U.S. patent application number 10/826976 was filed with the patent office on 2006-11-16 for composite roof and wall system -- three in one -- fireproof, insulation, and waterproofing.
Invention is credited to Jian W. Mulligan.
Application Number | 20060254207 10/826976 |
Document ID | / |
Family ID | 37417734 |
Filed Date | 2006-11-16 |
United States Patent
Application |
20060254207 |
Kind Code |
A1 |
Mulligan; Jian W. |
November 16, 2006 |
Composite roof and wall system -- three in one -- fireproof,
insulation, and waterproofing
Abstract
A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, which combines fireproof,
waterproofing and insulation into one system comprising expanded
polystyrene (EPS) foam insulation board; tough waterproofing
membrane applied onto the board surface; polyester woven mesh, the
reinforcement medium laid over tough waterproof surface; covered by
the tough cover, the system's protective part applied onto the
mesh. This system can be directly applied onto any existing roof
and wall substrate; or pre-constructed into boards, shingles and
tiles using tough water proof material to adhere to the existing
roof or wall substrate. This system is nail free to avoid leaking
problems, survives physical and weather damages. Pigment can be
either mixed with the tough cover or applied onto the surface of
the cover. It provides an environmentally safe, lightweight,
comparatively inexpensive, energy saving, form flexible and long
lasting roof and wall systems, which conserve natural
resources.
Inventors: |
Mulligan; Jian W.; (Long
Beach, CA) |
Correspondence
Address: |
William Mulligan;Advanced Construction Products, Inc.
P. O. Box 3642
Long Beach
CA
90803
US
|
Family ID: |
37417734 |
Appl. No.: |
10/826976 |
Filed: |
May 2, 2005 |
Current U.S.
Class: |
52/794.1 ;
52/309.8 |
Current CPC
Class: |
E04D 11/02 20130101 |
Class at
Publication: |
052/794.1 ;
052/309.8 |
International
Class: |
E04C 1/00 20060101
E04C001/00 |
Claims
1. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, comprising an expanded polystyrene
foam board adhered onto the existing roof deck or wall by using a
tough modified bitumen waterproofing membrane coating as the
adhesive to glue onto the existing roof or wall substrate and
connected with each other by construction tape, such as butyl tape,
or by using the modified bitumen waterproofing membrane coating to
seal the seams between the foam boards; the waterproofing membrane
is fully brushed, rolled or sprayed over the foam boards with a
mesh material placed over said tough waterproof membrane coating
for reinforcement; and a composition of cement, clay, perlite,
sand, etc. to form a tough cover is placed over the mesh by
brushing or rolling or spraying onto said system to protect if from
fire, physical and weather damages.
2. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, comprising according to claim 1
wherein said expanded polystyrene foam board must be rigid and
non-flammable and is between 2 inches to 8 inches in thickness,
placed on the surface of said tough waterproof membrane coating
freshly and well brushed or rolled or sprayed onto the surface of
the existing roofs or walls as the first waterproofing coating.
3. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, comprising, according to claim 1
wherein said tough waterproofing material is made of modified
asphalt emulsion with natural and synthetic resins, applying two to
three times onto the roof or wall surface using 0.125 to 0.25
gallon per square yard.
4. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1 wherein said
reinforcement medium mesh is woven polyester type of mold and
mildew free and non-flammable or non-combustible having a weight
between 0.01 to 1 ounces per square yard depending on the
needs.
5. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1 wherein said
lightweight tough coat comprising cement, clay, silicate (perlite),
sand, etc., mixed with water to make it into paste form at job site
and having a thickness of said paste between 0.125 inches to 0.75
inches, using said lightweight tough coat mixture between 3 to 10
pounds per square yard and allowing twenty days or so to be fully
cured.
6. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1, claim 2, claim
3, claim 4 and claim 5, said tough waterproofing membrane coating
having excellent elongation ability and tough cover featuring fire
and ultra violet related weather resistance, said foam board
insulation being not necessary needed for the flat or inclined
roofs or walls.
7. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claims 1 through 5, said
system also being pre-constructed into the forms of boards,
shingles or tiles.
8. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1, claim 2 and
claim 6, said expanded polystyrene foam boards used as the base of
said boards, shingles or tiles.
9. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1, claim 3 and
claim 7, tough waterproofing coating is applied to the surface of
said board by brushing, rolling or spraying onto the surface of
said board, playing the waterproofing role of said system.
10. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 1, claim 4 and
claim 8, said mesh material is laid over the surface of the tough
waterproof coating when freshly applied.
11. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to all the above claims,
said tough cover, a protective lightweight concrete coating
material being brushed, or rolled or sprayed onto said mesh laid
over the surface of tough waterproof membrane coating to avoid any
physical or weather damages, said system of said boards, shingles
and tiles being formed after a natural curing period of 20 days at
10.0 or higher centigrade degrees.
12. A composite roof and wall system, three-in-one: fireproof,
insulation and waterproofing, according to claim 11, said system of
pre-constructed boards, shingles and tiles laid over the existing
roofs or walls, using a tough waterproof membrane coating to adhere
and said tough waterproofing coating being well applied onto the
surface of the existing roofs or walls to double the waterproofing
of said composite roof and wall system, whereby a structure will
have strong three-in-one: fireproof, insulation and waterproofing,
system.
Description
REFERENCES CITED [REFERENCED BY]
[0001] U.S. Patent Documents [0002] U.S. Pat. No. 4,712,349
December, 1987 Riley; Elizabeth; Petersen; Wayne E. [0003] U.S.
Pat. No. 4,965,977 October, 1990 White; Daniel R. [0004] U.S. Pat.
No. 5,215,805 June, 1993 Pavia, Jr.; Alfred [0005] U.S. Pat. No.
5,251,416 October, 1993 White; Daniel R. [0006] U.S. Pat. No.
5,735,092 April, 1998 Clayton; Thomas M.; Letts; John B. [0007]
U.S. Pat. No. 5,787,668 August, 1998 Carkner; Philip M.; Corley;
Todd L.; Dudley; Hubert T.; Kersey; Timothy L. [0008] U.S. Pat. No.
5,822,943 October, 1998 Frankoski; Stanley P.; Jolitz; Randal J.
[0009] U.S. Pat. No. 6,044,604 April, 2000 Clayton; Thomas M.;
Letts; John B. [0010] U.S. Pat. No. 6,110,846 August, 2000
Brzozowski; Kenneth J.; Chernotowich; Ken [0011] U.S. Pat. No.
6,177,024 January, 2001 Sandoval; Christopher Paul; Bauer; Mary
Margaret Georgene; DePorter; Craig Donald [0012] U.S. Pat. No.
6,256,957 July, 2001 Kelly; Thomas L. [0013] U.S. Pat. No.
6,398,976 June, 2002 Sandoval; Christopher Paul; Bauer; Mary
Margaret Georgene [0014] U.S. Pat. No. 6,418,687 July, 2002 Cox;
Stanley Alfred
TECHNICAL FIELD
[0015] This invention relates to the art of roofing and wall
systems, and more particularly to the application of fireproof,
insulation and waterproof three-in-one roof and wall protective
system.
BACKGROUND OF THE INVENTION
[0016] Waterproofing has been one of the main concerns and
improvement objections in roofing and building development and so
inventions have taken place all the time. However, serious problems
still remain such as leaking, roofing and other related materials
are too heavy, or energy costly, or not environmentally conscious,
and or economically costly. Some attempts have been made to solve
one or some of these problems. Examples to see are: U.S. Pat. Nos.
4,965,977; 5,215,805; 5,735,092; 6,044,604; 6,177,024; 6,398,976
and 6,418,687.
[0017] U.S. Pat. No. 4,965,977 describes a panelized roof system
comprising a foam insulation board with a protective
rubber-modified bitumen-saturated synthetic fiber mat bonded to the
foam board using rubber-modified bitumen-saturated synthetic fiber
strips applied with hot-mopped asphalt to render waterproof.
[0018] U.S. Pat. No. 5,215,805 describes a construction panel
comprising a closed cell, expandable foam material having a first
surface with two coatings to enhance fire resistance abrasion
resistance and a second surface to connect the panel to underlying
structure. This construction panel of cellular structural foam is
objected to be a replacement for ceramic and /or cast concrete
roofing tiles.
[0019] U.S. Pat. No. 5,251,416 describes an insulated panelized
roofing system comprising a foam insulation board with synthetic
fiber mat and a rubber sheet bonded to the top surface completed
with a plurality of fasteners penetrates the sides of the panels
and rendered waterproof by a plurality of synthetic fiber
reinforced rubber strips applied with adhesive or adhesive tape to
the panels' joints.
[0020] U.S. Pat. No. 6,044,604 describes composite roofing recovery
boards having improved dimensional stability and related methods
comprising a foam board with a facer reinforced with a group of
materials and comprising a sheet consisting of reinforced polymer
and cellulosic materials reinforced with a material selected from
glass strands, glass fibers and mixtures thereof and gypsum board
applied to the opposite major surface of the foam core.
