U.S. patent application number 13/614001 was filed with the patent office on 2013-03-14 for granule coated waterproof roofing membrane.
This patent application is currently assigned to Owens Corning Intellectual Capital, LLC. The applicant listed for this patent is James E. Loftus, Jay D. Wagner. Invention is credited to James E. Loftus, Jay D. Wagner.
Application Number | 20130065020 13/614001 |
Document ID | / |
Family ID | 47830081 |
Filed Date | 2013-03-14 |
United States Patent
Application |
20130065020 |
Kind Code |
A1 |
Loftus; James E. ; et
al. |
March 14, 2013 |
GRANULE COATED WATERPROOF ROOFING MEMBRANE
Abstract
A roofing membrane includes a membrane layer. An adhesive layer
is adhered to a first side of the membrane layer and a layer of
granules is adhered to the first adhesive layer.
Inventors: |
Loftus; James E.; (Newark,
OH) ; Wagner; Jay D.; (Holland, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Loftus; James E.
Wagner; Jay D. |
Newark
Holland |
OH
OH |
US
US |
|
|
Assignee: |
Owens Corning Intellectual Capital,
LLC
Toledo
OH
|
Family ID: |
47830081 |
Appl. No.: |
13/614001 |
Filed: |
September 13, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61533999 |
Sep 13, 2011 |
|
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|
Current U.S.
Class: |
428/143 |
Current CPC
Class: |
Y10T 428/24388 20150115;
D06N 5/006 20130101; E04D 5/10 20130101; E04D 5/12 20130101; E04D
5/148 20130101; Y10T 428/24372 20150115 |
Class at
Publication: |
428/143 |
International
Class: |
E04D 5/12 20060101
E04D005/12 |
Claims
1. A granule coated waterproof roofing membrane comprising: a
waterproof membrane layer; an adhesive layer adhered to a first
side of the waterproof membrane layer; and a layer of granules
adhered to the first adhesive layer.
2. The roofing membrane according to claim 1, wherein the adhesive
layer defines a first adhesive layer, and wherein the roofing
membrane further includes a second adhesive layer bonded to a
second side of the membrane layer.
3. The roofing membrane according to claim 2, further including a
release layer adhered to the second adhesive layer.
4. The roofing membrane according to claim 1, wherein the membrane
layer is reinforced with a woven or knitted fibrous material.
5. The roofing membrane according to claim 4, wherein the woven or
knitted fibrous material is formed from at least one of polyester
fiber, glass fiber, and combinations thereof.
6. The roofing membrane according to claim 1, wherein the
waterproof membrane is reinforced with a non-woven fibrous
material.
7. The roofing membrane according to claim 6, wherein the non-woven
or knitted fibrous material is formed from at least one of
polyester fiber, glass fiber, and combinations thereof.
8. The roofing membrane according to claim 1, wherein the
waterproof membrane layer is formed substantially from at least one
of ketone ethylene ester (KEE) resin, polyvinyl chloride (PVC),
ethylene propylene diene monomer rubber (EPDM), and thermoplastic
polyolefin (TPO).
9. The roofing membrane of claim 8 wherein the waterproof membrane
layer is formed substantially from a blend of KEE and PVC.
10. The roofing membrane according to claim 2, wherein the first
and second adhesive layers comprise asphalt.
11. The roofing membrane according to claim 10, wherein the asphalt
of the first and second adhesive layers is a polymer modified
asphalt.
12. The roofing membrane according to claim 11, wherein the polymer
modified asphalt includes one of styrene-butadiene-styrene (SBS),
styrene-isoprene-styrene (SIS), styrene-butadiene (SB), and blends
thereof.
13. The roofing membrane according to claim 12, wherein the polymer
modified asphalt further includes at least one of a thermoplastic
polymer and a thermoplastic polyolefin.
14. The roofing membrane according to claim 13, wherein the polymer
modified asphalt further includes at least one of polyethylene,
polypropylene, an ethylene-propylene copolymer, limestone,
dolomite, talc, recycled roofing material, tackifying resin,
process oil, and wax.
15. The roofing membrane of claim 2, wherein the roofing membrane
is self-adhering.
16. The roofing membrane of claim 2 further comprising an adhesion
promoting layer between the waterproof membrane and the adhesive
layer for enhancing the adhesion between the adhesive layer and the
waterproof membrane.
17. The roofing membrane of claim 16 wherein the adhesion promoting
layer is a stranded material that has strand ends that extend into
the adhesive layer.
18. The roofing membrane of claim 16 wherein the adhesion promoting
layer is a stranded material that is bonded to the waterproof
membrane and has strand ends that extend into the adhesive
layer.
19. The roofing membrane of claim 1 wherein the granules are
roofing granules.
20. A roofing system configured for application to a low-slope
roof, the roofing system comprising: a roofing membrane having a
waterproof membrane layer, an adhesive layer adhered to a first
side of the waterproof membrane layer, and a layer of roofing
granules adhered to the adhesive layer; wherein the granules of the
layer of roofing granules define at least one of a color and a
color blend; wherein the low-slope roof is one of attached and
adjacent a building structure having a roof covered with
granule-coated roofing shingles, the granule-coated roofing
shingles defining at least one of a color and a color blend; and
wherein the at least one of a color and a color blend of the layer
of roofing granules is substantially the same as the at least one
of a color and a color blend of the granule-coated roofing
shingles.
21. The roofing system according to claim 21, wherein the adhesive
layer defines a first adhesive layer, and wherein the roofing
membrane further includes a second adhesive layer bonded to a
second side of the membrane layer.
22. The roofing system according to claim 21, wherein the roofing
membrane further includes a layer of release material adhered to
the second adhesive layer.
23. The roofing system according to claim 20, wherein the membrane
layer is reinforced with a woven or knitted fibrous material.
24. The roofing system according to claim 23, wherein the woven or
knitted fibrous material is formed from at least one of polyester
fiber, glass fiber, and combinations thereof.
25. The roofing system according to claim 20, wherein the membrane
is reinforced with a non-woven fibrous material.
26. The roofing system according to claim 25, wherein the non-woven
fibrous material is formed from at least one of polyester fiber,
glass fiber, and combinations thereof.
27. The roofing membrane according to claim 20, wherein the
membrane layer is formed from a sheet of water impermeable
material.
28. The roofing system according to claim 27, wherein the sheet of
water impermeable material is formed substantially from at least
one of ketone ethylene ester (KEE) resin, polyvinyl chloride (PVC),
ethylene propylene diene monomer rubber (EPDM), and thermoplastic
polyolefin (TPO).
29. The roofing system according to claim 21, wherein the first and
second adhesive layers comprise asphalt.
30. The roofing system according to claim 29, wherein the asphalt
of the first and second adhesive layers is a polymer modified
asphalt.
31. The roofing system according to claim 30, wherein the polymer
modified asphalt includes styrene-butadiene-styrene (SBS),
styrene-isoprene-styrene (SIS), styrene-butadiene (SB), and blends
thereof.
