Liquid-Applied Roofing Base Layers for Steep-Slope Sag Control
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Solution Overview
Problem
The challenge of preventing or controlling the flowing and sagging of liquid roofing materials on steep slope roofs, as well as forming a watertight seal with roof structures, has hindered the application of liquid roofing materials on residential steep slope roofs. Additionally, there is a need for a quick and easy-to-install temporary roofing system that can provide immediate protection against water penetration and be convertible to a permanent roof.
Innovation Solution
Mechanical, chemical, and additive methods are employed to control sagging, including the use of base layers such as permeable meshes, woven fabrics, and fillers, along with fasteners and underlayments to secure the liquid roofing material, and a temporary roofing system using a lipophilic base layer covered by a hydrophobic layer for immediate protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid roofing material is applied to a steep slope roof, then waterproofing coverage is achieved, but flowing and sagging occurs before curing
Solution Approach 1:
A base layer is applied to the roof substrate before applying the liquid roofing material. The base layer serves as a preliminary structure that provides mechanical support and flow resistance to the liquid roofing material before it cures, preventing sagging and flowing on steep slopes while maintaining waterproofing coverage.
Solution Approach 2:
The system combines a base layer with the liquid roofing material to create a composite structure. The base layer (made of materials like asphalt-saturated felt, foam, or fabric) works together with the liquid roofing material to provide both structural stability and waterproofing, resolving the contradiction between flow control and coverage.
2Reliability
If traditional roofing materials are used after natural disasters, then permanent replacement is achieved, but material and labor shortage delays installation
Solution Approach 1:
The patent introduces a temporary roofing system using a base layer and liquid roofing material that can be quickly installed to provide immediate waterproofing protection. This temporary solution can be applied rapidly with minimal materials and labor, protecting the roof until permanent replacement materials and labor become available.
Solution Approach 2:
The roofing system is designed to be dynamic in its lifecycle - serving as a temporary protective measure initially, then being convertible to or replaced by a permanent solution. This dynamic approach allows the system to adapt to changing conditions of material and labor availability after natural disasters.
3Ease of operation
If liquid roofing material is applied without a base layer, then application simplicity is maintained, but flowing and sagging cannot be controlled
Solution Approach 1:
The base layer is applied as a preliminary step before the liquid roofing material, creating a simple two-step process. This preliminary structure provides the necessary flow control and support, while the overall application remains straightforward and maintainable the simplicity of liquid roofing application.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The methods and systems effectively prevent sagging and flowing of liquid roofing materials on steep slopes, ensuring a watertight seal and enabling a quick, labor-efficient temporary roofing solution that can be converted to a permanent roof when materials and labor are available.
Implementation Method 1
a lipophilic base layer covered by a hydrophobic layer for immediate protection
Implementation Method 2
the use of base layers such as permeable meshes, woven fabrics, and fillers, along with fasteners and underlayments to secure the liquid roofing material
Data Source
AI summary
A method of forming a sloped roof can comprise obtaining a base layer comprising at least one of a permeable mesh, woven fabric, non-woven fabric, plastic, foam material or combinations thereof; applying the base layer over a roofing substrate of the sloped roof; and applying a liquid roofing material to the base layer to form a liquid applied roof.