U.S. patent application number 11/735489 was filed with the patent office on 2007-08-16 for method for installing a roofing system.
Invention is credited to Brian S. Alexander, James E. Burkett, Michael J. Hubbard.
Application Number | 20070186505 11/735489 |
Document ID | / |
Family ID | 32995955 |
Filed Date | 2007-08-16 |
United States Patent
Application |
20070186505 |
Kind Code |
A1 |
Hubbard; Michael J. ; et
al. |
August 16, 2007 |
METHOD FOR INSTALLING A ROOFING SYSTEM
Abstract
A roofing system in which a thermoplastic roofing membrane is
affixed to a roof deck can be finished by a method in which two or
more types of roofing peripherals are provided to the roof deck.
Each of the peripherals includes adhesive on at least some portion
thereof, and the adhesive is protected by a release liner. The
release liner is removed from each of the peripherals, and the
peripherals are affixed to the roofing system.
Inventors: |
Hubbard; Michael J.;
(Maumee, OH) ; Burkett; James E.; (Perrysburg,
OH) ; Alexander; Brian S.; (Toledo, OH) |
Correspondence
Address: |
Chief Intellectual Property Counsel
Bridgestone Americas Holding, Inc.
1200 Firestone Parkway
Akron
OH
44317-0001
US
|
Family ID: |
32995955 |
Appl. No.: |
11/735489 |
Filed: |
April 15, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10775206 |
Feb 11, 2004 |
|
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11735489 |
Apr 15, 2007 |
|
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60446277 |
Feb 11, 2003 |
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60446283 |
Feb 11, 2003 |
|
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Current U.S.
Class: |
52/741.4 ;
52/741.3 |
Current CPC
Class: |
Y10T 156/10 20150115;
E04D 5/148 20130101; E04D 13/12 20130101; C09J 7/38 20180101; C09J
2301/408 20200801; Y10T 428/28 20150115; C09J 7/22 20180101; C08K
5/0066 20130101; E04D 5/12 20130101; C08K 5/005 20130101; Y10T
428/1476 20150115; E04D 5/143 20130101 |
Class at
Publication: |
052/741.4 ;
052/741.3 |
International
Class: |
E04G 21/00 20060101
E04G021/00; E04G 23/00 20060101 E04G023/00 |
Claims
1. A method for finishing a roofing system where a thermoplastic
roofing membrane is affixed to a roof deck, said method comprising:
a) providing two or more types of roofing peripherals, each of
peripherals comprising adhesive on at least some portion thereof,
said adhesive being protected by a release liner; b) removing said
release liner from each of said two or more roofing peripherals;
and c) affixing said roofing peripherals to said roofing system,
thereby finishing said roofing system.
2. The method of claim 1 wherein one of said roofing peripherals is
a pipe boot.
3. The method of claim 2 wherein another of said roofing
peripherals is a flashing article.
4. The method of claim 3 wherein another of said roofing
peripherals is a walkway pad.
5. The method of claim 2 wherein another of said roofing
peripherals is a walkway pad.
6. The method of claim 1 wherein one of said roofing peripherals is
a flashing article.
7. The method of claim 6 wherein said flashing article is
semi-rigid.
8. The method of claim 6 wherein said flashing article is a
universal flashing.
9. The method of claim 8 wherein said roof deck comprises two or
more surfaces which are angled with respect to each other and at
least a portion of at least one of said surfaces being covered by
said thermoplastic roofing membrane.
10. The method of claim 9 wherein said roof deck comprises three or
more surfaces, each of which is angled with respect to the others,
said universal flashing being adhered to each of said surfaces.
11. A method for weatherproofing a building, comprising: a)
providing to said building one or more rolls of thermoplastic
roofing membrane and two or more types of roofing peripherals, each
roofing membrane and each of said peripherals comprising adhesive
on at least some portion thereof, said adhesive being protected by
a release liner; b) removing said release liner from said roofing
membrane and adhering said membrane to the roof deck of said
building; and c) removing said release liner from each of said two
or more roofing peripherals and affixing said roofing peripherals
to at least one of said roofing membrane and a structure of said
building not covered by said membrane, thereby waterproofing said
building.
12. The method of claim 11 wherein one of said roofing peripherals
is a pipe boot.
13. The method of claim 12 wherein another of said roofing
peripherals is a flashing article.
14. The method of claim 13 wherein another of said roofing
peripherals is a walkway pad.
