CA2815451A1 - Roofing material and method of use - Google Patents
Roofing material and method of use Download PDFInfo
- Publication number
- CA2815451A1 CA2815451A1 CA2815451A CA2815451A CA2815451A1 CA 2815451 A1 CA2815451 A1 CA 2815451A1 CA 2815451 A CA2815451 A CA 2815451A CA 2815451 A CA2815451 A CA 2815451A CA 2815451 A1 CA2815451 A1 CA 2815451A1
- Authority
- CA
- Canada
- Prior art keywords
- roofing material
- roofing
- mat
- elastomeric
- surface coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 239000000463 material Substances 0.000 title claims abstract description 76
- 238000000034 method Methods 0.000 title description 13
- 238000000576 coating method Methods 0.000 claims abstract description 32
- 239000011248 coating agent Substances 0.000 claims abstract description 31
- 239000000758 substrate Substances 0.000 claims abstract description 12
- 229920000642 polymer Polymers 0.000 claims description 5
- 230000005855 radiation Effects 0.000 claims description 5
- 239000003292 glue Substances 0.000 claims description 4
- 238000009434 installation Methods 0.000 claims description 3
- 229920002544 Olefin fiber Polymers 0.000 claims description 2
- 239000004743 Polypropylene Substances 0.000 claims description 2
- 239000000835 fiber Substances 0.000 claims description 2
- 238000007654 immersion Methods 0.000 claims description 2
- 239000004767 olefin fiber Substances 0.000 claims description 2
- -1 polypropylene Polymers 0.000 claims description 2
- 229920001155 polypropylene Polymers 0.000 claims description 2
- 239000007921 spray Substances 0.000 claims description 2
- 239000010426 asphalt Substances 0.000 description 15
- 239000012528 membrane Substances 0.000 description 7
- 238000001035 drying Methods 0.000 description 5
- 238000005520 cutting process Methods 0.000 description 4
- 229920001971 elastomer Polymers 0.000 description 4
- 239000000806 elastomer Substances 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000003973 paint Substances 0.000 description 3
- 230000004224 protection Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 239000002184 metal Substances 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 230000006750 UV protection Effects 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000004026 adhesive bonding Methods 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000002791 soaking Methods 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
- E04D1/20—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of plastics; of asphalt; of fibrous materials
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
- E04D5/02—Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
- Roof Covering Using Slabs Or Stiff Sheets (AREA)
Abstract
A roofing material for use on flat or sloped roofs comprising a non-woven polymeric mat substrate, and an elastomeric surface coating applied to and impregnating the polymeric mat substrate.
Description
ROOFING MATERIAL AND METHOD OF USE
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to roofing materials and in particular relates to non-tar based roofing materials.
BACKGROUND
FIELD OF THE DISCLOSURE
[0001] The present disclosure relates to roofing materials and in particular relates to non-tar based roofing materials.
BACKGROUND
[0002] One of the most common roofing surfaces in the world is an asphalt shingle. These types of shingles are widely used as roofing covers since they are relatively inexpensive and relatively simple to install. The singles are made typically of fibre product coated with asphalt or tar and a layer of small stones or other material to provide some UV protection to the tar.
[0003] Asphalt shingles, however, break down over time. The tar is sensitive to UV light and over time breaks down, causing the shingles to crack, break or fail. The effects of changes in temperature also contribute to the degradation of the performance of asphalt shingles.
[0004] Further, since asphalt or tar is used, often these shingles are black or darkly colored, and therefore absorb heat from the sun. Such heat absorption may negatively impact a home, especially in warmer climates where cooling is being used inside the home.
[0005] Other roofing surfaces exist, but many of these are also asphalt or tar based. For example, low slope roofs tend to use membrane roofing systems which also utilize a tar or asphalt base that is then coated with stones. Such membranes are typically difficult to install and require specialized expertise.
Further, such membranes are also subject to break down due to UV and temperature changes.
