U.S. patent application number 11/333603 was filed with the patent office on 2007-08-02 for self-stick metal plate and method of applying the same.
This patent application is currently assigned to BUILDING MATERIALS INVESTMENT CORPORATION. Invention is credited to Vijay G. Shah.
Application Number | 20070175170 11/333603 |
Document ID | / |
Family ID | 38320634 |
Filed Date | 2007-08-02 |
United States Patent
Application |
20070175170 |
Kind Code |
A1 |
Shah; Vijay G. |
August 2, 2007 |
Self-stick metal plate and method of applying the same
Abstract
A coated metal plate is provided as a mechanical fastening
device for a roof deck. The top side of the metal plate can have a
coated layer, and the bottom side of the metal plate has an
adhesive layer. The adhesive layer is covered by a film, which is
removable and can be peeled off at the time of installation. The
bottom side of the metal plate is attached to the roof deck by the
adhesive layer, and a roofing membrane is heat welded to the coated
top side of the metal plate. The disc shaped metal plate can have a
hole in the center of the plate, and a fastening device such as a
screw can extend through the hole and attach the metal plate to the
roof deck for additional support.
Inventors: |
Shah; Vijay G.; (Parlin,
NJ) |
Correspondence
Address: |
GAF MATERIALS CORPORATION;Attn: William J. Davis, Esq.
Legal Department
1361 Alps Road, Building No. 8-2
Wayne
NJ
07470
US
|
Assignee: |
BUILDING MATERIALS INVESTMENT
CORPORATION
|
Family ID: |
38320634 |
Appl. No.: |
11/333603 |
Filed: |
January 17, 2006 |
Current U.S.
Class: |
52/741.1 |
Current CPC
Class: |
E04D 5/145 20130101;
E04D 5/148 20130101; E04D 5/147 20130101; E04D 5/143 20130101; F16B
43/00 20130101 |
Class at
Publication: |
052/741.1 |
International
Class: |
E04B 1/00 20060101
E04B001/00 |
Claims
1. A mechanical fastener for a roofing structure, comprising: a
metal plate, the metal plate having a top side and a bottom side;
and an adhesive layer on the bottom side of the metal plate.
2. The mechanical fastener for a roofing structure of claim 1,
further comprising: a coated layer on the top side of the metal
plate.
3. The mechanical fastener for a roofing structure of claim 1,
further comprising: a removable film covering the bottom of the
metal plate having the adhesive layer.
4. The mechanical fastener for a roofing structure of claim 1,
wherein the metal plate is disc shaped.
5. The mechanical fastener for a roofing structure of claim 1,
wherein said adhesive of the adhesive layer is selected from the
group consisting of a butyl compound or other waterproofing
compound such as single component PVAc (polyvinyl acetate)
water-resistant adhesive, water-resistant polyvinyl acetate
adhesive, EVA (ethylene vinyl acetate)-hot melt adhesives, pressure
sensitive hot melt adhesive atactic polypropylene (APP) base
pressure sensitive tapes, polyurethane adhesives, thermoplastic
adhesive film based with co-polyamides, thermoplastic adhesive film
based with mixed polyolefin and co-polyamide, animal base adhesive,
asphaltic base adhesive styrol or verstat acrylate types, and
neoprene rubber cementic base adhesive.
6. The mechanical fastener for a roofing structure of claim 1,
further comprising: a hole at the center of the metal plate
extending from the top side to the bottom side of the metal
plate.
7. The mechanical fastener for a roofing structure of claim 6,
further comprising: a fastening device provided through the
hole.
8. The mechanical fastener for a roofing structure of claim 7,
wherein the fastening device comprises a screw.
9. A method of applying a mechanical fastener to a roof deck, the
method comprising: peeling a film off a bottom side of a metal
plate, the bottom side having an adhesive layer; and attaching the
bottom side of the metal plate having the adhesive layer onto a
roof deck.
10. The method of applying a mechanical fastener to a roof deck of
claim 9, the method further comprising: heat welding a roofing
membrane on a coated top side of the metal plate and the roof
deck.
11. The method of applying a mechanical fastener to a roof deck of
claim 9, the method further comprising: fastening a fastening
device through the metal plate and into the roof deck.
12. The method of applying a mechanical fastener to a roof deck of
claim 11, wherein the fastening device extends through a hole
provided at the center of the metal plate.
13. The method of applying a mechanical fastener to a roof deck of
claim 9, wherein the metal plate is disc shaped.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to mechanical
fasteners, and more specifically, to a peel and stick type of
coated mechanical fastener that secures a flexible sheet or
membrane to the roof without penetrating the membrane and to a
method of applying the same.