32. The roofing system according to claim 30, wherein the polymer
modified asphalt further includes at least one of a thermoplastic
polymer and a thermoplastic polyolefin.
33. The roofing system according to claim 30, wherein the polymer
modified asphalt further includes at least one of polyethylene,
polypropylene, an ethylene-propylene copolymer, limestone,
dolomite, talc, recycled roofing material, tackifying resin,
process oil, and wax.
34. The roofing system of claim 21, wherein the roofing membrane is
self-adhering.
35. The roofing system of claim 20, wherein the weathering
performance of the roofing membrane is improved relative to an
asphalt based, low-slope roofing membrane.
Description
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S.
provisional patent application No. 61/533,999, filed on Sep. 13,
2011, and titled "Roofing Membrane." U.S. provisional patent
application No. 61/533,999 is incorporated herein by reference in
its entirety.
FIELD OF THE INVENTION
[0002] Various embodiments of a granule coated waterproof roofing
membrane are described herein.
BACKGROUND OF THE INVENTION
[0003] A roof may have a steep-slope or a low-slope. Traditional
tabbed or laminated shingles are typically used for steep-slope
roofing applications. Traditional tabbed or laminated shingles are
referred to as "water-shedding" products. That is, water that falls
on a shingle on an upper portion of the roof runs down the shingle
and onto an underlying, next lower shingle. The water runs down the
shingles, until the water reaches the bottom of the steep roof.
[0004] As the slope of a roof decreases, more emphasis is placed on
the need for waterproofing the roof covering, because less aid to
physical movement of water is provided by the slope of the roof.
Residential and commercial products are available for low-slope
roofing applications. Most products used in residential low-slope
roofing applications include two or more plies or layers to enhance
long-term performance. A typical low-slope roofing product may have
one or more underlayment or base sheets and a separate cap sheet.
Typically, the separate cap sheets are similar to typical asphalt
roofing shingles and may include a woven or non-woven fiber mat
that is coated on both upper and lower surfaces with asphalt. The
separate cap sheet may have a layer of roofing granules on the
upper surface that is configured to match the roofing shingles of a
nearby steep-slope roof. One or both of the base sheet and the
separate cap sheet may be self-adhering.
[0005] Many low-slope roofing products used in commercial
applications are non-asphalt based membranes that are installed on
a low-slope roof using a variety of attachment means, such as with
cold or hot applied adhesive materials, or with mechanical
fasteners. The seams between portions of the membrane may be heat
welded or glued. Typical commercial membranes are manufactured in
solid colors, commonly white or black, and may be limestone
covered. Other known low-slope roofing products include membranes
with patterns printed on the visible surface, and membranes coated
with paint or a reflective coating.
SUMMARY OF THE INVENTION
[0006] The present application describes various embodiments of a
waterproof granule coated roofing membrane. One embodiment of the
roofing membrane includes a membrane layer. An adhesive layer is
bonded to a first side of the membrane layer and a layer of roofing
granules is adhered to the first adhesive layer.
[0007] Other advantages of the roofing membrane will become
apparent to those skilled in the art from the following detailed
description, when read in view of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a perspective view of a building structure and an
attached low-slope roof according to the invention;
[0009] FIG. 2 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0010] FIGS. 2A-2C are enlarged cross-sectional views of exemplary
embodiments of reinforced granule-coated waterproof roofing
membranes;
[0011] FIG. 2D is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane with an
adhesion enhancing layer that enhances the adhesion between an
adhesive layer and a waterproof membrane layer;
[0012] FIG. 2E is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane with a
single layer that both enhances the adhesion between an adhesive
layer and a waterproof membrane layer and reinforces the waterproof
membrane layer;
[0013] FIG. 3 is a plan view of an exemplary embodiment of a
granule coated waterproof roofing membrane having the shape of a
three-tab shingle;
[0014] FIGS. 4A and 4B illustrate exemplary embodiments of granules
having different shapes;
[0015] FIG. 5 is a plan view of an exemplary embodiment of a
rectangular granule coated waterproof roofing membrane having an
appearance of a three-tab shingle;
[0016] FIG. 5A is a sectional view illustrating one embodiment of
the rectangular granule coated waterproof roofing membrane
illustrated by FIG. 5;
[0017] FIG. 5B is a sectional view illustrating another embodiment
of the rectangular granule coated waterproof roofing membrane
illustrated by FIG. 5;
[0018] FIG. 6 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0019] FIGS. 7A-7D are enlarged cross-sectional views of exemplary
embodiments of granule-coated waterproof roofing membranes;
[0020] FIG. 8 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0021] FIG. 9 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0022] FIG. 10 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0023] FIG. 11 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0024] FIG. 12 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0025] FIG. 13 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0026] FIG. 14 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0027] FIG. 15 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0028] FIG. 16 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane;
[0029] FIG. 17 is an enlarged cross-sectional view of an exemplary
embodiment of a granule-coated waterproof roofing membrane; and
[0030] FIG. 18 is perspective view of a roll of the granule-coated
roofing membrane.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The present invention will now be described with occasional
reference to the specific embodiments of the invention. This
invention may, however, be embodied in different forms and should
not be construed as limited to the embodiments set forth herein.
Rather, these embodiments are provided so that this disclosure will
be thorough and complete, and will fully convey the scope of the
invention to those skilled in the art.
[0032] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise.
[0033] Unless otherwise indicated, all numbers expressing
quantities of ingredients, properties such as molecular weight,
reaction conditions, and so forth as used in the specification and
claims are to be understood as being modified in all instances by
the term "about." Accordingly, unless otherwise indicated, the
numerical properties set forth in the specification and claims are
approximations that may vary depending on the desired properties
sought to be obtained in embodiments of the present invention.
Notwithstanding that the numerical ranges and parameters setting
forth the broad scope of the invention are approximations, the
numerical values set forth in the specific examples are reported as
precisely as possible. Any numerical values, however, inherently
contain certain errors necessarily resulting from error found in
their respective measurements.
[0034] As used in this application, the phrase "low-slope roof" is
defined as a roof having a slope or pitch within the range of from
about 1/4:12 to about 4:12. Proper roof design requires some slope
to promote drainage and prevent water ponding. As used in this
application, the phrase "steep-slope roof" is defined as a roof
having a slope or pitch greater than 4:12. Typical steep-slope
roofs have a slope or pitch from about 4:12 to about 18:12,
however, some steep-slope roofs may be even steeper. Details of
typical steep-slope roofs can be found in the Asphalt Roofing
Residential Manual, 2006, published by The Asphalt Roofing
Manufacturers Association (ARMA). Unless otherwise indicated, the
roofing materials described herein can be used in low-slope
applications and steep-slope applications.
[0035] As used in this application, the terms "pitch" and "slope"
in the context of a building structure roof are defined as the
amount of rise a roof has compared to the horizontal measurement of
the roof. A roof having a slope of 4:12 therefore means that for
every 12 inches of horizontal measurement, or roof run, the
vertical measurement, or roof rise is 4 inches.
[0036] Referring now to FIG. 1, a building structure 10 is shown
having a steep roof 11 with a shingle-based roofing system 12.
