U.S. patent application number 11/364627 was filed with the patent office on 2007-08-30 for self-seal ring for roofing nail.
This patent application is currently assigned to BUILDING MATERIALS INVESTMENT CORPORATION. Invention is credited to Luis F. Duque.
Application Number | 20070199276 11/364627 |
Document ID | / |
Family ID | 38442717 |
Filed Date | 2007-08-30 |
United States Patent
Application |
20070199276 |
Kind Code |
A1 |
Duque; Luis F. |
August 30, 2007 |
Self-seal ring for roofing nail
Abstract
A self-seal ring for creating a water tight seal around a nail
used in affixing a roof shingle, underlayment and insulation to a
roof deck. Also disclosed is a method for installing the self-seal
ring and nail to the underlying support.
Inventors: |
Duque; Luis F.; (Englewood,
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: |
38442717 |
Appl. No.: |
11/364627 |
Filed: |
February 28, 2006 |
Current U.S.
Class: |
52/741.4 ;
52/408 |
Current CPC
Class: |
F16B 15/00 20130101;
E04D 1/34 20130101; E04D 2001/005 20130101; F16B 43/001 20130101;
E04D 2001/3423 20130101; F16B 15/02 20130101; F16B 1/0071
20130101 |
Class at
Publication: |
052/741.4 ;
052/408 |
International
Class: |
E04B 5/00 20060101
E04B005/00 |
Claims
1. A self-seal ring for creating a water-tight seal around roof
nails, comprising: 1) a ring-like pad having a center base having a
bore therein that fits around a nail having a stem and a head, said
ring-like pad having an upper surface and a lower surface; 2) a
layer of adhesive optionally applied to said upper surface and said
lower surface; and 3) a release liner applied upon said adhesive
layers.
2. The self-seal ring of claim 1 wherein the head of said nail
covers said bore to prevent the entering of moisture into an
underlying deck.
3. The self-seal ring of claim 1 wherein said adhesive is selected
from the group consisting of: polyisobutanes, polybutanes,
polyisoprene butyl rubber, styrene-isoprene-styrene,
styrene-butadiene-styrene, styrene-ethylene-butadiene-styrene,
acrylics, polyurethanes, atacticpolypropylene or mixtures
thereof.
4. The self-seal ring of claim 1 wherein said release liner is
selected from the group consisting of waxed paper, polycoated
paper, film-based paper and plastic.
5. The self-seal ring of claim 1 having a size the diameter of
which is from about 0.5 inches to about 2.0 inches.
6. The self-seal ring of claim 1 comprising: of about 50% to about
75% w/w of asphalt; of from about 25% to about 40% w/w of a filler;
and of from about 1% w/w to about 5% w/w of a modifier selected
from the group consisting of styrene-butadiene-styrene, polybutane
and polybutylene and mixtures thereof.
7. The self-seal ring of claim 6 wherein said ring comprises 60 to
70% w/w asphalt.
8. The self-seal ring of claim 1 having a thickness in the range of
0.5 inches to 4.0 inches.
9. A method for preparing a self-seal ring comprising the steps of:
mixing an asphalt, filler and modifier to form a mixture; placing
the mixture in a roller machine to produce a film; conditioning the
film at about 40.degree. F.; cutting the film with a die to the
desired specification; and puncturing the center with a heated
element to allow for the insertion of a nail.
10. A method of installing a self-seal ring with a nail therein
into an underlayment, roof shingle and roof deck comprising the
steps of: fitting the self-seal ring around a nail; positioning the
self-seal ring with the nail therein onto said underlayment, roof
shingle and roof deck; applying pressure on the self-seal ring and
nail so that the nail punctures the shingle, underlayment and roof
deck.
11. The method of installing a self-seal ring with a nail therein
comprising: a) a self-seal ring comprising a pad having a center
bore that fits around the nail, said nail having a stem and a head,
said pad having an upper surface and a lower surface; b) a layer of
adhesive optionally applied to said upper surface and to said lower
surface; and c) a release liner applied upon said adhesive layers;
the method comprising the steps of: positioning the nail into the
pad around the nail; positioning said pad with the nail therein
comprising a roof shingle, insulation, and underlayment; removing
said liner comprising the adhesive and inserting and pressing said
nail into a substrate comprising a roof shingle, insulation and
underlayment into a substrate to create a tight seal around the
nail.
12. The method of claim 11 wherein said adhesive is selected from
the group consisting of: polyisobutanes, polybutanes, polyisoprene,
butyl rubber, styrene-isoprene-styrene, styrene-butadiene-styrene,
styrene-ethylene-butadiene-styrene, acrylics, polyurethanes,
atactic polypropylene or mixtures thereof.