15. The method of claim 12 wherein another of said roofing
peripherals is a walkway pad.
16. The method of claim 11 wherein one of said roofing peripherals
is a flashing article.
17. The method of claim 16 wherein said flashing article is
semi-rigid.
18. The method of claim 16 wherein said flashing article is a
universal flashing.
19. The method of claim 18 wherein said building comprises two or
more structures which are angled with respect to each other and at
least a portion of two of said structures being covered by said
thermoplastic roofing membrane.
20. The method of claim 19 wherein said building comprises three or
more structures, each of which is angled with respect to the
others, said universal flashing being adhered to each of said
structures.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No.
11/775,206, filed 11 Feb. 2004 and presently pending, which claims
the benefit of U.S. provisional applications 60/446,277 and
60/486,283, both filed 11 Feb. 2003; the entire disclosures of each
of the foregoing are incorporated herein by reference.
BACKGROUND INFORMATION
[0002] The present invention relates generally to covering systems
for building structures.
[0003] Thermoplastic covering membranes of a covering system for
building structures are typically installed using some combination
of mechanical fasteners (e.g., screw and plate combinations which
hold roofing membranes to the roof deck), adhesives applied on-site
to the covering membrane and/or the building structure to be
covered, and hot air. The installation of conventional roofing
systems can be quite expensive, even for professional
installers.
[0004] Roofing peripherals, such as pipe boots, walkway pads and
flashing, that are adhered to roofing membranes in a roofing system
using an adhesive or a hot air weld applied to the peripheral at
the site of the roofing system installation. This requires a
professional installer to have some degree of skill in applying
adhesives and working with hot air weld devices.
SUMMARY OF THE INVENTION
[0005] The present invention provides a covering system that may be
installed easily and quickly by a non-professional without special
tools. An adherent roofing flashing may be used in this or a
variety of other covering systems for building structures.
[0006] According to a first broad aspect of the present invention
is provided a covering product that includes a membrane including a
thermoplastic and a dead load shear capable adhesive on at least a
portion of a backside of the membrane in a quantity sufficient to
adhere a majority of the membrane to a building structure.
[0007] According to second broad aspect of the invention is
provided a method for installing a covering system. The method
includes providing a substrate and adhering a first membrane (of
the type just described) to a building structure using a first
adhesive bonded to at least a portion of a backside of the first
membrane. A majority of the surface area of the first membrane is
adhered to the building structure.
[0008] According to third broad aspect of the invention is provided
a covering product that includes a universal flashing and a dead
load shear capable adhesive on at least a portion of a backside of
the universal flashing in a quantity sufficient to adhere a
majority of the universal flashing to a building structure or a
thermoplastic membrane.
[0009] According to a fourth broad aspect of the invention is
provided a method for installing a flashing that includes providing
a universal flashing and adhering the universal flashing to at
least two surfaces that are angled to each other, wherein the
flashing is adhered to a building structure and/or a membrane
adhered to the building structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be described in conjunction with the
accompanying drawings, in which:
[0011] FIG. 1 illustrates in simplified form a section of a roofing
system constructed in accordance with a preferred embodiment of the
invention;
[0012] FIG. 2 is a cross-sectional view of one embodiment of a
flashing of the present invention;
[0013] FIG. 3 is a cross-sectional view of another embodiment of a
flashing of the present invention;
[0014] FIG. 4 is a cross-sectional view of another embodiment of a
flashing of the present invention;
[0015] FIG. 5 is a perspective view of an embodiment in which a
universal flashing is used in conjunction with two building
structure surfaces that meet at right angles;
[0016] FIG. 6 is a perspective view of an embodiment in which a
universal flashing is used in conjunction with an exterior corner
of a building structure;
[0017] FIG. 7 is a perspective view of an embodiment in which a
universal flashing is used in conjunction with an interior corner
of a building structure; and
[0018] FIG. 8 illustrates in simplified form a section of a
covering system constructed in accordance with a preferred
embodiment of the invention in which a covering system is applied
to the underside of the upper interior portion of a tunnel.
DETAILED DESCRIPTION
[0019] The following definitions are used throughout this
application. Where the definition of a term departs from the
commonly used meaning of that term, the explicitly included
definition is intended to control.
[0020] The term "construction materials" refers to materials
typically used in construction such as wood, brick, concrete,
metal, insulation materials, plaster, plasterboard, etc.
[0021] The term "elements" refers to rain, wind, water, ice, snow,
sun, etc.