While the building structure 10 illustrated in FIG. 1 is a
residential home, it will be understood that the building structure
10 may be any type of structure, such as a garage, church, arena,
an industrial or commercial building, having a steep-slope roof 11
with a shingle-based roofing system 12 having a plurality of
shingles 14. A low-slope roof 16 extends from the building
structure 10 and may cover an open or enclosed patio, garage, or
carport, for example. The low-slope roof 16 includes a low-slope
roof deck 18.
[0037] FIG. 2 illustrates an exemplary embodiment of a
granule-coated roofing membrane 20. In the example illustrated by
FIG. 2, the granule-coated roofing membrane 20 includes a
waterproof membrane layer 22, an adhesive 24, and a layer of
roofing granules 28. The adhesive 24 adheres to the waterproof
membrane layer 22. The layer of roofing granules 28 is adhered to
the waterproof membrane layer 22 by the adhesive 24.
[0038] The waterproof membrane layers described in this application
may be made from a wide variety of different materials. For
example, the waterproof membrane 22 may be any membrane that
prevents water on a top side 22A of the membrane from passing
through the membrane 22 to a bottom side 22B of the membrane. That
is, the waterproof membrane layer 22 may be made from any water
impermeable material. Examples of materials that the waterproof
membrane layer 22 can be made from include, but are not limited to,
any thermoset material or any thermoplastic material. Examples of
thermoset materials that can be used include, but are not limited
to, EPDM (ethylene, propylene, diene monomer rubber), CSPE
(chlorosulfonated polyethylene), such as DuPont.RTM. Hypalon.RTM.,
CR (Neoprene), ECR (Epoxy Coated Rebar). Examples of thermoplastic
materials that can be used include, but are not limited to,
polyester, nylon, TPO (Thermoplastic Polyolefin), CPA (Copolymer
Alloy), PVC (polyvinylchloride), EIP (Ethylene Interpolymer), NBP
(Nitrile Alloy), PIB (Polyisobutylene), and CPE (Chlorinated
Polyethylene). The waterproof membrane can be made from any
combination of thermoset and/or thermoplastic materials, including
but not limited to, any combination of the thermoset and/or
thermoplastic materials disclosed by this application. The
waterproof membrane layer 22 may be formed as extruded sheets of
any one or any combination of these materials. The material of the
membrane layer 22 may have fire retardant properties, thereby
enhancing the fire retardant properties of the granule-coated
roofing membrane 20. In one exemplary embodiment, the membrane
layer is made from a ketone ethylene ester resin, such as
Dupont.TM. ELVALOY.RTM., polyvinylchloride (PVC), or a combination
of ketone ethylene ester and PVC.
[0039] The waterproof membrane layer 22 may be between about 1 and
about 120 mils thick. In one exemplary embodiment, the waterproof
membrane layer 22 is about 15-120 mils, such as between about 15
and about 80 mils or about 45-80 mils. In one exemplary embodiment,
when the waterproof membrane layer 22 is between 1-15 mils, the
waterproof membrane layer has a melting temperature that is greater
than 350 degrees F.
[0040] The waterproof membrane layer 22 may have a wide variety of
different configurations. Referring to FIG. 1, a low-slope roof 16
may use large, rectangular waterproof granule coated membrane
sheets 30. For a steep slope roof 11, the waterproof membrane layer
22 may have a smaller rectangular form or may be cut to provide the
appearance of a traditional shingle 14. For example, FIG. 3
illustrates that the waterproof membrane layer 22 may be cut into
the shape of a three-tab shingle 300. Such a waterproof membrane
layer 300 may be used to construct granule coated roofing membranes
20 that provide substantially the same appearance as a shingle and
can be installed in substantially the same manner as a shingle.
Individual three-tab shingles 300 may be made with the waterproof
membrane layer as illustrated by FIG. 3 or continuous/repeating
three-tab shingles 300 may be provided in roll form.
[0041] The adhesives described in this application may take a wide
variety of different forms. For example, the adhesive 24 may be any
material capable of adhering the granules 28 to the waterproof
membrane 22. Examples of materials that may be used as an adhesive
include, but are not limited to, asphalt, polymer modified asphalt,
butyl based adhesives, such as polyisobutylene, adhesives that cure
by drying, such as solvent based adhesives and polymer dispersion
adhesives, pressure sensitive adhesives, contact adhesives, hot
melt adhesives, such as thermoplastic adhesives, and
multi-component adhesives, such as acrylics, urethanes, and
epoxies. Examples of multi-part adhesives include polyester
resin-polyurethane resin, polyols-polyurethane resin, and acrylic
polymers-polyurethane resins. When adhesives other than asphalt
based adhesives are used, the adhesive may be dyed or otherwise
processed to have the dark or black appearance of asphalt.
[0042] In one exemplary embodiment, the granule holding function of
the adhesive layer 24 is provided by the waterproof membrane 22
itself, so that a separate adhesive layer is not required. For
example, the waterproof membrane 22 may be heated to provide the
waterproof membrane 22 with adhesive properties. Granules 28 can
then be applied to the waterproof membrane. For example, the
granules can be pressed into the adhesive. In another exemplary
embodiment, the granules 28 are heated and pressed into the surface
of the membrane 22. The heat from the granules 28 causes the
waterproof membrane to melt or partially melt around the granules.
In either case (membrane heating and/or granule heating), when the
waterproof membrane 22 and/or the granules 28 cool, the granules 28
are permanently adhered to the membrane 22.
[0043] When the adhesive(s) disclosed in this application is an
asphalt, the asphalt may be any asphalt-based material capable of
adhering the granules 28 to the waterproof membrane 22 and/or
capable of adhering the waterproof membrane 22 to a roof deck. In
one exemplary embodiment, the asphalt is not modified with a
polymer. In another exemplary embodiment, the asphalt is polymer
modified asphalt. The asphalt may be modified by any suitable
polymer, such as with styrene-butadiene-styrene (SBS), or
styrene-isoprene-styrene (SIS). Examples of polymer modified
asphalts are disclosed in U.S. Pat. Nos. 4,738,884 to Algrim et al.
and 3,770,559, to Jackson the contents of which are incorporated
herein by reference in their entirety. The asphalt used as the
adhesive layer 24 may include various types or grades of asphalt,
including flux, paving grade asphalt blends, propane washed
asphalt, oxidized asphalts, and/or blends thereof. Effective blends
of asphalt or bituminous materials are understood by those of
ordinary skill in the art. These polymer modified asphalts may also
include fillers. For example, the first adhesive layer 24 may
include a filler of finely ground inorganic particulate matter,
such as ground limestone, dolomite or silica, talc, sand, or
calcium carbonate in an amount within the range of from about 25
percent to about 60 percent by weight of the first adhesive layer
24. Other materials suitable for use in an asphalt adhesive layer
include process oils, tackifying resins, and other types of natural
and synthetic rubber materials and thermoplastic polymers.