[0021] U.S. Pat. No. 6,398,976 describes a single ply membrane
roofing system including a single ply roofing membrane adhered to
the major surface of an insulation board coated with a latex
coating comprising clay, sodium silicate and latex.
[0022] U.S. Pat. No. 6,418,687 describes an insulated roofing
system comprising a closed sell foamed in place insulation applied
over the roof deck or existing substrate. The preferred foamed in
place insulation is a urethane foam.
[0023] All these above and some others teach use of panelized or
closed cell foam board roofing systems.
[0024] All efforts objected to achieve better roofing systems,
which can replace the conventional type of roofing systems
comprising natural materials, which are less and less in supply and
so more and more expensive to afford and, in most cases, cannot or
are difficult to survive from weather deteriorations. Improvement
and progress have been made to make the roofing systems less
expensive but more better in terms of weight, energy saving and
life span. However, problems of leaks, environmental worries,
limited flexibility and some others still exist and need to be
solved. A complete, flexible, environmentally safe, economically
inexpensive and fireproof, insulation and waterproofing
three-in-one composited roof or wall system is needed.
DISCLOSURE OF THE INVENTION
[0025] In accordance with the present invention, applicant provides
a composite fireproof, insulation and waterproof three-in-one roof
and wall system for application over a roof or wall substrate
comprising a protective surfacing material ToughCover, waterproof
material ToughWaterproof, a synthetic fiber mat or any other
non-combustible woven reinforcement material, named mesh in this
invented system and insulation material expanded polystyrene (EPS)
foam insulation board. The flexibility of this system allows the
system applied directly onto a roof or wall surface at a
construction site or pre-constructed into boards, shingles, tiles
and any other shaped forms and using ToughWaterproof material to
adhere them to the existing roof or wall surface at the
construction site. The flexibility of this invented system also
helps to make a heat resistant roof or wall without using EPS foam
board to insulate as the protective cover material ToughCover has
the function to prevent not just fire but resist heat or cold as
well. Plus, the elongation ability of the waterproofing material
ToughWaterproof helps out the system to survive the damages of
thermal changes.
Four Materials Employed and Their Application Methods
[0026] 1. A rubber like fluid named ToughWaterproof, waterproofing
membrane material applied as an emulsion product. It is odorless,
self-adhesive and brush, spray or roller applied. The
characteristics of this coating are environmentally safe, excellent
protection to avoid weather damages to the surface membranes, easy
to apply using spray, brush or roller at a suitable viscosity and
comparatively inexpensive. The cured ToughWaterproof's
characteristics typically are: a. elongation 200-800%; b. durometer
(Die-C) 20-80; c. non-permeable; and d. self adhering.
[0027] 2. A reinforcement medium, constructed of polyester or other
type of non-combustible, mold and mildew resistant fibers, which is
in woven mesh form and, when it is embedded into a film of
elastomeric coating, shall become totally adhered and wrinkle free.
This medium is strong enough to hold the lightweight concrete like
covering material, ToughCover in place, and it is placed between
ToughWaterproof and ToughCover. The mesh plays the role of
reinforcement supporting the attachment of ToughCover to
ToughWaterproof to make the system strong and long lasting.
[0028] 3. ToughCover is the protective surface of the three-in-one
composite roof and wall system. It is mainly a composition of
cement, clay, perlite, sand, etc. At job or construction sites,
ToughCover is mixed with water to make it into paste form, which is
sprayed or rolled onto the mesh, which is overlaid on the
ToughWaterproof, the waterproofing part of the three-in-one system.
This protective surfacing may be applied from one-sixteenth (
1/16th) inch to one (1) inch thick, and it is sufficiently strong
to support normal pedestrian traffic. This ToughCover coating
resists fire; weather damages including ultraviolet (UV) and ozone
degradation, winds' uplift, rain, hail, and other dropped objects'
ruin and provides insulation values by resisting heat buildup
and/or absorption.
[0029] This three-in-one composite system fits both roof and wall
systems and both the materials used and the steps involved for
using them are the same.
[0030] 4. Expanded polystyrene (EPS) foam insulation board is used
to insulate this three-in-one roof and wall system, if it is
desired for an existing roof or wall, or it is used as the base for
pre-constructing said system into tile or shingle and flat or
shaped board forms. While EPS foam board is required to be used as
the base of the pre-constructed system in shingle, or tile or board
forms, it is optional when dealing with flat or slightly sloped
roofs or walls when insulation is not needed or wanted. EPS foam
board gives the three-in-one roof or wall system a surplus of
insulation. The composite roof and wall system is simply done as
following:
[0031] For the non-sloped flat roof, the EPS foam board is pre-cut
precisely according to the slop degree needed to suit water
draining needs of the existing roof. Then, the pre-cut EPS foam
board is glued on the roof surface using ToughWaterproof as the
glue or adhesive material.
