Guide boards for adhesive roofing systems

Abstract

An induction board for use in a roofing system. The induction board includes a base and an adhesive covering the base or a portion of the base. Metal wire, which may be in the form of a metal wire mesh, is coated with the adhesive and disposed on the base. The metal wire may be used as a susceptor in an induction heating process. The roofing system also includes a roof deck onto which the induction board is secured and a membrane above the induction board. The adhesive is activated by the addition of heat generated during the induction heating process, bonding all or a portion of the membrane to the induction board.

Description

[Technical Field]

[0001] Technical Field The present application relates to guide boards for adhesive roofing systems and adhesive roofing systems. [Background technology]

[0002] background Low-slope roofing systems are used, among other things, to cover and waterproof roofs. They are fastened to roofs and typically include insulation covered with a cover board and a membrane to help weatherize the roof. In some applications, the membrane may comprise PVC (polyvinyl chloride), TPO (thermoplastic polyolefin), or EPDM (ethylene propylene diene terpolymer). The membrane is typically fastened to the roof with mechanical fasteners. Such fasteners provide discrete points to which the membrane is secured. When mechanical fasteners are used, the membranes are typically positioned so that they overlap, allowing the fasteners to be covered by portions of adjacent sections of the membrane. The overlapping portions may then be secured to the adjacent membranes, such as by welding or by the use of adhesives.

[0003] Alternatively, current membranes may be secured to the roof or coverboards through the use of adhesives, resulting in fully-adhesive roofing systems. In such systems, the membrane is adhered to the roof deck or coverboard using water-based, solvent-based, or urethane adhesives. These materials are applied as liquids by spray or paint-type roller application. While these methods are effective in fully adhering the roof, they require a relatively significant amount of time and effort. These systems are also dependent on weather conditions when placed on the roof. For example, temperature and humidity each play a role in the ability to apply this type of fully-adhesive roofing system and the curing time required for the adhesive. Furthermore, the adhesive must cure on the roof after application of the adhesive and placement of the membrane. Furthermore, once the membrane is placed on the adhesive, it is relatively difficult to adjust its position.

[0004] Yet another type of system used to fasten roofing membranes is known as the RhinoBond® system and is available from Sika Sarnafil. This system uses individual mechanical fasteners at intervals to hold down the cover board. The mechanical fasteners are coated with a material to which the roofing membrane is fused. This system uses induction to fuse the membrane to the membrane mechanically fastened to each plate. This system is not fully bonded, and the membrane is fastened to the roof deck at intervals. The system uses an induction power unit and a fastening iron to heat the plate and fuse or bond the membrane to the coating on the fasteners.

[0005] In many applications, it is desirable to be able to provide a complete adhesive system without having to apply the adhesive in the field and then secure the membrane onto the uncured adhesive. Summary of the Invention [Means for solving the problem]

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

[0007] In one embodiment, a roofing system is provided that includes an induction board secured to a roof deck, the induction board comprising a base material and a metal wire configured to act as a susceptor disposed on the base material. The roofing system further includes an adhesive disposed on the base material, the metal wire being coated with a thermally activated adhesive. The roofing system further includes a membrane disposed on the induction board, the membrane being adhered to the base by the thermally activated adhesive. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view of a guidance board according to one embodiment. [Figure 2] 1 is a cross-sectional view of a roofing system according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0009] Detailed Description An induction board adapted for use on a roof is generally designated 10 in the drawings. The induction board 10 comprises a base 12, a metal wire 14, and an adhesive 16. In one embodiment, the metal wire 14 is coated with the adhesive 16. "Coated," as used in reference to the adhesive 16 on the metal wire 14, means that the metal wire is fully coated or partially coated. Furthermore, as used herein, metal wire refers to any suitable metallic material that can be used with the adhesive 16 and base 12 to enable inductive heating of the metal wire 14, as further described below.