[0003] 2. Prior Art
[0004] A roofing system generally includes a roof deck which is
considered the structural supporting surface of a building
extending between the 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 polyisocyanarate or any
other suitable material applied over the roof deck.
[0005] To make the roof deck and building weather resistant a
single-ply membrane roof is installed over the roof deck. The
single-ply membrane roof refers to a water impermeable single sheet
of polymeric material such as ethylene propylene diene rubber
(EPDM) having a preapplied hot melt adhesive, chlorinated
polyethylene, polyvinyl chloride, or chlorosulfanated polyethylene.
The membrane roof has heretofore been installed on the roof deck
using a variety of different methods.
[0006] For example, the field or interior of the membrane roof may
be held to the roof deck by the use of ballast and/or penetrating
or non-penetrating fastener means as known in the art. A large
number of commercial and factory plant roofs are of a flat roof
design wherein the roofing material itself is often of a built-up
asphalt and in more modern systems of a single ply EPDM elastomeric
sheet or membrane. Adhered roof membrane retention systems suffer
from the cost penalty while mechanical fasteners and related
fastening systems generally require fixation to the roofing
substrate via mechanical fasteners. Mechanical fastening is
extensively used in conventional single ply membrane roof
assemblies. Low slope roof membranes like TPO or PVC are usually
mechanically fastened at the roof to limit thermally induced
lateral movement. Mechanical fastening reduces the bulk of material
required in the roof and may also reduce or avoid the need for hot
bitumen.
[0007] There are two basic kinds of mechanical fasteners, namely,
membrane penetrating and non-penetrating ones. Each of these types
of fasteners has a number of favorable features and each of them is
also subject to various drawbacks and disadvantages.
[0008] Mechanical fastening systems of the penetrating type
generally require fixation to the roofing substrate by a metal
fastener with metal or rubberized nailing strips. Penetrating type
fastening systems use various rigid and semi-rigid members to
secure the membrane to the roof. These systems require openings to
be formed in the membrane either for receiving a fastening plate or
by the attaching anchoring members.
[0009] An example of a penetrating fastener means for retaining the
field of a membrane roof installed to a roof deck is by utilizing a
plurality of small, circular, metal plates having a hole in the
center and a roofing screw or other suitable fastener. In order to
anchor the membrane roof, the small, circular, metal plates are
spaced apart in rows on the membrane roof and the fastener is
driven through the hole in each plate, the membrane roof, any
insulation material and then into the roof deck. The metal plates
are then covered by overlapping roof membrane. An example of a
non-penetrating fastener means would include totally adhering the
field of the membrane roof to the roof deck.
[0010] An important consideration for a mechanically fastened
membrane roof system is that the system withstand wind uplift
forces. Consequently, in order to withstand wind uplift forces the
membrane is typically fastened to the deck at close intervals over
the entire membrane surface thereby minimizing the areas of
membrane not secured to the roof deck. If the membrane sheets are
secured only along the longitudinal edges the width of the membrane
sheets should be restricted to a dimension of about 5-6 feet in
order to ensure adequate resistance to uplift in the membrane
between fastening locations.
[0011] Although the many known variations for attaching a membrane
roof to a roof deck may perform satisfactorily under certain
conditions, further improvements on attaching a membrane roof to a
roof deck are desired as several problems occur in the mechanical
fasteners in the prior art. Mechanically fastened membranes are
subject to billowing from wind up lift forces which stress the
membrane, plates and the fasteners. Mechanical fasteners that are
adhered to the underside of the membrane may also create problems
if the fasteners pull out of the deck and subsequently puncture the
membrane. Mechanical fasteners that puncture the roof membrane may
create weak points in a waterproofing system. Further, the
possibility of cold surfaces at the inside ends of the plates along
with fasteners raises the likelihood of condensation and
corrosion.
[0012] Although both the penetrating and non-penetrating type
fastening systems do work satisfactory for some applications, it is
desirable to have a non-penetrating system that provides a reliable
and secure attachment between the roof deck and the roofing
membrane. Therefore, there is a need in the roofing industry for a
non-penetrating mechanical fastening system that provides for a
proper dependable attachment between the roof deck and the roofing
membrane.
