Sensing plate for adhesive roofing system

Abstract

An inductive panel for a roofing system. The sensing plate includes a base and an adhesive covering the base or a portion of the base. Metal wires, which may be in the form of a net of metal wires, are coated with an adhesive and disposed on the base. The metal wire may be used as a susceptor in an induction heating process. The roof system also includes a roof deck and a membrane over a sensing plate secured on top of the roof deck. The adhesive is activated under heat generated during the addition of the induction heating process to bond all or part of the film to the induction plate.

Description

Technical Field

[0001] The present invention relates to an induction panel for an adhered roof system and an adhered roof system. Background Art

[0002] Low-slope roof systems are particularly useful for covering and waterproofing roofs. Low-slope roof systems are fixed to the roof and typically include an insulating material covered with a cover sheet and a membrane to help weatherproof the roof. In some applications, the membrane may include PVC (polyvinyl chloride), TPO (thermoplastic polyolefin) or EPDM (ethylene propylene diene terpolymer). The membrane is typically secured to the roof by mechanical fasteners. Such fasteners provide discrete points for securing the membrane. When mechanical fasteners are used, the membrane is typically laid in an overlapping manner so that the fastener can be covered by a portion of an adjacent portion of the membrane. The overlapping portion can then be secured to the adjacent membrane, for example, by welding or by using an adhesive.

[0003] Alternatively, current membranes can be fixed to the roof or cover board by using an adhesive. This can produce a fully adhered roof system. In such a system, the membrane is adhered to the roof deck or cover board using a water-based, solvent-based or polyurethane adhesive. These materials are applied as liquids by spraying or paint-type roller coating. Although these methods are effective for fully adhering the roof, they require a relatively large amount of time and labor. These systems are also affected by weather conditions when they are placed on the roof. For example, temperature and humidity can affect whether a fully adhered roof of this type can be evenly applied, or the curing time required for the adhesive. In addition, after applying the adhesive and placing the membrane, the adhesive must be cured on the roof. In addition, once the membrane is laid on the adhesive, it is relatively difficult to adjust its position.

[0004] Another type of system used to secure roof membranes is known as system and is available from SikaSarnafil. The system uses spaced discrete mechanical fasteners to hold the cover boards in place. The mechanical fasteners are coated with a material that fuses with the roof membrane. The system mechanically fastens the membrane to each board using induction to fuse the membrane. The system is not fully adhesive, the membrane is secured to the roof deck at spaced intervals. The system uses an induction power unit and a fixing iron that heats the board and fuses or adheres the membrane to the coating on the fasteners.

[0005] In many applications, it is desirable to be able to provide a fully adhered system without having to apply the adhesive in the field and then secure the membrane to the uncured adhesive. Summary of the invention

[0006] In an embodiment, an induction board for roofing applications is provided, comprising a base material and a metal wire disposed on the base material. The metal wire is configured to act as a susceptor for an induction welding process. The induction board further comprises an adhesive disposed on the base material, wherein the metal wire is coated with the adhesive, and wherein the adhesive is heat activated.

[0007] In an embodiment, a roof system is provided, comprising an induction panel secured to a roof deck, the roof deck comprising a base material and a metal wire disposed on the base material and configured to act as a susceptor. The roof system further comprises an adhesive disposed on the base material, wherein the metal wire is coated with a heat activated adhesive. The roof system further comprises a membrane disposed on the induction panel, wherein the membrane is adhered to the base by the heat activated adhesive. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a cross-sectional view of a sensing plate according to one embodiment; and

[0009] Figure 2 is a cross-sectional view of a roof system according to one embodiment. DETAILED DESCRIPTION

[0010] An induction panel suitable for use on a roof is generally indicated in the figure at 10. The induction panel 10 includes a base 12, a metal wire 14, and an adhesive 16. In an embodiment, the metal wire 14 is coated with the adhesive 16. As used in connection with the adhesive 16 on the metal wire 14, "coated" means that the metal wire is completely coated or partially coated. In addition, as used herein, the metal wire refers to any suitable metal material that can be used in combination with the adhesive 16 and the base 12 to allow the metal wire 14 to be inductively heated, as further discussed below.