Additionally, recycled roof tear-off materials, such as shingles,
may be included in the asphalt adhesive. Recycled shingles may be
processed in a wide variety of different ways to allow the material
to be used in the adhesive. For example, tear off shingles may be
processed as described in U.S. Patent Application 20110049275 to
Zickell, to be used as a filler or an additive to the adhesive
layer 24.
[0044] The adhesive layer 24 can be applied to the substrate 22 in
a wide variety of different manners. In one exemplary embodiment,
the adhesive layer may be between about 10 mils and about 100 mils
or may be between about 15 mils and about 100 mils. The adhesive
layer 24 may be applied to the entire upper surface 22A of the
substrate 22 or only portions of the substrate. For example, the
adhesive layer 24 may be applied to the area of the roofing
material 20 that is exposed (i.e. the area that is not covered by
other roofing material 20) and the adhesive layer 24 is not applied
to the unexposed area (i.e. the area that is covered by other
roofing material 20) or a portion of the unexposed area.
[0045] The roofing granules 28 may take a wide variety of different
forms. In an exemplary embodiment, the roofing granules are dense,
non-porous, UV-ray resistant, natural mineral particles coated in
ceramic. The mineral particles may be silica rich minerals, such as
rhyolite. Colored pigments may be applied to the base mineral by
the ceramic coating that covers the granule. Roofing granules are
available from 3M.
[0046] Any desired color, color blend, or combinations of colors
and color blends of granules may be applied to define the layer of
roofing granules 28. Advantageously, the granule-coated roofing
membrane 20 may be manufactured to include colors and/or color
blends of granules 28 that match, coordinate with, and/or
complement the colors and/or color blends of the granules of the
roofing shingles 14 installed on other portions of the building
structure 10. For example, in one exemplary embodiment, the
traditional shingles 14 are used on one portion of the building and
the roofing material 20 is used on another portion of the building.
By matching, coordinating with, and/or complementing the colors
and/or color blends of the granules of the roofing shingles 14 with
the granule-coated roofing material 20, an aesthetically pleasing
appearance is achieved.
[0047] The waterproof membrane 22 provides flexibility in the
selection of the granules 28 that may be used on the roofing
material 20. Since the waterproof membrane provides the
waterproofing and/or water shedding feature of the roofing material
20, the granules 28 may be selected to provide an aesthetically
pleasing appearance without needing to meet the high performance
requirements of granules of conventional shingles. For example,
granules that are not typically used in roofing applications may be
used.
[0048] As is mentioned above, traditional roofing granules are
UV-ray resistant/UV opaque and have a ceramic coating. The UV
resistance and the ceramic coating protects the asphalt of
traditional shingles. If a waterproof membrane 22 and/or adhesive
24 do not need to be protected from UV rays, granules that are not
traditionally used in roofing applications can be used. For
example, granules that are not UV opaque and/or that are not coated
in ceramic can be used. Examples of granules that are not
traditionally exposed in roofing applications that may be used with
the waterproof membrane 22 include, but are not limited to uncoated
mineral particles, such as rhyolite and other silica rich minerals,
rock dust, and coal slag.
[0049] The roofing granules 28 may have a variety of different
sizes. In one exemplary embodiment, the size and/or shape of the
granules 28 used on the roofing material 20 is different than the
size and/or shape of the granules used of the corresponding
conventional shingles 14. For example, the average size of the
granules used on the roofing material 20 are about 10%, about 20%,
about 30%, about 40%, about 50%, or between 10% and 50% larger or
smaller than the average size of the granules of a corresponding
conventional shingle.
[0050] Referring to FIG. 4A, the granules of a traditional shingle
may have roughly equivalent length L.sub.1, height H.sub.1, and
width W.sub.1 dimensions. Referring to FIG. 4B, the granules 28 of
the roofing material 20 may be selected to have a shorter height
dimension H.sub.2 vs. a wider width dimension W.sub.2 and/or a
longer length dimension L.sub.2 (i.e. flatter granule). This allows
fewer granules and less granule material to be used on the roofing
material 20 as compared to a traditional shingle 14. For example, a
ratio R of granule height H over granule width W and granule length
L:
R=H/(W+L)
[0051] of the granules for the roofing material 20 may be
significantly lower than the ratio for the granules of a
traditional shingle. For example, the average ratio R.sub.2 of the
granules used on the roofing material 20 are about 10%, about 20%,
about 30%, about 40%, about 50%, or between 10% and 50% less than
the ratio R.sub.1 for the granules of a corresponding conventional
shingle.
[0052] Roofing granules used to define the layer of roofing
granules 28 may be applied to the first adhesive layer 24 by any
desired method. Examples of methods and apparatus for applying
roofing granules to an asphalt coated sheet are disclosed in U.S.
Pat. Nos. 5,746,830 to Burton et al., 6,228,422 to White et al.,
6,610,147 to Aschenbeck, and 7,163,716 to Aschenbeck, each of which
is incorporated herein by reference in their entirety.
[0053] The layer of roofing granules 28 can be applied to the
substrate 22 in a wide variety of different manners. The layer of
roofing granules 28 may be applied to the adhesive coating 24 or
only portions of the adhesive coating. For example, the layer of
granules may be applied to the area of the roofing material 20 that
is exposed (i.e. the area that is not covered by other roofing
material 20) and the layer of granules is not applied to the
unexposed area (i.e. the area that is covered by other roofing
material 20) or a portion of the unexposed area.
[0054] The layer of granules 28 can be applied in a manner that
provides the roofing material 20 with a desired appearance. For
example, referring to FIG. 5 the adhesive 24 and/or the roofing
granules 28 can be applied to an uncut rectangular substrate 400 to
provide the appearance of a traditional three-tab shingle. Areas
402 having the appearance of the cuts between tabs 404 can be
provided by applying darker or black granules 28 in the areas 402,
masking, applying mineral dust, or otherwise preventing the layer
of granules 28 from being applied in the areas (See FIG. 5B),
and/or masking, applying mineral dust, or otherwise preventing the
granules and adhesive 24 from being provided in the areas 402 (See
FIG. 5A). In one embodiment, the adhesive 24 may be applied to the
entire tab region 404 of the roofing material and a mineral dust
406 or other material that prevents adhesion of the granules is
deposited in the areas 400 (See FIG. 5B). A wide variety of
different appearances can be provided by the roofing material 20,
without cutting a rectangular shaped substrate 22, by controlling
the application of the adhesive 24 and/or granules.
[0055] Referring to FIGS. 2A-2C, in one exemplary embodiment, the
physical properties of the membrane layer 22 may be enhanced by a
reinforcing layer 200. The membrane layer 22 may be applied to the
reinforcing layer 200 or the reinforcing layer 200 may be applied
to the membrane layer 22 in a wide variety of different ways. In
FIG. 2A, the reinforcing layer 200 is on the top surface 22A of the
waterproof membrane layer 22. In FIG. 2B, the waterproof membrane
layer 22 is on the reinforcing layer 200. In FIG. 2C, the
reinforcing layer 200 is inside the waterproof membrane layer 22 or
between two waterproof membrane layers.