13. The method of claim 12 wherein the release liner is selected
form the group consisting of waxed paper, polycoated paper,
film-based paper and plastic.
14. The method of claim 12 wherein the release liner has a
thickness in the range of 2 to 9 mils.
15. The method of claim 9 wherein the self-seal ring is made by:
mixing an asphalt, a filler and a modifier to form a mixture;
placing the mixture in a roller machine to produce a film;
conditioning the film at about 40.degree. F.; cutting the film with
a die to the desired specification; and puncturing the center with
a heated element to allow for the insertion of a nail.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to self-seal fasteners for roofing
nails. More particularly, the invention relates to self-seal rings
positioned under the fasteners to prevent/reduce penetration of
moisture in the form of rain, snow or ice into the tar paper or
felt applied to the roof prior to the application of roofing
shingles.
[0003] 2. Reported Developments
[0004] In covering a roof structure, a liner such as tar paper or
felt is applied to the roof deck prior to the application of roof
shingles. The liner material is made from paper products such as
cloth and fiberglass and is coated with a petroleum-based tar to
increase the strength of the paper products and to render the liner
waterproof. The liner is secured to the roof deck by roofing ails
or tacks which have enlarged heads to hold the liner to the
underlying wood deck. Such securing means are disclosed, for
example, in U.S. Pat. Nos. 3,983,779 and 5,567,101. The securing
means is equipped with an enlarged head or tang to hold the
underlining to the roof deck and to cover the hole made by the nail
body to prevent penetration of moisture.
[0005] Most liners resist water penetration except at the nail hold
where water can migrate through the holes and collect, thereby
causing damage to the underlying roof deck. The damage caused
includes mildew formation, warping and rotting of the roof
deck.
[0006] To reduce the penetration of moisture through the nail
holes, the prior art proposes articles exemplified by U.S. Pat.
Nos. 5,365,709 and 5,497,596.
[0007] The '709 patent discloses a felt or tar paper that has a
plurality of nail tabs attached to the felt base material prior to
coating the felt base with a water-resistant material such as
petroleum tar. In a second embodiment, the nail tabs are attached
to the felt during installation of the felt to the roof. The
roofing material is attached to the roof with roofing nails that
are driven through the tabs.
[0008] The '596 patent discloses a method of reducing penetration
of liquid through a non-woven sheet, which has been pierced by one
or more fastening elements, comprising: [0009] a non-woven sheet
having a coating of hydrophobic foam on a surface of the sheet, the
foam being in strips corresponding to the plurality of fastening
element bases; [0010] positioning the sheet against the framing
structure such that the foam aligns with the fastening element
bases of the framing structure; and [0011] fastening the sheet to
the fastening element through the foam in order to provide
resistance to liquid penetration between the sheet and the
fastening element.
[0012] As it appears from the above-cited references, it is
important to prevent penetration of liquid through holes created by
or around the piercing of nails or staples when the underlayment is
attached to the underlying roof deck. The main object of the
present invention is to prevent/eliminate water penetration through
such a hole created by a nail or staple in a roof deck.
SUMMARY OF THE INVENTION
[0013] The present invention provides an accessory such as a ring
for a nail to provide a water-tight barrier around the nail. The
present invention also provides a method of installing the
accessory hereinafter sometimes referred to as a "ring" with a nail
to an underlying roof deck.
[0014] The invention and the method of its installation provide a
leak-proof seal preventing water penetration to the underlying roof
deck.
[0015] The accessory comprises: [0016] a self-seal ring comprising
of about 50% to about 75% w/w of asphalt, and preferably of about
60% to about 70% asphalt; [0017] 25% to 40% w/w of a filler; [0018]
1% to 5% w/w of a modifier; and preferably 2% to 3% of a modifier
selected from the group consisting of styrene-butadiene-styrene
(SBS), polybutane and polybutylene and mixtures thereof.
[0019] The thickness of the accessory ranges of from about 0.5
inches to about 4.0 inches.
[0020] The shape of the accessory is preferably round, however it
may be oval, square or rectangular.
[0021] The method of preparing the accessory comprises the steps
of: [0022] mixing asphalt, filler and modifier together; [0023]
placing the mixture in a roller machine to make a film; [0024]
conditioning the film at about 40.degree. F.; [0025] cutting the
film with a die to the desired specification; and [0026] puncturing
the center with a heated element to allow for the insertion of a
nail.