[0011] The base 12 may comprise any suitable material and may be rigid or semi-rigid. In an embodiment, the base 12 comprises a cover board. Common cover boards include fiberglass mat faced gypsum, fiber reinforced gypsum, perlite, OSB, and plywood. Less common is high density insulation board (compressed polyisocyanurate core with a coated glass mat face). Available cover boards also include plastic, cellulose, and various combinations of all of the above. In an embodiment, materials for such cover boards may also include recycled cellulose and plastic materials. Some cover boards that may be used and constructed of the above materials include those provided by Georgia Pacific Gypsum. Provided by USG, Inc., Chicago, Illinois Gypsum fiber roofing board, Everboard supplied by Continuus Materials in The Woodlands, Texastm Composite roofing panels and Nathonal Gypsum, Inc. of Charlotte, NC Roofing Sheets. The sheathing may have a thickness of half an inch to one inch. In an embodiment, the sheathing comprises recycled sheathing. However, it should be understood that the thickness of the sheathing may vary, and any suitable thickness may be used.

[0012] In other embodiments, the base 12 may include a rigid or semi-rigid insulation material. For example, the base 12 may include a high density or standard density polyisocyanurate insulation material. One suitable polyisocyanurate insulation material is Supplied by Duro-Last, Inc. of Saginaw, MI. The polyisocyanurate may have a thickness of one-half inch to six inches. However, it should be understood that the thickness of the insulating material may vary, and any suitable thickness may be used. In an embodiment, the base 12 may include a combination of a cover sheet and an insulating material.

[0013] As previously described, the induction plate 10 includes a metal wire 14. In some embodiments, the metal wire 14 includes a metal wire mesh, as shown in the accompanying drawings. The metal wire 14 of the induction plate 10 is suitable for use as a susceptor in an induction heating process. The process may also be referred to as induction welding herein. In an embodiment, the metal wire mesh can be divided into several sections. For example, the metal wire mesh section can be 24 inches by 24 inches. The metal wires within the metal wire mesh can include any suitable diameter. For example, the metal wire can have a diameter of 0.014 inches. It should be understood that the size of the metal wire mesh can be any size and shape that allows the metal wire 14 to be placed on the top surface of the base 12 and below the membrane 28, as described below.

[0014] The induction plate 10 also includes an adhesive 16. In an embodiment, the adhesive 16 is heat activated. In an embodiment, the adhesive 16 is stable from sub-zero temperatures to at least 150° F. The adhesive 16 will not activate within this temperature range and will allow the adhesive 16 to be activated by introducing heat above the activation temperature of the adhesive. It should be understood that in other embodiments, the temperature range over which the adhesive 16 is stable may vary.

[0015] The adhesive 14 is used to coat the metal wires 14. In an embodiment, the metal wires 16 are dipped in the adhesive 16 and dried. The adhesive 14 may fill all or part of the openings in the wire mesh to produce a solid substrate. The coated metal wires 14 are placed on the base 12. In an embodiment, the produced solid substrate may be used as a face of the base 12. In an embodiment, the solid substrate is used as a face of the high-density polyisocyanurate insulation base 12.

[0016] In an embodiment, the adhesive 16 may be laminated to the base 12. In this embodiment, the metal wire 14 is placed on the base 12 and may be pressed onto the base 12. Then, the adhesive 16 is applied to the metal wire 14 and the base 12 so that it covers the metal wire 14. Once the adhesive 16 has coated the wire 14 and is on the base 12, it will not activate until its activation temperature is reached.

[0017] The induction board 10 is suitable for use in a roof system generally indicated at 10. The roof system includes the induction board 10 having a base 12, a wire 14, and an adhesive 16 thereon. The induction board 10 is suitable for placement on a roof deck 20. Figure 2 In the illustrated embodiment, the induction plate is secured to the roof deck by suitable fasteners, generally indicated at 22. The fasteners 22 may include a plate 24 and screws 26. The plate 24 may include a load distribution plate having openings therethrough, as is well known in the industry. The screws extend through holes in the plate 24 and into the roof deck 20.

[0018] A membrane 28 is disposed over the induction plate 10 and the fasteners 22. The membrane 28 may include any suitable membrane for helping to weatherproof the roof. In an embodiment, the membrane 28 includes a PVC membrane, which may also include scrim. In another embodiment, the membrane may include a TPO membrane, which may also include scrim.

[0019] To assemble the roof system 18 according to an embodiment, the induction panel 10 including the base 12, the wire 14 and the adhesive 16 is fastened to the roof deck 20 using the fasteners 22. The membrane 28 is then placed on the induction panel 10, particularly on the adhesive 16 and the fasteners 22. The membrane 28 can be moved relatively easily until it is in the proper position, which can provide greater flexibility to position the membrane 28 in a desired position or orientation. Once the membrane 28 is positioned, the wire 14 can act as a susceptor during the electromagnetic induction heating process. When the wire 14 is heated, the wire 14 in turn heats the adhesive 16 to a temperature at which the adhesive 16 will activate. The adhesive in turn bonds the membrane to the induction panel 10 fixed to the roof deck 20. In addition, the membrane 28 can also be heated during the induction heating process of the adhesive, which can allow the membrane to adhere more strongly to the induction panel 10.