[0010] Base 12 can comprise any suitable material and can be rigid or semi-rigid. In one embodiment, base 12 comprises a cover board. Commonly available cover boards include fiberglass mat-faced gypsum, fiber-reinforced gypsum, perlite, OSB, and plywood. Less common are high density insulation panels (compressed polyisocyanurate core with coated glass mat facings). Available cover boards also include plastic, cellulose, and all of the various combinations of the aforementioned materials. In one embodiment, the material used for such cover boards may also include regenerated cellulose and plastic materials. Some cover boards that may be used and may be constructed from the above materials include DensDeck® offered by Georgia Pacific Gypsum, Securock® Gypsum-Fiber Roof Board offered by USG Corporation (Chicago, Illinois, USA), Everboard™ Composite Roof Cover Board offered by Continuus Materials of The Woodlands (Texas, USA), and Dexcell® Roof Board offered by National Gypsum Company (Charlotte, North Carolina, USA). The cover board may have a thickness of ½ inch to 1 inch. In one embodiment, the cover board comprises recycled cover board. However, it will be understood that the thickness of the cover board may vary and any suitable thickness may be used.

[0011] In other embodiments, the base 12 may include rigid or semi-rigid insulation. By way of example, the base 12 may include high-density or standard-density polyisocyanurate insulation. One suitable polyisocyanurate insulation is Duro-Guard®, offered by Duro-Last, Inc. of Saginaw, Michigan, USA. The polyisocyanurate may have a thickness of ½ inch to 6 inches. However, it will be understood that the thickness of the insulation may vary and any suitable thickness may be used. In one embodiment, the base 12 may include a combination of a cover board and insulation.

[0012] As previously mentioned, the induction board 10 includes metal wire 14. In some embodiments, the metal wire 14 includes a metal wire mesh, as shown in the figures. The metal wire 14 of the induction board 10 is adapted to be used as a susceptor in an induction heating process, which is sometimes referred to herein as induction welding. In one embodiment, the metal wire mesh may be segmented. By way of example, a metal wire mesh segment may be 24 inches by 24 inches. The metal wires within the metal wire mesh may have any suitable diameter. By way of example, the metal wires may have a diameter of 0.014 inches. It will be appreciated that the size of the metal wire mesh may be any size and shape that allows for placement of the metal wire 14 mesh on the top surface of the base 12 and under the membrane 28, as described below.

[0013] The induction board 10 further comprises an adhesive 16. In one embodiment, the adhesive 16 is thermally activated. In one embodiment, the adhesive 16 is stable from sub-zero temperatures up to at least 150°F. The adhesive 16 does not activate within this temperature range, allowing for its activation by the introduction of heat above the activation temperature of the adhesive. It will be understood that in other embodiments, the temperature range for adhesive stability 16 may vary.

[0014] Adhesive 14 is used to coat metal wire 16. In one embodiment, metal wire 16 is dip-coated in adhesive 16 and allowed to dry. Adhesive 14 may fill all or a portion of the openings in the wire mesh to create a solid substrate. The coated metal wire 14 is placed on base 12. In one embodiment, the resulting solid substrate can be used as a facer for base 12. In one embodiment, the solid substrate is used as a facer for high-density polyisocyanurate insulation base 12.

[0015] In one embodiment, adhesive 16 can be laminated onto base 12. In this embodiment, metal wire 14 may be placed on base 12 and pressed onto base 12. Adhesive 16 is then applied over metal wire 14 and base 12, covering metal wire 14. Once adhesive 16 coats wire 14 and is on base 12, it does not activate until it reaches its activation temperature.

[0016] The guide board 10 is adapted for use in a roof system generally designated 10. The roof system comprises the guide board 10 having a base 12, metal wire 14, and adhesive 16 thereon. The guide board 10 is adapted to be placed on a roof deck 20. In the embodiment shown in FIG. 2, the guide board is secured to the roof deck by suitable fasteners generally designated 22. The fasteners 22 may comprise plates 24 and screws 26. The plates 24 may comprise load distribution plates with openings as is well known in the industry. The screws extend through holes in the plates 24 and into the roof deck 20.

[0017] A membrane 28 is disposed over the guide board 10 and fasteners 22. The membrane 28 may comprise any suitable membrane used to aid in weatherizing a roof. In one embodiment, the membrane 28 comprises a PVC membrane that may also include an internal scrim. In another embodiment, the membrane may comprise a TPO membrane that may also include an internal scrim.