[0032] When this fourth material-EPS foam board-is used, the
water-proofing of this three-in-one roof and wall system takes
place after the EPS foam board is placed on the surface of the
existing roof or wall, it (ToughWaterproof) is sprayed on or rolled
on the surface of the EPS foam board. And, the reinforcement medium
material "mesh" is laid on the ToughWaterproof membrane applied
over the EPS foam board. The last step is to spray or roll on the
protective material ToughCover onto the reinforcement medium
material mesh applied on the EPS foam board.
[0033] To make this three-in-one composite roof and wall system
tiles or shingles or wallboards, the first step is to spray or roll
ToughWaterproof onto the pre-cut EPS foam board and place the
pre-cut mesh onto the fresh and wet surface of the ToughWaterproof
applied on the surface of the EPS foam board. Then, ToughCover
pre-mixed paste is brushed or rolled onto the mesh placed on the
Tough-Waterproof. After the tiles or shingles or the wallboards are
made, they can either be dried naturally or put into a pre-heated
oven to dry to the cured degree. The ToughWaterproof is used to
glue these tiles or shingles or wallboard onto the existing roof,
and no nails are needed or allowed.
[0034] These tiles or shingles or wallboards are shaped to overlap
or interlock with each other and the waterproofing material
ToughWaterproof is applied between the EPS foam board as the base
and ToughCover as the surface of the tile or shingle or the
wallboards. A waterproofing membrane on the surface of the existing
roofs or walls is unnecessary, however, as ToughWaterproof material
is used to adhere the pre-constructed shingles, tiles, or boards to
the existing roof or wall substrate. So, the ToughWaterproof is
well rolled or brushed or sprayed onto the existing roof or wall
surface to adhere the pre-constructed shingles, or tiles or walls
to the existing roof or wall surface; in the meantime it doubles
the waterproofing of the roofs or walls.
SUMMARY OF THE INVENTION
[0035] The object of this invention is to provide a "Composite
Roofing and Wall System-Three-in-One--Fireproof, Insulation and
Waterproof," which is energy saving, environmentally safe, weather
resistant rendered, economically inexpensive with a longer
dependable life span.
[0036] In this objected fireproof, insulation and waterproof
three-in-one composite roofing and wall system, EPS foam insulation
board is optional in the case of applying directly onto the
existing roof or wall substrate. ToughWaterproof material can be
directly applied onto the existing roof or wall substrate
reinforced by non-combustible polyester woven mesh and covered by
ToughCover, the protective cover material and the objected
three-in-one composite roof or wall system is constructed. However,
the EPS foam insulation board is recommended to gain energy saving
and to help the waterproofing membrane to last longer.
[0037] This invented system is also objected to pre-construct a
fireproof, insulation and waterproof three-in-one composite system
in shingle, tile or panelized board forms, comprising a pre-cut EPS
foam insulation board in the shape and size desired or wanted,
ToughWaterproof applied onto the EPS foam board surface to get
waterproof membrane done, then the reinforcement medium mesh is
laid over onto the ToughWaterproof material; and ToughCover, the
protective cover material is applied onto the mesh and the
fireproof, insulation and waterproof three-in-one composite roof or
wall system is constructed in shingle, or tile or panelized board
forms. And, at the job or construction site, they can be easily
adhered to the existing roof or wall substrate using
ToughWaterproof as the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1: This system is installed onto the substrate of
existing wood, concrete, metal and many other kinds of roofs or
walls.
[0039] FIG. 2: This system is installed onto an intermediate rigid
foam substrate base surface. The rigid foam is installed onto
ToughCover filled metal deck flutes. However, the foam may also be
mechanically attached directly to the metal deck. The installed
rigid foam insulation becomes the base for receipt of this
system.
[0040] FIG. 3: The system is installed onto a previously installed
rigid foam insulation base.
[0041] FIG. 4: This system is applied onto single-shaped rigid foam
insulation shingle, or tile or flat or shaped board. The completed
shingle or tile or board is then installed onto properly sloped
roof deck or vertical wall substrates.
[0042] FIG. 5 The system is applied onto shingle-shaped rigid foam
insulation shingle. The completed shingle is then installed onto
properly sloped roof deck or vertical wall substrates.
* * * * *