BRIEF DESCRIPTION OF THE DRAWINGS
Further, such membranes are also subject to break down due to UV and temperature changes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The present disclosure will be better understood with reference to the drawings, in which:
Figure 1 is a top perspective view of a mat capable of being used with the embodiments of the present disclosure;
Figure 2 is a top perspective view of the mat of Figure 1, impregnated with an elastomeric paint;
Figure 3 is a schematic view of a production process for the present roofing material; and Figure 4 is side plan view of the roofing material installed by gluing the material to a roofing surface.
DETAILED DESCRIPTION OF THE DRAWINGS
Figure 1 is a top perspective view of a mat capable of being used with the embodiments of the present disclosure;
Figure 2 is a top perspective view of the mat of Figure 1, impregnated with an elastomeric paint;
Figure 3 is a schematic view of a production process for the present roofing material; and Figure 4 is side plan view of the roofing material installed by gluing the material to a roofing surface.
DETAILED DESCRIPTION OF THE DRAWINGS
[0007] The present disclosure provides a roofing material comprising: a non-woven polymeric mat substrate; and an elastomeric surface coating applied to and impregnating the polymeric mat substrate.
[0008] In accordance with one embodiment of the present disclosure, a roofing material is provided comprising a non-woven polymer mat coated with an elastomeric paint.
[0009] In particular, the mat may be a non-woven polyester, polypropylene, olefin fiber, or other such material, and may comprise a mat such as those made by Ozite Corporation, for example. Such mat provides for a durable, flexible substrate on to which to apply the polymeric paint. Typically such mats are flexible and tear resistant and do not fray.
[0010] The mat may be water, mold and mildew resistant and further provide for ultra-violet (UV) protection. Thus the mat does not break down with extended exposure to sunlight.
[0011] The mat further is resistant to heat and cold, and does not break or rip in extreme heat or cold, thereby creating an effective substrate that lasts longer than a traditional asphalt or tar base.
[0012] In one embodiment, the mat may include recycled polymers. For example, the mat may include EcofiTM 100% post-consumer recycled plastic bottle technology from Ozite corporation. As will be appreciated by those in the art, such resources are readily available and provide for an environmentally friendly and cheap raw material.
[0013] Reference is now made to Figure 1, which shows a mat 110, comprising a non-woven polymer pile 112, which optionally may be placed on a backing layer 114. In one embodiment, backing layer 114 may be comprised of latex or other similar material.
[0014] In one embodiment, the mat is then impregnated with an elastomeric surface coating. Such impregnation may occur by soaking the mat in an elastomeric surface coating bath, spraying the mat, rolling the elastomeric surface coating on to the mat, among other options, as described below.
[0015] Reference is now made to Figure 2. In the example of Figure 2, mat 110 of Figure 1 in impregnated with an elastomeric surface coating to form roofing material 210. Roofing material 210 includes the elastomeric layer 212 which is impregnated into polymer pile 112. As with the embodiment of Figure 1, a backing layer 114 may exist in the embodiment of Figure 2.
[0016] One option of elastomeric surface coating is sold under the brand name LANCO WhiteSealTM ultra elastomeric roof sealer. However, this is merely an example of an elastomeric surface coating that may be used.
[0017] The elastomeric surface coating may be resistant to extreme hot or cold temperatures experienced by roofs in various geographical locations.
[0018] Both the elastomeric surface coating and the non-woven mat may be fire retardant to provide for additional protection for a roof.
[0019] Further, unlike metal roofs, the applicant has further found that snow adheres to the roofing material, which reduces the likelihood that snow will slide off in sheets, potentially harming those below or causing damage.
[0020] The applicant has further found that the roofing material of the present disclosure may be up to 50% lighter than similar traditional roofing materials, making the present roofing material easier to handle.
[0021] In one embodiment, the elastomeric surface coating may be white or light colored. This would make the roofing material more heat resistant. In particular, a white or light roof will reflect more ultra-violet radiation than a dark asphalt roof, which will absorb the heat. This will lead to attics of houses or commercial properties being cooler than with a traditional tar or asphalt roof. However, the present disclosure is not limited to white or light colored surface coatings. Rather, the surface coating can be tinted to any color, thus allowing flexibility in terms of design with and use of the roofing material.