[0020] In an embodiment, the roof system 18 can be used to fully adhere the membrane 28 to the induction panel 10. This can be advantageous, especially in situations where the roof is subject to high wind forces. It should be understood that, as used herein, a fully adhered roof can have areas where the membrane 28 is not fused to the induction panel 10. These areas can be relatively small compared to the areas where the membrane 28 is fused to the induction panel 10. In another embodiment, the roof system can be used to partially adhere the membrane 28 to the induction panel 10. In such an embodiment, as an example, a fully adhered roof may not be required, where the roof may not experience high wind forces or other weather events. Furthermore, in an embodiment, the roof system 18 can be a combination of a fully adhered roof and a partially adhered roof.

[0021] Thus, the roof system 18 as described herein can provide flexibility during roof installation. That is, the membrane 28 can be fully adhered to the induction board 10 on all or part of the roof deck 20, and the membrane 28 can be partially adhered to the induction board 10 on other parts of the roof deck 20. In an embodiment, the membrane 28 can be partially adhered to the induction board so that the membrane 28 is not adhered to a portion of the roof deck. The use of the wire 14 and particularly the wire mesh can increase the hail resistance of the roof system 18. In addition, the roof system 18 can reduce the labor time required to install the roof system 18 to the roof deck. The number of mechanical fasteners 22 that may be required can be reduced. In addition, the roof system 18 greatly reduces (if not eliminates) mechanical fastener penetration of the membrane 28. In addition, the roof system 18 can provide a more consistent application of the adhesive 16 to the membrane 28, which can result in a more consistent adhesion of the membrane 28 to the induction board 10.

[0022] It should be understood that the foregoing is a description of one or more embodiments of the present invention. The present invention is not limited to the specific embodiments disclosed herein, but is limited only by the appended claims. In addition, the statements contained in the foregoing description relate to specific embodiments and should not be interpreted as limitations on the scope of the present invention or the definitions of terms used in the claims, unless the terms or phrases are clearly defined above. Various other embodiments and various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. All such other embodiments, changes and modifications are intended to fall within the scope of the appended claims.

[0023] The terms "such as," "for example," and the verbs "comprising," "having," "including," and their other verb forms used in this specification and claims, when used in conjunction with a list of one or more components or other items, are to be interpreted as open-ended, meaning that the list should not be considered to exclude other additional components or items. Other terms will be interpreted using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

Claims

1. An induction panel for roof applications, comprising: Base material; a metal wire disposed on the base material, wherein the metal wire is configured to act as a susceptor for an induction welding process; An adhesive is disposed on the base material, wherein the metal wire is coated with the adhesive, and wherein the adhesive is heat activated.

2. The induction plate according to claim 1, wherein: The metal wires are in the form of a metal wire mesh.

3. The induction plate according to claim 2, wherein: The metal wire mesh is laminated to one side of the base material, and the adhesive is disposed on the base material and the metal wire mesh.

4. The induction plate according to claim 2, wherein: The base material is rigid or semi-rigid.

5. The induction plate according to claim 4, wherein: The base is a cover plate.

6. The induction plate according to claim 5, wherein: The cover plate comprises recycled material.

7. The induction plate according to claim 4, wherein: The base material includes an insulating material.

8. The induction plate according to claim 7, wherein: The insulation material includes standard or high density polyisocyanurate.

9. A roof system comprising: an induction panel secured to a roof deck, the induction panel comprising a base material, a metal wire disposed on the base material and configured to act as a susceptor for an induction welding process, and an adhesive disposed on the base material, wherein the metal wire is coated with a heat activated adhesive; A film is disposed on the induction plate, wherein the film is adhered to a base by the heat activated adhesive.

10. The roof system according to claim 9, wherein: The metal wires are in the form of a metal wire mesh.

11. The roof system according to claim 9, wherein: The base includes a cover plate.

12. The roof system according to claim 9, wherein: The base includes an insulating material.

13. The roof system according to claim 9, wherein: The membrane is fully adhered to the sensing plate.

14. The roof system according to claim 9, wherein: The membrane is partially adhered to the sensing plate.

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