated that one may
control the amount of adhesive being applied to the membranes 12
and 14 by adjusting the speed of rotation of the screw 42 or amount
of pressure applied by the piston 54.
[0022] The patents and documents described herein are hereby
incorporated by reference.
[0023] Having described presently preferred embodiments of the
invention, it is to be understood that it may be otherwise embodied
within the scope of the appended claims.
* * * * *