[0056] The reinforcing layer 200 can be made from a wide variety of
different materials. Any material that increases the physical
properties, such as tear strength, tensile strength, and/or
puncture resistance of the granule coated waterproof membrane 20
can be used. Examples of suitable materials that the reinforcing
layer 200 can be made from include, but are not limited to, woven,
knitted, or nonwoven glass, polyester, or combinations thereof. An
example of a knitted material is a weft inserted fabric. The
reinforcing layer 200 can be applied to the waterproof membrane
layer 22 in a variety of different ways. For example, the
reinforcing layer 200 can be fused to the waterproof membrane layer
22 or an adhesive, such as a polymeric adhesive, can be used to
adhere the reinforcing layer 200 to the waterproof membrane layer
22.
[0057] The combination of the reinforcing material and material of
the waterproof membrane 22 provides improved breaking strength,
tearing strength, and puncture resistance. Additionally, the
material of the membrane layer 22 and/or the reinforcing layer 200
may have fire retardant properties.
[0058] In one exemplary embodiment, the waterproof membrane layer
22 and the reinforcing layer 200 are configured to have a much
higher "nail pull through" force than a conventional shingle 14.
Shingles are typically secured to a roof deck with nails. The nail
pull through force is the amount of force required to pull the
shingle material over the head of the nail. ASTM D3462 requires
conventional shingles to pass a minimum of 20 lbf nail pull test.
The nail pull through force for some conventional shingles with an
unreinforced nail zone is about 40 lbf. In one exemplary
embodiment, the nail pull through force for a granule coated
substrate 20 having a woven or knitted reinforcement layer 200 on a
rear surface 22A of the membrane layer is over 100 lbf, may be over
140 lbf, and may be over 200 lbf. In exemplary embodiments, the
nail pull through force for a granule coated substrate 20 having a
woven or knitted reinforcement layer 200 is over 7 times, over 8
times, over 9 times, or over ten times the nail pull through force
for a conventional shingle with an unreinforced nail zone.
[0059] In one exemplary embodiment, the waterproof membrane layer
22 and the reinforcing layer 200 are configured to have a much
higher puncture resistance than a conventional shingle 14. The
puncture resistance for some conventional low-slope roofing
materials is about 20 to 50 lbf. In one exemplary embodiment, the
puncture resistance for a granule coated substrate 20 having a
woven or knitted reinforcement layer 200 is over 175 lbf, such as
from about 175 lbf to about 250 lbf. In exemplary embodiments, the
puncture resistance for a granule coated substrate 20 having a
woven or knitted reinforcement layer is about five times to about
ten times the puncture resistance for a conventional low-slope
roofing material.
[0060] In one embodiment, the membrane layer 22 is the
FIBERTITE.RTM. membrane product manufactured by Seaman Corporation
of Wooster, Ohio. (See http://fibertite.com/home.php, accessed Sep.
2, 2011). In this embodiment, the membrane consists of a woven or
knitted fabric layer coated with an adhesive and a proprietary
blend of DuPont ELVALOY.RTM. ketone ethylene ester (KEE) resin. In
this alternate embodiment, the resin may be applied to one or both
sides; i.e., the broad faces, of the woven or knitted fabric layer
and may impregnate the woven or knitted fabric layer.
[0061] Referring to FIG. 2D, in one exemplary embodiment, the
adhesion between the membrane layer 22 and the adhesive 24 may be
enhanced by an adhesion promoting layer 300. The adhesion promoting
layer 300 can take a wide variety of different forms. The adhesion
promoting layer 300 provides a textured multi-dimensional surface
which optimizes adhesion with asphalt or other adhesive 24 for the
exposed surface of the granule coated waterproof membrane 20. In an
exemplary embodiment, the adhesion promoting layer 300 is bonded to
the membrane layer 22. The adhesion promoting layer 300 can be
bonded to the waterproof membrane layer 22 in a variety of
different ways. For example, the adhesion promoting layer 300 can
be fused to the waterproof membrane layer 22 or an adhesive, such
as a polymeric adhesive, can be used to adhere the adhesion
promoting layer 300 to the waterproof membrane layer 22. The
illustrated adhesion promoting layer 300 includes discrete
projections 302, strands, or other surfaces that extend into the
adhesive 24 to promote a strong bond between adhesion promoting
layer 300 and the adhesive 24.
[0062] Examples of materials that can be used for the adhesion
promoting layer 300 include, but are not limited to felt material,
such as polyester non-woven fleece, texturized yarns, bare yarn,
and any other material that provides a textured surface for better
mechanical adhesion of the adhesive to the membrane 22.
[0063] Referring to FIG. 2E, in one exemplary embodiment the
functions of the adhesion promoting layer 300 and the reinforcing
layer 200 may be provided by a single layer. For example, a surface
250 of one of the reinforcing layers 200 described above may be
treated or processed to provide discrete projections 302 or strands
that promote adhesion. Further, a non-woven reinforcement layer 200
may already have characteristics that also make the layer a good
adhesion promoting layer. A woven or knitted reinforcement layer
200 have the surface 250 that contacts the adhesive 24 processed to
provide adhesion promoting properties. For example, the surface 250
of the woven or knitted reinforcement layer may be initially formed
with extending projections or strands, or may be abraded, scuffed,
grated or cut to provide projections or strands that promote
adhesion.
[0064] The reinforcement layer 200 may include strands of textured
yarns, such as textured polyester yarns. Air textured yarn is a
yarn that has been processed to introduce durable crimps, coils,
loops or other fine distortions along the length of the fibers,
thereby altering the surface texture and topography of the
reinforcement layer fabric. The texturing process may include one
or more of the following processes: twisting yarn, heat-setting and
then untwisting; passing the yarn through a heated "stuffer box";
passing the heating yarn over a knife edge; passing the heated yarn
between a pair of geared wheels or some similar device; and
knitting the yarn into a fabric reinforcement layer, heat-setting,
then unraveling the yarn. The use of air textured yarn in the
reinforcement layer 200 improves adhesion of asphalt, or other
adhesive 24 to the waterproof membrane 22. As such, a woven or
knitted reinforcement layer may be selected to both promote
adhesion and reinforce the membrane layer 22.
[0065] In one exemplary embodiment, the waterproof membrane 22 may
be processed to perform the functions of the adhesion promoting
layer 300 and thereby eliminate an adhesion promoting layer made
from discrete materials. For example, a surface 22A or 22B of the
waterproof membrane 22 may be treated or processed to provide
discrete projections or strands that promote adhesion. For example,
a surface of the waterproof membrane layer may be initially formed
with projections or strands, or may be abraded, scuffed, grated or
cut to provide projections or strands that promote adhesion.
[0066] The layers of granules 28, adhesive 24, waterproof membranes
22, reinforcement layers 200, and/or adhesion promoting layers 300
disclosed herein can be combined in a variety of different ways to
construct many different granule coated waterproof membranes 20.
FIGS. 6-11 illustrate some of the possible configurations.