[0022] The term "building structure" refers to any building,
portion of a building or other structure made of construction
materials that is exposed to the elements. Examples of building
structures include roofs, building walls, free standing walls,
sheds, chimneys, exposed pipes, culverts, above-ground or
underground tunnels, etc.
[0023] The term "weatherproofing" has its conventional meaning,
i.e., protecting building structures such as roofs, chimneys,
walls, etc., from the elements.
[0024] The term "majority of a membrane" refers to more than half
of the surface area of a membrane. The majority of a membrane
includes one adhesive on its surface to allow the membrane to be
adhered to a building structure. A second adhesive may be used to
adhere the edges of the membrane to the surface of the building
structure or to a second membrane overlapped by a first membrane.
Also, the edges of a membrane may be left free of adhesive to allow
the use of other means to fasten a membrane to a building
structure.
[0025] The term "roofing membrane" refers to a water impermeable
sheet of polymeric material intended to be secured to and
waterproof a roof deck. A roofing membrane may use polymeric
materials such as EPDM, chlorinated polyethylene, PVC,
chlorosulfanated polyethylene, TPO, etc. The roofing membrane may
be made from a blended composite polymer having additives, such as
UV screeners, UV absorbers, fire retardants, etc., to improve
weatherability.
[0026] The term "building peripheral" refers to any structure
mounted on or adhered to a covering product for a building
structure. Roofing peripherals are one type of common building
peripheral.
[0027] The term "roofing peripheral" refers to a building
peripheral for a roofing membrane. Examples of roofing peripherals
include flashing, pipe boots, walkway pads, etc.
[0028] The term "flashing" refers to pieces of material, including
at least one that may be used to cover seams or joins between
covering membranes or between building structures and covering
membranes. Often the joins that are covered by flashings occur
where two surfaces meet at an angle. One portion of flashing may be
adhered to a building structure surface or to a membrane covering
material, while the second portion of the flashing is adhered to a
second building structure surface or covering material that is at
an angle with respect to the first building structure. For example,
one portion of flashing may be adhered to a flat roof and then the
flashing may be bent to allow a second portion of the flashing to
be adhered to a chimney extending at a 90.degree. angle with
respect to the roof. Although in most of the examples described
below and shown in the drawings, the two building structure
surfaces form a 90.degree. angle with respect to each other, the
building surface may form other angles. For example, when the
flashing is used with a roof surface and a chimney, the roof
surface may be angled so that the surface of the roof and a chimney
extending from the roof make an angle greater or less than
90.degree.. Flashing may include more than two portions with
multiple bends and have a variety of shapes to allow the flashing
to cover particular vertical, horizontal, and angled roofs and
structures associated with roofs. Flashing may be made of a
flexible material, thereby allowing a sheet of flashing to be used
in a variety of situations. Alternatively, flashing may be made of
a material capable of holding a shape to allow the flashing to be
used to cover particular structures. Flashing may have different
shapes depending on the application. For example a piece of
flashing may be round, circular, oval, square, rectangular, oblong,
etc., and may include bends.
[0029] The term "semi-rigid flashing" refers to a flashing that is
pre-shaped to include permanent bends that allow the semi-rigid
flashing to cover a combination of surfaces such as an interior
corner, an exterior corner, a bend, etc. A semi-rigid flashing when
made from a thermoplastic such as EPDM may be somewhat bendable to
aid in installation of the universal flashing, but after being
molded, is not capable of being bent to form a permanent bend
without the application of heat sufficient to melt the semi-rigid
flashing material.
[0030] The term "universal flashing" refers to a flexible flashing
capable of being bent from a substantially flat surface to a
configuration such that the flashing has portions that are
simultaneously in at least 3 orthogonal planes without requiring
cuts in the flashing. For example, the multiply bent flashing shown
in FIGS. 6 and 7 requires cuts in the flashing to allow the
flashing to be bent, whereas the universal flashing that seals the
joint between the multiply bent flashing and building structure
does not. Although a universal flashing is capable of being bent
simultaneously in 3 orthogonal directions to cover the exterior or
interior corner of a box-like structure, for many applications, a
universal flashing may extend in less than 3 orthogonal directions.
For example, a universal flashing may only be need to be bent once
to be adhered to two surfaces that are perpendicular with respect
to each other. Also, the angles between the surfaces to which a
universal flashing is adhered may be more or less than 90.degree.
with respect to each other. Universal flashing may have different
shapes depending on the application. For example a piece of
universal flashing may be round, circular, oval, square,
rectangular, oblong, etc.