SUMMARY OF THE INVENTION
[0013] One object of the present invention is to provide an
inexpensive mechanical fastener of improved durability and improved
resistance to wind uplift forces. Yet another object of the present
invention is to provide a mechanical fastener that does not
penetrate the roofing membrane or roof deck in order to prevent
leaking in the roof structure. Another object of the present
invention is to provide an improved method of securing a membrane
roof to a roof deck in a manner which reduces labor and material
costs. It is a further object of the present invention to provide
an improved mechanical fastener that provides a strong and improved
attachment between the roofing membrane and roof deck. Yet another
object of the present invention is to provide a method of
installing a membrane roof to a roof deck that is simple and
economical.
[0014] Accordingly, a mechanical fastener for a roofing structure
is provided, the mechanical fastener comprising a metal plate, the
metal plate having a top side and a bottom side, and an adhesive
layer on the bottom side of the metal plate. The mechanical
fastener can have a coated layer on the top side of the metal
plate.
[0015] The mechanical fastener further comprises a removable film
covering the bottom of the metal plate having the adhesive layer.
The metal plate can be disc shaped, square, reef or any other shape
known in the art. The adhesive of the adhesive layer is selected
from the group consisting of a butyl compound or other
waterproofing compound such as single component PVAc (polyvinyl
acetate) water-resistant adhesive, water-resistant polyvinyl
acetate adhesive, EVA (ethylene vinyl acetate)-hot melt adhesives,
pressure sensitive hot melt adhesive atactic polypropylene (APP)
base pressure sensitive tapes, polyurethane adhesives,
thermoplastic adhesive film based with co-polyamides, thermoplastic
adhesive film based with mixed polyolefin and co-polyamide, animal
base adhesive, asphaltic base adhesive styrol or verstat acrylate
types, and neoprene rubber cementic base adhesive.
[0016] The mechanical fastener further comprises a hole at the
center of the metal plate extending from the top side to the bottom
side of the metal plate, and a fastening device can be provided
through the hole. The fastening device can comprise a screw, nail,
or any other similar device.
[0017] Additionally, a method of applying a mechanical fastener to
a roof deck is provided, the method comprising peeling a film off a
bottom side of a metal plate, the bottom side having an adhesive
layer, and attaching the bottom side of the metal plate having the
adhesive layer onto a roof deck.
[0018] The method further comprises heat welding a roofing membrane
on a coated top side of the metal plate and the roof deck. The
method further comprises fastening a fastening device through the
metal plate and into the roof deck. The fastening device extends
through a hole provided at the center of the metal plate.
[0019] The above and other features of the invention, including
various novel details of construction and combinations of parts,
will now be more particularly described with reference to the
accompanying drawings and pointed out in the claims. It will be
understood that the particular device embodying the invention is
shown by way of illustration only and not as a limitation of the
invention. The principles and features of this invention may be
employed in various and numerous embodiments without departing from
the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] These and other features, aspects, and advantages of the
apparatus and methods of the present invention will become better
understood with regard to the following description, appended
claims, and accompanying drawings where:
[0021] FIG. 1(a) illustrates a top view of a metal plate in
accordance with a first embodiment of the present invention;
[0022] FIG. 1(b) illustrates a bottom view of the metal plate
having an adhesive covered by a film in accordance with the first
embodiment of the present invention;
[0023] FIGS. 2(a)-2(c) illustrate a second embodiment of the metal
plate of the present invention;
[0024] FIGS. 3(a)-3(b) illustrate a method of application of the
first embodiment of the present invention to a roof deck; and
[0025] FIGS. 4(a)-4(b) illustrate a method of application of the
second embodiment of the present invention to a roof deck.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0026] Although this invention is applicable to numerous and
various types of roofing structures, it has been found particularly
useful in the environment of the attachment of roofing membranes to
a roof deck. Therefore, without limiting the applicability of the
invention to the above, the invention will be described in such
environment.
[0027] With reference now to the drawings, the metal plate
mechanical fastener of the present invention will be described.
FIG. 1(a) illustrates a top side 101 of a metal plate 100 used as a
mechanical fastener for roofing membranes. The metal plate 100 is
preferably disc shaped, and approximately 1 inch to 12 inches in
diameter, and preferably 1 to 3 inches. The top side 101 of the
metal plate 100 can be coated with a plastic material. Examples of
materials that can be used to coat the top side 101 are plastic,
thermoplastic olefins, and polyvinyl chloride.