[0067] In FIG. 6, a first adhesive layer 24 is applied to a first
side 22A of the membrane layer 22 (upwardly facing surface when
installed on a roof). A second adhesive layer 26 is applied to a
second side 22B of the membrane layer 22 (downwardly facing surface
when installed on a roof). A layer of roofing granules 28 is
applied to the first adhesive layer 24 and defines a granule-coated
surface 30.
[0068] A release layer 32 is applied to the second adhesive layer
26. The release layer may take a wide variety of different forms.
The release layer 32 can be any material that removably adheres to
the second adhesive layer 26. Examples of acceptable materials for
the release layer 32 include, but are not limited to, plastic
materials, such as plastic films (i.e. polyolefin film,
polypropelyne film, etc.), coated materials, such as paper, plastic
or other material coated with silicone or other release material.
The release layer 32 prevents the granule-coated roofing membrane
20 from adhering to itself when arranged in a roll 34 (See FIG.
18), as described below or when sheets of the granule coated
roofing membrane 22 are stacked. The release layer 32 may be
removed by a roof installer so that the bottom surface, or surface
opposite the granule-coated surface 30 of granule-coated roofing
membrane 20, will adhere to the low-slope roof deck 18 or
steep-slope roof as shown in FIG. 1.
[0069] The second adhesive layer 26 may be identical to the first
adhesive layer 24. In the embodiments disclosed herein, the second
adhesive layer 26 is provided to adhere or bond the granule-coated
roofing membrane 20 to the low-slope roof deck 18 or the
steep-slope roof 11. Alternatively, the second adhesive layer 26
may be a softer asphalt material relative to the asphalt material
of the first adhesive layer 24. The second adhesive layer 26 may
also contain more light oil relative to the first adhesive layer
24, therefore making the second adhesive layer 26 softer, more
flexible, and have stronger or better adhesion properties than the
first adhesive layer 24. One method of applying a relatively
non-adhesive asphaltic material and an adhesive asphalt coating to
a woven or non-woven fibrous mat is disclosed in U.S. Pat. No.
6,296,912 to Zickell, which is incorporated herein by reference in
its entirety.
[0070] It will be understood that the second adhesive layer 26 is
not required and that the granule-coated roofing membrane 20 may be
manufactured without the second adhesive layer 26. In an embodiment
without the second adhesive layer 26, the granule-coated roofing
membrane 20 may be attached to the low-slope roof deck 18 or
steep-slope roof deck, or any layer of material intermediate the
low-slope roof deck 18 or steep-slope roof deck and the
granule-coated roofing membrane 20, by any desired means. For
example, the granule-coated roofing membrane 20 may be attached to
the low-slope roof deck 18 with an adhesive applied to any one or
more of the low-slope roof deck 18, the membrane layer 22, and an
intermediate layer of material. The granule-coated roofing membrane
20 may also be attached to the low-slope roof deck 18 or
steep-slope roof deck with mechanical fasteners.
[0071] In the example illustrated by FIGS. 7A-7D, the granule
coated waterproof membrane 20 includes a layer of granules 28, a
first adhesive layer 24, such as a first asphalt adhesive layer, an
adhesion promoting layer 300, a waterproof membrane 22, and a
reinforcement layer 200. In the example illustrated by FIG. 7B, the
granule coated waterproof membrane 20 also includes a second
adhesive layer 26, such as a second asphalt adhesive layer.
Referring to FIG. 7C, in an exemplary embodiment, the surface 250
of the reinforcement layer 200 is configured to promote adhesion of
the reinforcement layer 200 to the second adhesive layer 26. For
example, in FIG. 7C the surface 250 is illustrated as having
strands or projections 302. FIG. 7D is an embodiment that is
similar to the embodiment of FIG. 7C, except the adhesion promoting
layer 300, the waterproof membrane 22, and the reinforcement layer
200 are flipped. That is, in the FIG. 7C embodiment, the
reinforcement layer 200 is on top of the waterproof membrane 22 and
the adhesion promoting layer is on the bottom of the waterproof
membrane 22.
[0072] FIG. 8 illustrates exemplary embodiments of self adhering,
waterproof, granule coated roofing membranes 800. The following is
a description of the different layers illustrated by FIG. 8:
[0073] 801--Roofing Granules, such as the roofing granules 28
described herein.
[0074] 802--Adhesive, such as the layer of adhesive 24 described
herein.
[0075] 803--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0076] 804--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0077] 806--Reinforcement material, such as the reinforcement layer
200 described herein.
[0078] 805--Adhesive, such as a polymer adhesive, which may be a
polyvinylchloride adhesive, for adhering the layer 806 to the layer
804.
[0079] 808--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0080] 807--Adhesive, such as a polymer adhesive, which may be a
polyvinylchloride adhesive, for adhering the layer 808 to the layer
806.
[0081] 809--Adhesive, such as the layer of adhesive 26 described
herein.
[0082] Any combination of the layers illustrated by FIG. 8 can be
used to make a variety of different self adhering, waterproof,
granule coated roofing membranes 800. The rows of the following
table identify some of the possible combinations. An "X" in a cell
of each row indicates the presence of each layer in the example
indicated by the row. A cell without an "X" indicates that the
layer is not included in the example indicated by the row.
TABLE-US-00001 Layer Layer Layer Layer Layer Layer Layer Layer
Layer 801 802 803 804 805 806 807 808 809 X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X
[0083] FIG. 9 illustrates exemplary embodiments of fastener (for
example, nails) applied, waterproof, granule coated roofing
membranes 900. The following is a description of the different
layers illustrated by FIG. 9:
[0084] 901--Roofing Granules, such as the roofing granules 28
described herein.
[0085] 902--Adhesive, such as the layer of adhesive 24 described
herein.
[0086] 903--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0087] 904--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0088] 906--Reinforcement material, such as the reinforcement layer
200 described herein.
[0089] 905--Adhesive, such as a polymer adhesive, which may be a
polyvinylchloride adhesive, for adhering the layer 906 to the layer
904.
[0090] 908--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0091] 907--Adhesive, such as a polymer adhesive, which may be a
polyvinylchloride adhesive, for adhering the layer 908 to the layer
906.
[0092] Any combination of the layers illustrated by FIG. 9 can be
used to make a variety of different fastening, waterproof, granule
coated roofing membranes 900. The rows of the following table
identify some of the possible combinations. An "X" in a cell of
each row indicates the presence of each layer in the example
indicated by the row. A cell without an "X" indicates that the
layer is not included in the example indicated by the row.
TABLE-US-00002 Layer Layer Layer Layer Layer Layer Layer Layer 901
902 903 904 905 906 907 908 X X X X X X X X X X X X X X X X X X X X
X
[0093] FIG. 10 illustrates additional exemplary embodiments of self
adhering, waterproof, granule coated roofing membranes 1000. The
following is a description of the different layers illustrated by
FIG. 10:
[0094] 1001--Roofing Granules, such as the roofing granules 28
described herein.
[0095] 1002--Adhesive, such as the layer of adhesive 24 described
herein.
[0096] 1003--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0097] 1004--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0098] 1005--Reinforcement material, such as the reinforcement
layer 200 described herein.