[0031] The term "horizontal" surface refers to any surface that
includes a horizontal dimension, i.e., extends in a direction
substantially parallel with the ground. Examples of horizontal
surfaces include roof substrates, roofing membranes mounted on roof
substrates, etc.
[0032] The term "flexible" refers to any material capable of being
bent, twisted, bowed, curved, etc. For example, a flexible material
may be a material capable of being formed into a coil and capable
of being unrolled from a coil to lie substantially flat. A flexible
material may have the capability to be coiled in any direction.
Alternatively, a flexible material may be a material that is
capable of being repeatedly folded and unfolded.
[0033] The term "roof deck" has its conventional meaning, i.e., a
structural supporting surface of a building extending between the
surrounding exterior walls of the building. A roof deck may be
constructed from plywood, metal decking or concrete or any other
suitable material or combination of materials and may include
insulation material.
[0034] The term "thermoplastic" has its conventional meaning, i.e.,
a compound substance that exhibits the property of a material, such
as a high polymer, that softens when exposed to heat and generally
returns to its original condition when cooled to room temperature.
Examples of thermoplastics suitable for use include PVC and
thermoplastic polyolefins such as polyethylene (PE) including
linear polyethylene (LPE), polybutenes, polypropylene (PP),
copolymers of polyolefins, ethylene-propylene rubber (EPR),
ethylene-propylene copolymer (EPM), EPDM blended with PP or PE or
copolymer, etc.
[0035] The term "room temperature thermoplastic" refers to a
thermoplastic that is solid at room temperature, i.e., will not
cold flow at room temperature.
[0036] The term "thermoplastic polyolefin" (TPO) has its
conventional meaning, i.e., polyolefins that are thermoplastics.
Examples of TPOs suitable for use include LPE, PE, PB, PP,
copolymers, EPR or EPDM blended with PP or PE or copolymer,
etc.
[0037] The term "UV absorber" refers to an additive blended into a
polymer to stabilize the adverse effects of light exposure, such as
a loss of strength, degradation and discoloration. The use of a UV
absorber may allow at least one layer of roofing membrane to
exhibit good weathering characteristics. Examples of preferred UV
absorbers additives include benzotriazole, benezophenones, hindered
amine light stabilizers (HALS), non-interacting HALS (NOR-HALS),
etc. The membranes, peripherals, flashings, universal flashings,
other parts of a covering system, etc., may be made from one or
more materials including one or more UV absorbers.
[0038] The term "UV screener" refers to an additive blended into a
polymer to reflect UV rays. Examples of preferred UV screener
additives include TiO.sub.2, carbon black, ZnO, etc. The membranes,
peripherals, flashings, universal flashings, other parts of a
covering system, etc., may be made from one or more materials
including one or more UV screeners.
[0039] The term "fire retardant" (FR) refers to an additive blended
into a polymer to reduce its flammability by retarding its rate of
combustion. Examples of preferred FRs include magnesium hydroxide,
brominated FR, SbO.sub.3, etc. The membranes, peripherals,
flashings, universal flashings, other parts of a covering system,
etc., may be made from one or more materials including one or more
fire retardants.
[0040] The term "dead load shear capable adhesive" refers to any
adhesive having the property of reliably adhering the weight of a
covering membrane, such as a roofing membrane and/or building
peripheral at the upper and lower service temperatures of the
covering system. A dead load sheer adhesive is capable of holding
20 g/in.sup.2 at room temperature for 2 hours. Preferred dead load
sheer capable adhesives are capable of holding 50 g/in.sup.2 at
70.degree. C. (158.degree. F.) for 24 hrs. An example is Adco
PSA-3.TM. adhesive manufactured by Adco Products, Inc.
[0041] In one embodiment is provided a roofing system in which all
of the components are secured by adhesive, thereby providing a
thermoplastic-type roofing system without the need for any hot air
welds. Such a roofing system may be simple enough to install by
non-professionals on jobs such as carport repairs, mobile home
re-roofing, etc. Even if hot air welding is used to weld together
(i.e., seam) roofing membranes to one another, using adhering
peripherals greatly reduces installation time of roofing
peripherals.