[0028] FIG. 1(b) illustrates a bottom side 102 of the metal plate
100 having an adhesive layer covered by a film 103. The bottom side
102 contains an adhesive layer on the surface of the bottom side
102 of the metal plate 100. The adhesive layer may be a butyl
compound or other waterproofing compound such as single component
PVAc (polyvinyl acetate) water-resistant adhesive, water-resistant
polyvinyl acetate adhesive, EVA (ethylene vinyl acetate)-hot melt
adhesives, pressure sensitive hot melt adhesive atactic
polypropylene (APP) base pressure sensitive tapes, polyurethane
adhesives, thermoplastic adhesive film based with co-polyamides,
thermoplastic adhesive film based with mixed polyolefin and
co-polyamide, animal base adhesive, asphalted base adhesive styrol
or overstate acryl ate types, neoprene rubber cementic base
adhesive.
[0029] The use of the adhesive layer in accordance with the present
invention provides a water resistant, strong and uniform adherence
of the bottom side 102 of the metal plate 100 to a roof deck. The
entire surface of the bottom side 102 is covered with a plastic
film 103, which covers and protects the adhesive layer from drying
before application of the metal plate to the roofing membrane. The
film 103 is removed during application of the metal plate 100. The
non penetrating metal plate 100 provides a quick and easy
installation of the metal plate 100 to a roof deck. The bottom side
102 having the adhesive layer is attached to a top of a roof deck
and/or insulation board, and a roofing membrane may be welded on
the top side 101 of the metal plate 100 having a coated layer,
which will be described in more detail later.
[0030] FIG. 2(a) illustrates a second embodiment of the metal plate
of the present invention having a fastener. FIG. 2(a) shows a metal
plate 200 having a top side 201 which can have a coated layer.
Additionally, a fastening device 204 is provided at the center 205
of the metal plate 200. Any known fastening device 204 can be used
as known to one of ordinary skill in the art, such as a screw. The
fastening device 204 preferably goes through the center 205 and
through the entire metal plate 200 from the top side 101 extending
through the bottom side 102, and screws onto the roof deck to
attach the metal plate 200 to the roof deck.
[0031] FIG. 2(b) illustrates a side view of the second embodiment
of the metal plate 200. FIG. 2(c) illustrates a bottom view of the
second embodiment of the metal plate 200, having a bottom side 202
and a film 203 that covers the adhesive layer on the bottom side
202 of the metal plate 200. The mechanical fastener 204 penetrates
through the entire metal plate 200 through the center 205. The
mechanical fastener attaches the metal plate 200 to the roof deck.
The mechanical fastener provides support in addition to the
adhesive layer on the bottom side 202 of the metal plate 200 in
attaching the metal plate 200 to the roof deck.
[0032] A method of application of the first embodiment of the metal
plate of the present invention is illustrated in FIGS. 3(a)-3(b).
As shown in FIG. 3(a), the metal plate 100 is to be positioned upon
the roof deck 301. As known in the art, insulation 302 may be
applied over the roof deck 301 as desired. Examples of suitable
insulation materials include polyurethane, polystyrene, wood
fiberboard, polyisocyanarate and the like. Usually, at an outer
perimeter of the roof deck 301 is a wall (not shown) which extends
generally perpendicularly upward from the roof deck 301 above the
plane of the roof deck 301.
[0033] The film 103 is then removed from the bottom side 102 of the
metal plate 100, and the bottom side 102 is attached to the top
surface 302a of the insulation 302. The adhesive layer on the
bottom side 102 of the metal plate 100 attaches the metal plate 100
to the insulation 302, or roof deck 301 if insulation 302 is not
used. The top side 101 has a coated layer, as described
earlier.
[0034] As shown in FIG. 3(b), a roof membrane assembly 303 is
positioned upon the roof deck 301 or insulation 302, and on the top
side 101 of the metal plate 100. The roof membrane assembly may
comprise one or more roof membranes. The roof membrane(s) can be
water impermeable single-ply sheets of polymeric material such as
thermoplastic olefins, chlorinated polyethylene, polyvinyl
chloride, or chlorosulfanated polyethylene or ethylene propylene
diene rubber (EPDM) having a preapplied hot melt adhesive such as a
commercially available polyester or butyl hot melt and the like.
The sheets may be of any suitable length and width as desired. It
will be appreciated that the width of each sheet may be as wide as
desired subject to manufacturing constraints. Moreover, it will be
appreciated that it is a feature of the present invention that any
number of roof membrane assemblies may be placed in overlapping
relation and bonded to form a preassembled continuous membrane
thereby further simplifying field installation.