[0018] To assemble a roof system 18 according to one embodiment, the guide board 10, which includes the base 12, metal wire 14, and adhesive 16, is fastened to the roof deck 20 using fasteners 22. The membrane 28 is then placed on top of the guide board 10, specifically on top of the adhesive 16 and fasteners 22. The membrane 28 can be moved relatively easily until it is in place, providing greater flexibility in positioning the membrane 28 in a desired location or orientation. Once the membrane 28 is positioned, the metal wire 14 can act as a susceptor during the electromagnetic induction heating process. As the metal wire 14 heats, it then heats the adhesive 16 to a temperature at which the adhesive 16 activates. The adhesive then bonds the membrane to the guide board 10, which is secured to the roof deck 20. Additionally, the membrane 28 may also be heated during the adhesive induction heating process, which may enable stronger adhesion of the membrane to the guide board 10.

[0019] In one embodiment, the roof system 18 can be used to fully bond the membrane 28 to the induction board 10. This can be particularly advantageous if the roof is subject to high wind uplift. As used herein, it is understood that a fully bonded roof may have areas where the membrane 28 is not fused to the induction board 10. Such areas may be relatively small compared to the areas where the membrane 28 is fused to the induction board 10. In another embodiment, the roof system can be used to partially bond the membrane 28 to the induction board 10. In such an embodiment, for example, if the roof is not likely to experience high wind forces or other weather events, fully bonding the roof may not be necessary. Furthermore, in one embodiment, the roof system 18 can be a combination of a fully bonded roof and a partially bonded roof.

[0020] Thus, the roofing system 18 described herein can provide flexibility during roof installation. That is, the membrane 28 can be fully bonded to the guide board 10 over all or a portion of the roof deck 20, or can be partially bonded to the guide board 10 over other portions of the roof deck 20. In one embodiment, the membrane 28 can be partially bonded to the guide board such that the membrane 28 is not bonded over portions of the roof deck. The use of metal wire 14, particularly metal wire mesh, can enhance the hail resistance of the roofing system 18. Additionally, the roofing system 18 can reduce the labor hours required to attach the roofing system 18 to the roof deck. There can be a reduction in the number of mechanical fasteners 22 that may be required. Furthermore, the roofing system 18 substantially reduces, if not eliminates, mechanical fastener penetration of the membrane 28. Furthermore, the roofing system 18 can provide a more consistent application of the adhesive 16 to the membrane 28, resulting in more consistent adhesion of the membrane 28 to the guide board 10.

[0021] It should be understood that the above 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 rather is defined solely by the following claims. Furthermore, statements contained in the foregoing description, unless they relate to specific embodiments and the term or phrase is expressly defined above, should not be construed as limitations on the scope of the invention or the definition of the terms used in the claims. 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.

[0022] As used in this specification and claims, the terms "for example," "for example," and the verbs "comprise," "have," "include," and other verb forms thereof, when used in conjunction with a list of one or more components or other items, are each to be construed as open-ended, meaning that the list should not be considered to exclude other additional components or items. Other terms are to be construed using their broadest reasonable meaning unless used in a context requiring a different interpretation.

Claims

1. A base material; a metal wire disposed on the base material, the metal wire configured to act as a susceptor for an induction welding process; and an adhesive disposed on the base material, the metal wire being coated with the adhesive, the adhesive being thermally activated; 1. A guide board for use in roofing applications comprising:

2. 10. The induction board of claim 1, wherein the metal wire is in the form of a metal wire mesh.

3. 3. The induction board of 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 board of claim 2 , wherein the base material is rigid or semi-rigid.

5. The induction board of claim 4 , wherein the base is a cover board.

6. The induction board of claim 5 , wherein the cover board comprises recycled material.

7. The induction board of claim 4 , wherein the base material comprises a thermal insulator.

8. 8. The induction board of claim 7, wherein the insulating material comprises standard or high density polyisocyanurate.

9. an induction board secured to a roof deck, the induction board comprising a base material, a metal wire configured to act as a susceptor for an induction welding process disposed on the base material, and an adhesive disposed on the base material, the metal wire being coated with a thermally activated adhesive; a membrane disposed on the induction board, the membrane being adhered to the base by the thermally activated adhesive; A roof system comprising:

10. 10. The roofing system of claim 9, wherein the metal wire is in the form of a metal wire mesh.

11. The roofing system of claim 9 , wherein the base comprises a cover board.

12. The roofing system of claim 9 , wherein the base comprises insulation.

13. The roofing system of claim 9 , wherein the membrane is fully adhered to the guide board.

14. The roofing system of claim 9 , wherein the membrane is partially adhered to the guide board.

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