[0042] FIG. 1 illustrates a section of a (peel-and-stick) roofing
system 102 mounted on a roof substrate 104. Roofing system 102
includes a roofing membrane 112, a roofing membrane 114 that
overlaps roofing membrane 112 at an overlap region 116, a flashing
118, a pipe boot 120, and a walkway pad 122. Roof substrate 104
includes a roof deck 124 and an insulation board 126 held on roof
deck 124 by short screws 128 and 130 and long screws 134, 136 and
138. Bordering roof deck 104 is a vertical wall 142 and extending
through roof deck 104 is a vertical pipe 144.
[0043] Roofing membrane 112 is adhered to roof deck 104 by a dead
load shear capable adhesive 146 that has been pre-applied to a
backside 148 of roofing membrane 112. Roofing membrane 112 is
additionally held to roof deck 104 by long screws 134 and 136.
Roofing membrane 114 is adhered to roof deck 104 by a dead load
shear capable adhesive 150 that has been pre-applied to a backside
152 of roofing membrane 114. Roofing membrane 114 is additionally
held to roof deck 104 by long screw 138. In overlap region 116,
roofing membrane 114 is adhered to roofing membrane 112 by adhesive
150.
[0044] Flashing 118 covers long screw 138, a joint region 158 where
roof deck 104 and vertical wall 142 meet, and vertical wall 142 and
provides protection from the elements. Flashing 118 includes a
lower horizontal portion 162, a vertical portion 164 and an upper
horizontal portion 166 and a dead load shear capable adhesive 170
coated on a backside 172 of flashing 118. Lower horizontal portion
162 covers long screw 138 and is adhered to roofing membrane 114.
Vertical portion 164 is adhered to a side face 174 of vertical wall
142. Upper horizontal portion 166 is adhered to a horizontal top
176 of vertical wall 142.
[0045] Pipe boot 120 surrounds vertical pipe 144 and covers long
screws 134 and 136 and opening 182 in roofing membrane 112 and
provides protection from the elements. Pipe boot 120 includes a
pressure sensitive adhesive 184 around a rim 186 of pipe boot 120
and adhesive 184 is used to adhere pipe boot 120 to roofing
membrane 112. Prior to adhering pipe boot 120 to roofing membrane
112, adhesive 184 is covered by a release liner (not shown).
[0046] Preferred pipe boots may have a configuration that allows
the pipe boot to be adhered to a roofing membrane by removing a
release liner and adhering the exposed adhesive to the roofing
membrane. Suitable pipe boots includes EPDM or TPO Peel &
Stick.TM. pipe boots, with included clamping rings (GenFlex Roofing
Systems; Maumee, Ohio).
[0047] Walkway pad 122 includes a thermoplastic mat 188 having a
slip reducing surface 190 and a pressure sensitive adhesive 192
coated on a backside 194 of mat 188 to allow pad 122 to be adhered
to roofing membrane 114. Prior to adhering pad 122 to roofing
membrane 114, adhesive 192 is covered by a release liner (not
shown).
[0048] Except for the use of a pressure sensitive adhesive, the
walkway pad is similar to conventional walkway pads, such as
Flexguard.TM. EPDM walkway pads (GenFlex). Walkway pads may be
mounted on roofs to allow access to mechanical equipment for
maintenance.
[0049] Preferably, a roofing membrane used in a roofing system of
the present invention is one in which a pressure sensitive adhesive
on at least one side of the membrane is protected by a release
liner made of any suitable release liner material such as waxed
paper, plastic, etc., treated with a release agent. Using a
pressure sensitive adhesive and release liner allows easier storage
and transportation of a roofing membrane.
[0050] Although pressure sensitive adhesives are only shown as
being on a backside of the roofing membranes in FIG. 1, one or more
sections of an upper side of the roofing membrane may also include
a pressure sensitive adhesive. By removing a release liner on the
pressure sensitive adhesive sections of an upper side of the
roofing membrane, peripherals that do not have adhesives may be
mounted on the roofing membrane. For example, if roofing membrane
114 in FIG. 1 had included a pre-applied adhesive (peel-and-stick)
section on its upper side, the walkway pad mounted on the roofing
membrane would not require its own pressure sensitive adhesive.
[0051] Although in FIG. 1 the overlapping roofing membranes are
bonded using dead load shear capable adhesive, in an alternative
embodiment the roofing membranes may instead be welded together
using a hot welding technique. When an adhesive is used to bond
overlapping roofing membranes together, the adhesive may either be
pre-applied to the edge region of the roofing membrane and
preferably covered by a separate release liner that is removed just
prior to bonding the overlapping membranes. The adhesive in the
edge region of the overlapping roofing membrane may or may not be
the same adhesive used on the rest of the roofing membrane.