[0027] The method of installing the accessory comprises the steps
of: [0028] fitting the accessory around a nail; [0029] positioning
the accessory with the nail therein onto the roof shingles; [0030]
applying pressure on the nail to penetrate the roof shingles and
the underlying deck to create a tight seal around the nail and the
roof shingles.
[0031] It is to be noted that the head of the nail is larger than
the stem of the nail and is from about 0.035'' to about 0.45 inches
so that it covers the nail hole of 0.025 inches to 0.040
inches.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 illustrates a top perspective view of the present
invention.
[0033] FIG. 2 illustrates a side elevational view of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] FIG. 1 is a top perspective view of the present invention
wherein: [0035] the numeral 10 denotes the self-seal ring and nail
positioned in the ring; [0036] the numeral 12 denotes the self-seal
ring; [0037] the numeral 14 denotes the head of a nail; and [0038]
the numeral 16 denotes the stem of the nail.
[0039] FIG. 2 is a side elevational view of the self-seal ring and
the nail positioned in the self-seal ring wherein: [0040] the
numeral 12 denotes the self-seal ring; [0041] the numeral 14
denotes the head of the nail; [0042] the numeral 16 denotes the
nail; [0043] the numeral 18 denotes the stem of the nail; [0044]
the numeral 20 denotes an adhesive on the top surface of the
self-seal ring; and [0045] the numeral 22 denotes an adhesive on
the bottom surface of the self-seal ring.
[0046] As indicated, the main object of the present invention is
accomplished by providing a ring for the roofing nail positioned
just below the head portion of the roofing nail. The ring comprises
a pad or carrier of a soft plastic mixture containing asphalt,
filler and an adhesive coated or deposited on the pad or carrier.
It shape may be round, oval or rectangular having a size of 0.5-2
or more inches in diameter, woven or non-woven material of
fiberglass. It can also be reinforced with strips, screen wire and
the like.
[0047] It is preferred that the carrier be coated with colored
roofing granules having a pleasing, decorative metallic appearance
and enhanced stability against degradation upon exposure of
atmospheric condition. The method comprises the steps of:
[0048] a) crushing and sizing a base mineral aggregate to form
granules therefrom;
[0049] b) preheating the granules to about 175-190.degree. F.;
[0050] c) preparing a coating composition comprising: water, an
alkali solution and a silica-encapsulated metallic flake pigment in
either powder or aqueous paste form;
[0051] d) combining said preheated granules and said coating
composition by missing to produce individually coated granules;
[0052] e) pre-drying said individually coated granules to reduce
their moisture content to about 0.1%-0.5%;
[0053] f) kiln-firing said granules at about 400.degree. F. to form
a transparent, partially insolubilized coating on the granules;
[0054] g) cooling said granules to reduce their temperature to
about 140-160.degree. F. by means of air flow and water spray
application;
[0055] h) applying along with the water spray application an
aluminum chloride solution to said granules to allow chemical
reaction to occur between the aluminum chloride and the alkali
silicate to complete insolubilization of said coating; and
[0056] i) treating said granules having the insolubilized coating
thereon with a mixture of process oil and an organosilicon compound
to impart dust control, and to improve adhesion to a substrate.
[0057] As indicated above, the substrate is the pad or carrier in
the form of round, oval or rectangular shape having an asphalt
coating thereon at least on one side thereof. The coated granules
are pressed and embedded in the asphalt layer of the carrier. Both
sides of the carrier may be coated with the granules so that
installation is without confusion as to which sides of the coated
granules form the carrier. The carrier, with asphalt coating and
decorative granules thereon, is ready for installation over an
underlayment. If, under certain temperature conditions increased
adhesion is necessary, an industrial adhesive of a polymeric base
may be used.
[0058] When needed to match the decorative appeal of the
asphalt-coated shingles, this step of (a) through (d)above are
optionally included in the present invention.
[0059] In addition to the use of nails with the self-seal ring of
the present invention, an adhesive may be used on the top and
undersides of the self-seal ring to insure adherence of the
self-seal ring to the underlying substrate and the shingles. The
adhesion used may include polyisobutanes (PIB), polybutanes,
polyisoprene, butyl rubber, styrene-isoprene-styrene (SIS),
styrene-butadiene-styrene (SBS), styrene-ethylene-butadiene-styrene
(SEBS), acrylics, polyurethanes, atactic polypropylene (APP) or
other similar adhesives and/or suitable mixtures thereof.
[0060] It is to be understood that various modifications can be
made based on the disclosure of the present invention without
departing from the spirit of the invention. It is therefore
intended that the invention not be limited to the exact form
described and illustrated, but should be constructed to cover all
modification that may fall within the scope of the appended
claims.
* * * * *