[0035] After the roof membrane assembly 303 is placed on top of the
metal plate 100, the roof membrane assembly 303 is then bonded to
the roof deck 301 or insulation 302 using any suitable technique
well known in the art. In a preferred embodiment, the roof membrane
assembly 303 is heat welded to the roof deck 301 or insulation 302
by using a conventional electric heat welder (not shown) which
applies heat through a single nozzle to the overlapping roof
membrane assembly 303 and compresses the roof membrane assembly 303
to aid in making a good bond or weld. Thus, the metal plate 100
provides a non-penetrating and leak-proof attachment between the
roof deck 301 and the roof membrane 303.
[0036] FIGS. 4(a)-4(b) shows a method of application of the second
embodiment of the metal plate 200 as illustrated in FIG. 2. In FIG.
4(a), the film is removed from the bottom side of the metal plate
200, and the bottom side is attached to the top surface 402a of the
insulation 402, similar to FIG. 3(a). The adhesive layer on the
bottom side of the metal plate 200 attaches the metal plate 200 to
the insulation 402, or roof deck 401 if insulation 402 is not used.
The top side 201 has a coated layer, as described earlier.
[0037] Further, at least one fastening device 204 is secured
through a center 205 of the metal plate and into the roof deck 401
and the insulation 402. The fastening device 204 may include a
plurality of conventional threaded fasteners and seam discs for
securing the metal plate to the roof deck, a plurality of
conventional threaded fasteners and one or more batten bars or, if
desired, a suitable combination of the foregoing.
[0038] As shown in FIG. 4(a), to install the threaded fastener of
the fastening device 204, the threaded fastener is inserted into a
hole in the center 205 of the plate 200 and into the roof deck 401.
Similar to FIG. 3(b), as shown in FIG. 4(b), a roof membrane
assembly 403 is positioned upon the roof deck 401 or insulation
402, and on the top side 201 of the metal plate 200. After the roof
membrane assembly 403 is placed on top of the metal plate 200, the
roof membrane assembly 403 is then bonded to the roof deck 401 or
insulation 402 using any suitable technique well known in the art,
as described above, such as heat welding.
[0039] The fastening devices 204 can be installed in the roof deck
401 or insulation 402 at a spacing ranging from approximately every
6 inches to every 16 inches depending upon the wind uplift forces
experienced by the roof membrane assembly 403. Under typical
conditions, the preferred fastening device 204 spacing is about
every 12 inches regardless of the fastening device used. It will be
appreciated that because the distance between fastening devices 204
can be substantially increased over distances typically used in the
past because of the adhesion provided on the metal plates, the time
and labor typically required for the installation of the fastening
devices is greatly reduced, and since this is a manual on site
operation, a large amount of the installation cost is saved.
[0040] The present invention provides several advantages that solve
the problems with prior art methods. Some of the advantages include
providing a mechanical fastener having self adhere coated metal
plates that increase adhesion from both the top side and bottom
side of the metal plate. The metal plates have the advantage of not
interrupting the component layers in the roof assembly since they
are peel and stick.
[0041] Further, the peel and stick coated metal plates of the
present invention have the advantage of performing the dual
functions of securement from top to end layer due to the coated top
side of the metal plate, which will weld to the bottom surface of
the roof, whereas the peel and stick side of the plate will adhere
to the cap sheet of the under layer of the roof. Thus, the first
overlap or seam area is locked from the bottom of the plate due to
adhesion and from the top of the plate due to the coated metal
welding. This increases the peel strength and ply adhesion of the
metal plates, which help increase the win up lift rating.
Additionally, the peel and stick coated metal plates help to
control condensation in a roof, due to the gum effect of the
adhesive barrier. Even in the penetrating type metal plates used
with the fastener, the adhesion is located as a sandwich between
the cap and fastener bottom, and provides thermal insulation, as
the melted adhesive adheres to the fasteners.
[0042] The above description of the present invention is only the
preferred embodiment of the invention. Embodiments may include any
currently or hereafter-known versions of the elements described
herein. Different adhesives may be used on the bottom side of the
metal plates, different size metal plates may be used, and
different types of coatings may be used on the top side of the
metal plates. Also, different types and sizes of fasteners may be
used where appropriate. Further, the metal plates are not limited
to mechanical fasteners between the roof deck and roof membrane
assembly, buy may also be used as a patch between two or more roof
membranes.
[0043] While there has been shown and described what is considered
to be preferred embodiments of the invention, it will, of course,
be understood that various modifications and changes in form or
detail could readily be made without departing from the spirit of
the invention. It is therefore intended that the invention be not
limited to the exact forms described and illustrated, but should be
constructed to cover all modifications that may fall within the
scope of the appended claims.
* * * * *