Alternatively, the edge region of the overlapping roofing membrane
may be free of adhesive prior to installation and the adhesive may
be applied during installation. When hot welding is used, a portion
of the overlapping roofing membrane is preferably not coated with
the adhesive.
[0052] A preferred material for the insulation board shown in FIG.
1 is polyisocyanurate.
[0053] Although the flashing shown in FIG. 1 includes an adhesive
on the entire backside of the flashing, some applications may not
need to coat part of the backside. For example, a portion of the
backside of the flashing may be uncoated with an adhesive to allow
the flashing to be welded to a roofing membrane using hot welding
or where the flashing is secured to a horizontal or vertical
structure using conventional fastening devices such as screws,
nails, etc. Also, although FIG. 1 only shows the use of adhesive to
secure the flashing to the roofing membrane and vertical structure,
the flashing may be additionally secured using conventional
fastening devices such as screws, nails, etc.
[0054] FIG. 2 illustrates a flashing 202 having a dead load shear
capable adhesive 204 coated on a backside 206 of flashing 202. One
end 212 of backside 206 is left uncoated with adhesive 204. A
release liner 222 covers adhesive 204.
[0055] FIG. 3 illustrates a flashing 302 having a dead load shear
capable adhesive 304 coated on a backside 306 of flashing 302. Ends
312 and 314 of backside 306 are left uncoated with adhesive 304. A
release liner 322 covers adhesive 304. Flashing 302 also includes a
dead load capable adhesive 332 on an upper side 334 of flashing
302. A release liner 336 covers adhesive 332. Adhesive 332 allows
roofing peripherals (not shown) that do not include their own
adhesive coating to be mounted on the flashing.
[0056] FIG. 4 illustrates a flashing 402 having a dead load shear
capable adhesive 404 coated on a backside 406 of flashing 402 in
two sections 408 and 410 of adhesive 404. Between sections 408 and
410 is an uncoated section 412. Release liners 418 and 420 cover
sections 408 and 410, respectively, of adhesive 404.
[0057] Although only a few types of flashing are illustrated in
FIGS. 2, 3 and 4, the flashing may have various shapes and having
adhesive coated on the backside of the flashing in a variety of
ways, including having the adhesive coated on the entire backside
of the flashing. Flashing may include one or more preformed angle
bend and may include materials to reinforce the flashing such as
internal fabric or reinforcing layers.
[0058] FIG. 5 illustrates a universal flashing 502 used in
conjunction with two building structure surfaces that meet at right
angles. Universal flashing 502 is adhered to an overlapping
flashing 504, an overlapped flashing 506 and a covering membrane
508. Universal flashing 502 covers and seals an overlap region 510
where overlapping flashing 504 overlaps overlapped flashing 506.
Universal flashing 502 includes a vertical portion 512, a
horizontal portion 514, a flap portion 516 and bends 522, 524 and
526, 528 and 530. Vertical portion 512 and horizontal portion 514
are adhered to overlapping flashing 504 and overlapped flashing
506. Flap portion 516 is adhered to covering membrane 508.
Overlapping flashing 504 is adhered to overlapped flashing 506 by a
pressure sensitive (peel-and-stick) adhesive in overlap region 510.
A vertical portion 542 of overlapping flashing 504 and a vertical
portion 544 of overlapped flashing 506 are adhered by a
peel-and-stick adhesive to a vertical surface 546 of a building
structure 548. A horizontal portion 552 of overlapping flashing 504
and a horizontal portion 554 of overlapped flashing 506 are adhered
to covering membrane 508, only a portion of which is shown in FIG.
5. Covering membrane 508 covers a horizontal surface 556 of
building structure 548. Overlapping flashing 504 includes a bend
564 and overlapped flashing 506 includes a bend 566. Overlapping
flashing 504 and overlapped flashing 506 seal ajoin region 568
where covering membrane 508 abuts vertical surface 546.
[0059] FIG. 6 illustrates an embodiment in which an oval universal
flashing 602 is used in conjunction with an exterior corner 604 of
a building structure 606. Building structure 606 includes a
horizontal surface (not visible in FIG. 6) covered by a covering
membrane 608 and a box-like vertical structure 610, extending
through an opening (not visible in FIG. 6) in covering membrane
608, including and four vertical surfaces 612, 614, 616 and 618.