[0099] 1006--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0100] 1007--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0101] 1008--Adhesive, such as the layer of adhesive 26 described
herein.
[0102] Any combination of the layers illustrated by FIG. 10 can be
used to make a variety of different self adhering, waterproof,
granule coated roofing membranes 1000. The rows of the following
table identify some of the possible combinations. An "X" in a cell
of each row indicates the presence of each layer in the example
indicated by the row. In FIG. 10, it should be noted that when
reinforcement layer 1005 is removed, the resulting depicted
configuration implies a single membrane layer (i.e. layers 1004 and
1006 merge). A cell without an "X" indicates that the layer is not
included in the example indicated by the row.
TABLE-US-00003 Layer Layer Layer Layer Layer Layer Layer Layer 1001
1002 1003 1004 1005 1006 1007 1008 X X X X X X X X X X X X X X X X
X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
X X
[0103] FIG. 11 illustrates exemplary embodiments of fastener (for
example, nails) applied, waterproof, granule coated roofing
membranes 1100. The following is a description of the different
layers illustrated by FIG. 11:
[0104] 1101--Roofing Granules, such as the roofing granules 28
described herein.
[0105] 1102--Adhesive, such as the layer of adhesive 24 described
herein.
[0106] 1103--Adhesion promoting material, such as the adhesion
promoting layer 300 described herein.
[0107] 1104--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0108] 1105--Reinforcement material, such as the reinforcement
layer 200 described herein.
[0109] 1106--Waterproof membrane material, such as the waterproof
membrane material 22 described herein.
[0110] Any combination of the layers illustrated by FIG. 11 can be
used to make a variety of different fastening, waterproof, granule
coated roofing membranes 1100. The rows of the following table
identify some of the possible combinations. An "X" in a cell of
each row indicates the presence of each layer in the example
indicated by the row. In FIG. 11, it should be noted that when
reinforcement layer 1105 is removed, the resulting depicted
configuration implies a single membrane layer (i.e. layers 1104 and
1106 merge). A cell without an "X" indicates that the layer is not
included in the example indicated by the row.
TABLE-US-00004 Layer Layer Layer Layer Layer Layer 1101 1102 1103
1104 1105 1106 X X X X X X X X X X X X X X X X X X X X
[0111] The granule coated waterproof roofing membrane may be formed
in a wide variety of different ways. In one exemplary embodiment,
the granule-coated roofing membrane 20 is formed using a continuous
manufacturing process. For example, the membrane layer 22 may be
provided as a continuous sheet of material having a width W of
about 3 feet (See FIG. 18). It will be understood that the membrane
layer 22 may have any other desired width. The width W of the
membrane layer 22 will be determined by the intended use of the
finished granule-coated waterproof roofing membrane 20. For
example, for residential building applications, the membrane layer
22 may have a width within the range of from about 2 feet to about
5 feet. For commercial building applications, the membrane layer 22
may have a much larger width, such as within the range of from
about 6 feet to about 12 feet. The membrane layer 22 may have any
other desired width, such as a width smaller than about 2 feet and
a width larger than about 12 feet.
[0112] In a first step of the manufacturing process, the first
adhesive layer 24 and the second adhesive layer 26 may be applied
to the first side 22A and the second side 22B, respectively, of the
membrane layer 22. As discussed above, one method of applying a
relatively non-adhesive asphaltic material and an adhesive asphalt
coating; i.e., the first adhesive layer 24 and the second adhesive
layer 26, to a woven or non-woven fibrous mat is disclosed in U.S.
Pat. No. 6,296,912 to Zickell. In an exemplary embodiment, the
method disclosed by Zickell is adapted to apply the first adhesive
layer 24 and the second adhesive layer 26 to the waterproof
membrane 22.
[0113] Granules 28 may then be applied to the first adhesive layer
24, thereby defining the granule-coated roofing membrane 20. As
discussed above, various examples of methods and apparatus for
applying roofing granules to an asphalt coated sheet are disclosed
in U.S. Pat. Nos. 5,746,830 to Burton et al., 6,228,422 to White et
al., 6,610,147 to Aschenbeck, and 7,163,716 to Aschenbeck.
[0114] If desired, the release layer 32 may then be applied to the
second adhesive layer 26. The release layer 32 may be applied to
the second adhesive layer 26 before, after, or concurrently with
the application of granules 28 to the first adhesive layer 24.
[0115] The granule-coated roofing membrane 20 may then be wound
into a roll 34, as shown in FIG. 18. The roll 34 of the
granule-coated roofing membrane 20 may have any desired diameter.
Alternatively, the granule-coated roofing membrane 20 may be cut to
discrete lengths and stacked for subsequent packaging and
shipping.
[0116] Advantageously, the granule-coated surface 30 of the
granule-coated roofing membrane 20 may be manufactured to include
colors and/or color blends of granules 28 that match, coordinate
with, and/or complement the colors and/or color blends of the
granules of the roofing shingles 14 installed on the building
structure 10. By matching, coordinating with, and/or complementing
the colors and/or color blends of the granules of the roofing
shingles 14 with the granule-coated roofing membrane 20, an
aesthetically pleasing appearance is achieved.
[0117] The granule-coated surface 30 of the granule-coated roofing
membrane 20 may prevent any unevenness in the underlying low-slope
roof deck 18 from telegraphing through the granule-coated roofing
membrane 20 by masking any such unevenness. The granule-coated
roofing membrane 20 may have improved weathering performance. In
one exemplary embodiment, the addition of ceramic-coated granules
to asphaltic roofing materials enhances weathering performance by
providing UV protection for the underlying asphalt base. The life
expectancy of a typical steep-slope shingle is typically 15 to 20
years or more. Likewise, typical commercial roofing membranes are
known to withstand the effects of weather and perform
satisfactorily over as many as 10 to 20 years. By combining a
robust membrane and ceramic-coated roofing granules, the weathering
performance of the granule-coated roofing membrane 20 of the
present invention will be improved relative to a typical low-slope
and steep-slope roofing products.
EXAMPLES
[0118] In the following examples, various membrane configurations
were supplied by Seaman Corporation. These membranes were coated on
a commercial roofing line operated by Northern Elastommics, Inc. in
Brentwood N.H. Coating consisted of a first asphalt layer 24 on the
upper surface followed by a second asphalt layer 26 on the lower
surface. Once coated, standard roofing granules 28 supplied by
Grantech Inc., were applied to the first asphalt coating 24. A
siliconized polyethylene release liner 32 was applied to the second
asphalt coating. The final product was cut to length and packaged
prior to testing.
[0119] Tables 1-4 reflect properties of examples of six
granule-coated roofing membranes made in accordance with the
present application. All testing is performed at 23.degree.
C.+/-2.degree. C. Puncture testing is based on a modified version
of ASTM D5602. Modifications include use of an instrumented tensile
tester with a 1/2'' radius steel probe at a penetration rate of
1/2'' per minute. Sample size is 4'' square, and is held in place
with a metal frame having a 2.5'' diameter circular, central open
area. Testing is done such that the probe penetrates the granule
side. Tensile Testing and Tear Testing are based on requirements of
ASTM D5147. Granule Embedment (also referred to as granule
adhesion, scrubs, or granule loss) is based on ASTM D4977.