[0022] Roofing material form a flexible material that is tear or rip resistant. It can be made into individual shingles to aesthetically look like current asphalt or tar shingles, or rolled into sheets.
[0023] In commercial production, a process may be utilized which has large rolls of the non-woven mat unrolled and exposed to the elastomeric surface coating either through a bath station or a spraying station. The roofing material may then proceeds through a drying station to dry the elastomeric surface coating and finally the dried roofing material may be cut into the appropriate size.
[0024] Reference is now made to Figure 3. As seen in Figure 3, a mat roll 310 is used to feed the production with the untreated mat.
[0025] The untreated mat is first provided to an elastomer application station 312. At elastomer application station 312, the elastomeric surface coating is applied to the mat. Such application may include an immersion bath through which the mat is passed. Other options include a spray application, rollers, squeegees, among others. The elastomer application station generally applies a relatively even coating of the elastomeric surface coating to the mat, where such elastomeric surface coating further impregnates and adheres to the mat material.
[0026] Once the mat and elastomeric surface coating emerge from the elastomer application station 312, the combination may then proceed into a drying station 314. Drying station 314 may use a combination of heat and air to dry the elastomeric surface coating. In other embodiments ultra-violet radiation or other drying techniques could be utilized in drying station 314.
[0027] Once the elastomeric surface coating is dried, the material may proceed to a cutting station 316. In one embodiment, cutting station 316 may form pre-determined sized rolls of the roofing material.
[0028] In other embodiments, the cutting station 316 may cut the roofing material into traditional shingle shapes in order to provide an aesthetic tile that a consumer may be used to.
[0029] From cutting station 316, the cut material may then proceed to packaging station 318, which may form packages of shingles, add labels to rolls of material or other such functionality.
[0030] The roofing material may be installed on a roof in a variety of ways.
If tiles are provided, such tiles may be installed utilizing traditional nail and overlapping technology on sloped roofs, may be glued down to the roof, among other options. Rolls or strips of the roofing material may further be used at points in the roof where the plane of the roof changes [0031] If using rolls of the material rather than tiles, the rolls of the roofing material may be applied to a sloped or flat roof and glued into place similar to carpet. If used on a sloped roof, the seams may be overlapping. On a flat roof, a joint sealer may be utilized between the seams of the roofing material.
If tiles are provided, such tiles may be installed utilizing traditional nail and overlapping technology on sloped roofs, may be glued down to the roof, among other options. Rolls or strips of the roofing material may further be used at points in the roof where the plane of the roof changes [0031] If using rolls of the material rather than tiles, the rolls of the roofing material may be applied to a sloped or flat roof and glued into place similar to carpet. If used on a sloped roof, the seams may be overlapping. On a flat roof, a joint sealer may be utilized between the seams of the roofing material.
[0032] The glue used may further provide water resistance to provide additional protection.
[0033] Reference is now made to Figure 4, which shows a side plan view of an installed roof. As seen in Figure 4, a roofing material 210 includes an elastomeric surface coating 212 applied to a mat 112. Mat 112 may have a backing layer 114.
[0034] The roofing material 210 is applied to a roof 420, which may form wood, metal, or any other type of roofing material. A layer of glue 422 is applied over the roof material 420 and the roll of roofing material 210 may then be layed over the glue.
[0035] Because the elastomeric surface coating and mat are lighter than a comparable tar membrane, in one embodiment the roofing material can be rolled into larger rolls for application to a roof. In particular, one limitation of current membrane technology is that the roll of the membrane must be capable of being handled by the installers. Thus, by reducing the weight of the roll, larger rolls or wider rolls may be utilized by an installer, thereby creating less seams and providing for a more water resistant roofing material.
[0036] Joints between different roof planes may be accommodated by simply bending the material to the other plane.
[0037] As will be appreciated by those in the art, this process is much simpler than the installation of a tar membrane, does not require open flames, and the present roofing material therefore does not require specialized expertise to install.
[0038] During installation, or once the roof is installed, walking on the roof will not cause damage such as that caused by walking on a hot asphalt roof. On a hot asphalt roof, the stones are displaced when walked on. However, the present roofing material does not rip or break in hot or cold weather, does not have stones, and will thus last longer and will be capable of being walked on.