Vertical surfaces 612, 614, 616 and 618 include respective top edge
surfaces 622, 624, 626 and 628. A flashing 630 with multiple bends
covers vertical structures 612, 614, 616 and 618 and top edge
surfaces 622, 624, 626 and 628. Prior cuts (not shown in FIG. 6) in
flashing 630 form bottom flaps 632 that are adhered (by a pressure
sensitive adhesive) to covering membrane 608. Prior cuts (not shown
in FIG. 6) in flashing 630 form top flaps 634 that are adhered to
top edge surfaces 622, 624, 626 and 628. Flashing 630 overlaps
itself in an overlap region 642 forming a seam 644. Universal
flashing includes bends 652, 654 and 656 and includes three
portions vertical portion 662, vertical portion 664 and horizontal
portion 666 that are in three planes orthogonal to each other.
Vertical portion 662 extends vertically and is adhered to a side
672 of flashing 630. Vertical portion 664 extends vertically and is
adhered to a side 674 of flashing 630. Horizontal portion 666
extends horizontally and is adhered to two bottom flaps 632 and to
covering membrane 608. Universal flashing 602 covers and seals a
join 676. Between top flaps 634 are seams 678.
[0060] An additional universal flashing, an additional flexible
flashing, or an appropriately shaped semi-rigid flashing may be
used to cover the other seams formed by the overlap region of the
flashing with multiple bends and the seams between the top flaps
and other joins between the covering flashing with multiple bends
and the horizontal surface. Also, instead of the universal flashing
shown in FIG. 6, a pre-shaped semi-rigid flashing can be
substituted to cover and seal the corner.
[0061] FIG. 7 illustrates an embodiment in which a rectangular
universal flashing 702 is used in conjunction with an interior
corner 704 of a building structure 706. Universal flashing 702 is
adhered to an overlapping flashing 708, an overlapped flashing 710
and a covering membrane 712. Overlapping flashing 708 is a
preformed semi-rigid flashing shaped to fit into interior corner
704. Universal flashing 702 covers and seals an overlap region 714
where overlapping flashing 708 overlaps overlapped flashing 710.
Universal flashing 702 includes a vertical portion 716, a
horizontal portion 718 including a horizontal flap portion 720 and
bends 722, 724 and 726 (as well as several bends not easily seen in
FIG. 7). Bend 722 is between vertical portion 716 and horizontal
portion 718 and bends 724 and 726 form are between horizontal flap
portion and a based portion 728 of horizontal portion 718. Vertical
portion 716 and horizontal portion 718 are adhered to overlapping
flashing 708 and overlapped flashing 710. Flap portion 720 is
adhered to covering membrane 712. Overlapping flashing 708 is
adhered to overlapped flashing 710 by a (peel-and-stick) adhesive
in overlap region 714. A vertical portion 742 of overlapping
flashing 708 and a vertical portion 744 of overlapped flashing 710
are adhered by a (peel-and-stick) adhesive to vertical surfaces 746
and 748 of building structure 706. A horizontal portion 752 of
overlapping flashing 708 and a horizontal portion 754 of overlapped
flashing 710 are adhered to covering membrane 712, only a portion
of which is shown in FIG. 7. Covering membrane 712 covers a
horizontal surface 756 of building structure 706. Overlapping
flashing 708 includes a bend 764 and overlapped flashing 710
includes a bend 766. Overlapping flashing 708 and overlapped
flashing 710 seal a join region (not visible in FIG. 7) where
covering membrane 712 abuts a corner vertical surface 746.
Overlapping flashing 708 also includes a bend 772 where overlapping
flashing covers interior corner 704.
[0062] Prior to being adhered to a flashing, a covering membrane or
a building structure surface, the adhesives used to adhere
flashings and universal flashings are preferably covered by a
release line. Although the flashings and universal flashings
illustrated in FIGS. 5, 6 and 7 are adhered using only adhesive,
the flashings and universal flashings may be adhered to one or more
surfaces by hot air welding. When hot air welding is used to adhere
a universal flashing to a surface, there is generally no adhesive
on the underside of the flashing in the region that is adhered by
hot air welding.
[0063] A universal flashing preferably may consist of a material
such an uncured rubber, such as EPDM, that is capable of holding a
shape into which the flashing may be bent. When using an uncured
rubber, the uncured rubber may be cured after installation. The
ability of a flashing to maintain a shape is particularly valuable
when the flashing is used to cover and seal corner structures or
other structures that require extensive bending of the
flashing.
[0064] A preferred adhesive for use with a universal flashing is a
butyl pressure sensitive adhesive.