Example 1
[0120] FIG. 12 schematically illustrates the roofing membrane 1200
of Example 1. The roofing membrane 1200 shown as 1 in Tables 1-4
was produced using an 18 to 20 oz./sq. yd. weft-inserted polyester
reinforcement 1202. A PVC based adhesive compound 1204 was coated
on the top side of the reinforcement 1202, but not on the bottom
side. An additional PVC/Elvaloy blend 1206 was coated on the top,
weathering, surface. Total thickness of this construction
(1202+1204+1206) was approximately 24 mils. In comparison to
Example 6 in Table 1, no adhesive was placed on the bottom side to
improve mechanical adhesion of the asphaltic adhesive coating
26.
Example 2
[0121] FIG. 13 schematically illustrates the roofing membrane 1300
of Example 2. The roofing membrane 1300 shown as 2 in Tables 1-4
was produced using an 18 to 20 oz./sq. yd. weft-inserted polyester
reinforcement 1302. The yarns used for the reinforcement structure
included a texturized polyester yarn. A PVC based adhesive compound
1204 was coated on the top side of the membrane, but not on the
bottom side. An additional PVC/Elvaloy blend 1206 was coated on the
top, weathering, surface. Total thickness of this construction
(1302+1204+1206) was approximately 27 mils. In comparison to 1, a
texturized yarn of the polyester reinforcement 1302 was used to
provide a "fuzzy" or stranded surface for mechanical adhesion of
the asphaltic adhesive coating 26.
Example 3
[0122] FIG. 14 schematically illustrates the roofing membrane 1400
of Example 3. The roofing membrane 1400 shown as 3 in Tables 1-4
was produced using an 18 to 20 oz./sq. yd. weft-inserted polyester
reinforcement 1202 identical to that used in 1. A PVC based
adhesive compound 1204 was coated on the top side of the membrane,
but not on the bottom side. An additional PVC/Elvaloy blend 1206
was coated on the top surface. A polyester fleece 1408 was then
adhered to the top surface. Total thickness of this construction
(1202+1204+1206+1408) was approximately 40 mils. In comparison to
1, the additional fleece was used to provide a "fuzzy" or stranded
top surface to promote mechanical adhesion of the asphaltic
adhesive coating 24.
Example 4
[0123] FIG. 15 schematically illustrates the roofing membrane 1500
of Example 4. The roofing membrane 1500 shown as 4 in Tables 1-4
was produced using an 18 to 20 oz./sq. yd. weft-inserted polyester
reinforcement 1302 identical to that used in 2. The yarns used for
the reinforcement structure included a texturized polyester yarn. A
PVC based adhesive compound 1204 was coated on the top side of the
membrane, but not on the bottom side. An additional PVC/Elvaloy
blend 1206 was coated on the top surface. A polyester fleece 1408
was then adhered to the top surface. Total thickness of this
construction (1302+1204+1206+1408) was approximately 40 mils. In
comparison to 2, the additional fleece was used to provide a
"fuzzy" top surface to promote mechanical adhesion of the asphaltic
adhesive coating 24.
Example 5
[0124] FIG. 16 schematically illustrates the roofing membrane 1600
of Example 5. The roofing membrane 1600 shown as 5 in Tables 1-4
was produced using a 24 oz./sq. yd. woven or knitted polyester
reinforcement 1602. A PVC based adhesive compound 1204 was coated
on the top side of the membrane, but not on the bottom side. This
modified reinforcement 1602 design provided a tighter weave,
preventing bleed-through of the adhesive compound to the back-side
of the membrane. An additional PVC/Elvaloy blend 1206 was coated on
the top surface. A polyester fleece 1408 was then adhered to the
top surface. Total thickness (1602+1204+1206+1408) of this
construction was approximately 40 mils. In comparison to 1, the
additional fleece was used to provide a "fuzzy" or stranded top
surface to promote mechanical adhesion of the asphaltic adhesive
coating 24, and the tighter weave provided for a bottom surface
virtually free of adhesive compound (caused by bleed-through of the
calendering process).
Example 6
[0125] FIG. 17 schematically illustrates the roofing membrane 1700
of Example 6. The roofing membrane 1700 shown as 6 in Tables 1-4
was produced using an 18 to 20 oz./sq. yd. weft-inserted polyester
reinforcement 1202. A PVC based adhesive compound 1204, 1704 was
coated on the top and bottom sides of the membrane. An additional
PVC/Elvaloy blend 1206 was coated on the top, weathering, surface.
Total thickness of this construction (1202+1204+1206+1704) was
approximately 27 mils.
[0126] Testing of physical properties of these granule-coated
roofing membranes is summarized in Table 1. The thicknesses and
weights of the granule coated waterproof membranes and the layers
of the granule coated waterproof membranes is summarized in Tables
2-4.
TABLE-US-00005 TABLE 1 Physical Properties of Example Granule
Coated Membranes Granule Tensile Granule Coated Puncture (lbf/in)
Tear (lbf) Embedment Membrane (lbf) CD MD CD MD (g) 1 230 230 280
250 230 1.82 2 190 200 300 140 200 1.52 3 290 300 360 340 330 4.23
4 240 210 370 200 330 3.34 5 250 270 320 310 360 1.72 6 250 260 310
210 200 3.12
TABLE-US-00006 TABLE 2 Granule Coated Waterproof Roofing Membrane
Thickness & Weight Granule Coated Thickness Sq Ft Wt Membrane
(mils) (lbs/sq ft) 1 122.1 0.84 2 125.5 0.85 3 148.4 0.78 4 136.5
0.70 5 148.5 0.82 6 132.2 0.92
TABLE-US-00007 TABLE 3 Reinforced Waterproof Membrane Thickness
& Weight Reinforced Waterproof Membrane Thickness Sq Ft Wt
Construction (mils) (lbs/sq ft) 1 24.8 0.135 2 26.8 0.129 3 49.6
0.171 4 48.6 0.177 5 48.2 0.166 6 28.0 0.170
TABLE-US-00008 TABLE 4 Granule Coated Roofing Membrane Composition
Thicknesses (Average Values) Top Reinforced Bottom Adhesive +
Waterproof adhesive Granules membrane layer Example (mils) (mils)
(mils) 1 91.8 24.8 5.5 2 91.7 26.8 7.0 3 88.8 49.6 10.0 4 70.2 48.6
17.7 5 80.5 48.2 19.8 6 95.9 28.0 8.3
[0127] Additionally, granule-coated roofing membrane of the present
invention may be formed as a single ply, thereby resulting in
reduced material and labor costs relative to typical multi-ply
low-slope and steep-slope roofing products.
[0128] The principle and mode of operation of the granule-coated
waterproof roofing membrane have been described in its preferred
embodiments. However, it should be noted that the granule-coated
waterproof roofing membranes described herein may be practiced
otherwise than as specifically illustrated and described without
departing from its scope.
* * * * *
References