This further enhances the ability to install the roofing material. For example, present roofing materials using asphalt or tar must be applied when the weather is relatively cool due to the damage that the roofing material suffers in hot weather. Conversely, the present roofing material in accordance with the embodiments of the present disclosure may be installed even in hot weather since it is not adversely affected by such heat.
This further enhances the ability to install the roofing material. For example, present roofing materials using asphalt or tar must be applied when the weather is relatively cool due to the damage that the roofing material suffers in hot weather. Conversely, the present roofing material in accordance with the embodiments of the present disclosure may be installed even in hot weather since it is not adversely affected by such heat.
[0039] The present roofing material is not subject to the same wear as current roofing materials such as tar based shingles and will last longer than such roofing materials. This is environmentally beneficial since less waste will be sent to landfill.
[0040] Further, the roof may be restored by simply re-applying the elastomeric surface coating after a certain period of time and thus does not require a complete reinstallation of the roof as with tar or asphalt shingles.
[0041] Once the roofing material does need to be changed, the roofing material in accordance with the present disclosure may be recycled, thereby further reducing waste in landfill.
[0042] The embodiments described herein are examples of structures, systems or methods having elements corresponding to elements of the techniques of this application. This written description may enable those skilled in the art to make and use embodiments having alternative elements that likewise correspond to the elements of the techniques of this application.
The intended scope of the techniques of this application thus includes other structures, systems or methods that do not differ from the techniques of this application as described herein, and further includes other structures, systems or methods with insubstantial differences from the techniques of this application as described herein.
The intended scope of the techniques of this application thus includes other structures, systems or methods that do not differ from the techniques of this application as described herein, and further includes other structures, systems or methods with insubstantial differences from the techniques of this application as described herein.
Claims (15)
1. A roofing material comprising:
a non-woven polymeric mat substrate; and an elastomeric surface coating applied to and impregnating the polymeric mat substrate.
a non-woven polymeric mat substrate; and an elastomeric surface coating applied to and impregnating the polymeric mat substrate.
2. The roofing material of claim 1, wherein the non-woven polymeric mat substrate is comprised of olefin fibers.
3. The roofing material of claim 1, wherein the non-woven polymeric mat substrate is comprised of polypropylene fibers.
4. The roofing material of claim 1, wherein the non-woven polymeric mat substrate is resistant to ultra-violet radiation.
5. The roofing material of claim 1, wherein the elastomeric surface coating is resistant to ultra-violet radiation.
6. The roofing material of claim 1, wherein the elastomeric surface coating is tinted to enhance reflection of ultra-violet radiation.
7. The roofing material of claim 1, wherein the polymeric mat substrate is made from a recycled polymer.
8. The roofing material of claim 1, wherein the roofing material is configured to be applied to a roofing surface using a glue.
9. The roofing material of claim 1, wherein the roofing material is further cut into tiles.
10. The roofing material of claim 1, wherein the roofing material is flexible.
11. The roofing material of claim 1, wherein the roofing material is recyclable.
12. The roofing material of claim 1, wherein the roofing material is configured to have an elastomeric surface coating re-applied after installation of the roofing material.
13. The roofing material of claim 1, wherein the elastomeric coating surface is applied in an immersion bath.
14. The roofing material of claim 1, wherein the elastomeric coating surface is applied through a spray.
15. The roofing material of claim 1, wherein the elastomeric coating surface is applied through a roller.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2815451A CA2815451A1 (en) | 2013-05-09 | 2013-05-09 | Roofing material and method of use |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA2815451A CA2815451A1 (en) | 2013-05-09 | 2013-05-09 | Roofing material and method of use |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2815451A1 true CA2815451A1 (en) | 2014-11-09 |
Family
ID=51894309
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2815451A Abandoned CA2815451A1 (en) | 2013-05-09 | 2013-05-09 | Roofing material and method of use |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA2815451A1 (en) |
-
2013
- 2013-05-09 CA CA2815451A patent/CA2815451A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| FZDE | Dead |
Effective date: 20170510 |