[0065] A preferred thickness of a flashing may be 0.001 to 6.0 cm.
A more preferred thickness of a flashing may be 0.01 to 3.0 cm. Yet
another more preferred thickness of a flashing may be 0.1 to 1.0
cm.
[0066] FIG. 8 illustrates in simplified form a section of a
covering system 802 that is applied to an underside 804 of an upper
portion 806 of a tunnel 808. Covering system 802 includes a
membrane 812 and a pressure sensitive adhesive 814 that adheres
membrane 812 to tunnel 808. Prior to adhering membrane 812 to
tunnel 808, adhesive 814 is covered by a release liner (not shown).
Covering system 802 also includes a pipe boot 818 that surrounds a
vertical pipe 820 that extends through an opening 824 in tunnel 808
and opening 826 in membrane 812. Pipe boot 818 includes a pressure
sensitive adhesive 828 around a rim 830 of pipe boot 818. Adhesive
828 is used to adhere pipe boot 818 to membrane 812. Prior to
adhering pipe boot 822 to membrane 812, adhesive 828 is covered by
a release liner (not shown).
[0067] The rim of the pipe boot and parts building peripherals used
with covering systems employed on curved or contoured surfaces,
such as the curved tunnel surface of FIG. 8, preferably either
shaped to be capable of being mounted on a curved surface or are
flexible enough to be mounted on a curved surface.
[0068] Although for simplicity only one section of membrane is
shown being used in FIG. 8, several overlapping membranes can be
used in covering systems of the type shown in FIG. 8, similar to
the way that overlapping membranes are used in the roofing/covering
system of FIG. 1. Also, as in the covering system of FIG. 1,
covering systems of the type shown in FIG. 8 may include several
building peripherals.
[0069] The covering system may have particular advantages when
being applied to a surface from below, as shown in FIG. 8, because
the covering system is provided with an adhesive that immediately
adheres the covering system to the surface.
[0070] A preferred dead load shear capable adhesive for use with
the covering system and flashing is Adco PSA-3.TM. pressure
sensitive adhesive (Adco Products, Inc.) that includes
styrene-ethylene-butylene-styrene (SEBS), a tackifying endblock
resin such as a cumarone-indene resin and a tackifying midblock
resin such as a terpene resin. Other preferred dead load shear
capable adhesives include butyl-based adhesives, EPDM-based
adhesives, acrylic adhesives, styrene-butadiene adhesives,
polyisobutylene adhesives, ethylene vinyl acetate adhesives,
etc.
[0071] One type of dead load shear capable adhesive may be used for
all of the roofing membranes and roofing peripherals of a system,
or different adhesives may be used for different components. Also,
different adhesives may be used on different sections of a
component. For example, a stronger adhesive or may more moisture
resistant adhesive may be used to adhere two overlapping membranes
to each other while a weaker and possibly cheaper adhesive may be
used to adhere the non-overlapping portion of the roofing membrane
to a roof substrate. The adhesive used for the seam may or may not
be SEBS.
[0072] A preferred thickness of a dead load shear capable adhesive
may be 0.001 to 0.5 cm. A more preferred thickness of a dead load
shear capable adhesive may be 0.01 to 0.25 cm. Yet another more
preferred thickness of a dead load shear capable adhesive may be
0.1 to 0.2 cm.
[0073] Although for convenience, the covering system of the present
invention is only described above as being applied from above to a
horizontal surface or from below to a curved surface, the covering
system may also be used on slanted surfaces, such as slanted or
peaked roofs, vertical surfaces, such as walls, chimneys,
combinations of vertical and horizontal surfaces, etc., curved
surfaces such as culverts, or contoured surfaces, such as
terracotta roofs, or may be applied from below to horizontal and
vertical surfaces such as roof overhangs or various curved or
contoured surfaces.
[0074] The parts of the covering system of the present invention
may be made colored or made of transparent materials to be less
noticeable when applied to a building structure.
[0075] Also, although only a few types of building structures are
depicted as being covered in the embodiments of the present
invention described above and illustrated in the drawings, the
covering system of the present invention may be used on a variety
of building structures.
[0076] Although the present invention has been fully described in
conjunction with the preferred embodiment thereof with reference to
the accompanying drawings, it is to be understood that various
changes and modifications may be apparent to those skilled in the
art. Such changes and modifications are to be understood as
included within the scope of the present invention as defined by
the appended claims, unless they depart therefrom.
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