US4016323A — Method and construction of roof system

Claim 1

Independent Claim 220 words

A method of preparing a building roof system having on its roof deck a prepared upper surface thereon, consisting of applying and affixing an impervious high strength heat resistant single sheet membrane to the adhesive primer and throughout the entire roof deck so as to tightly and completely adhere the membrane to the roof deck, said membrane having a self-adhering adhesive substance on its lower surface for effecting the adhesion of said membrane to said upper surface of said deck and having its upper surface adapted for bonding to insulating foam, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, applying directly to the top surface of the affixed and placed membrane a spray insulating foam to produce when set an even distribution of rigid urethane of a predetermined thickness, said urethane thickness being related to specific requirements of a specified U-factor for said roof system and having an exposed upper surface, subsequently applying directly to the exposed surface of the set urethane insulation a liquid sealant to a thickness exceeding 40 mils and which coats the entire exposed set insulation surface and provides a seamless film having a thickness when set which becomes a waterproof weather protecting surface final coating for the roof system.

Claim 2

Independent Claim 220 words

A method of preparing a building roof system having on its roof deck a prepared upper surface thereon, consisting of applying and affixing an impervious high strength heat resistant single sheet membrane to the adhesive primer and throughout the entire roof deck so as to tightly and completely adhere the membrane to the roof deck, said membrane having a self-adhering adhesive substance on its lower surface for effecting the adhesion of said membrane to said upper surface of said deck and having its upper surface adapted for bonding to insulating foam, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, applying directly to the top surface of the affixed and placed membrane a spray insulating foam to produce when set an even distribution of rigid urethane of a predetermined thickness, said urethane thickness being related to specific requirements of a specified U-factor for said roof system and having an exposed upper surface, subsequently applying directly to the exposed surface of the set urethane insulation a liquid sealant to a thickness exceeding 40 mils and which coats the entire exposed set insulation surface and provides a seamless film having a thickness when set which becomes a waterproof weather protecting surface final coating for the roof system.

Claim 3

Dependent Claim 32 words

The method of claim 1., including applying and affixing the single sheet membrane to the upper surface of the roof deck from rolls of material applied in successive parallel slightly overlapping rows.

Claim 4

Dependent Claim 31 words

The method of claim 1., including rolling the single sheet membrane with a weighted roller subsequent to placing and adhering of the membrane to the upper surface of the roof deck.

Claim 5

Dependent Claim 24 words

A method according to claim 1 including the step of applying a primer sealant coat to said roof deck prior to affixing said membrane.

Claim 6

Independent Claim 338 words

A method of preparing a building roof system having a building parapet wall consisting essentially of applying, beginning at the low point of the roof deck, sheet rolls of an impermeable rubberized membrane, applying the rolls of membrane in an overlapping manner of a sufficient number of inches of overlap to provide a bond between the successive rows of overlapping membrane, the membrane having an adhesive material on its lower surface as applied and adhering to the exposed upper surface of the roof deck and forming a permanent bond between the roof deck and membrane, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, applying continuously from the successive rows of overlapping membrane affixed to the roof deck in an overlapping manner the membrane along and up the surface of the parapet wall and thereby forming a continuous overlapping series of rows of membrane which become the intitial layer for the roof system, then applying directly to the top surface of the membrane a spray insulating foam to form a continuous monolithic insulating layer over the roof deck area and onto and abutting the membrane extending and affixed to the surface of the parapet wall, the spray foam insulation being applied in a thickness and manner to result in the top foam surface having a minimum slope of one-fourth inch per foot from the low level of the roof to the high point of the roof preventing pocket formations in the finished upper surface, then applying directly to the exposed surface of the spray foam insulation a liquid sealant elastomer which is applied to the entire exposed set foam surface providing a seamless water impermeable membrane exposed to the weather, the liquid sealant elastomer being applied in a continuous application over the spray foam and on up and onto the parapet wall, thereby providing a continuous impermeable coating and seal for the roof and junction of the roof deck with the parapet wall.

Claim 7

Independent Claim 338 words

A method of preparing a building roof system having a building parapet wall consisting essentially of applying, beginning at the low point of the roof deck, sheet rolls of an impermeable rubberized membrane, applying the rolls of membrane in an overlapping manner of a sufficient number of inches of overlap to provide a bond between the successive rows of overlapping membrane, the membrane having an adhesive material on its lower surface as applied and adhering to the exposed upper surface of the roof deck and forming a permanent bond between the roof deck and membrane, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, applying continuously from the successive rows of overlapping membrane affixed to the roof deck in an overlapping manner the membrane along and up the surface of the parapet wall and thereby forming a continuous overlapping series of rows of membrane which become the intitial layer for the roof system, then applying directly to the top surface of the membrane a spray insulating foam to form a continuous monolithic insulating layer over the roof deck area and onto and abutting the membrane extending and affixed to the surface of the parapet wall, the spray foam insulation being applied in a thickness and manner to result in the top foam surface having a minimum slope of one-fourth inch per foot from the low level of the roof to the high point of the roof preventing pocket formations in the finished upper surface, then applying directly to the exposed surface of the spray foam insulation a liquid sealant elastomer which is applied to the entire exposed set foam surface providing a seamless water impermeable membrane exposed to the weather, the liquid sealant elastomer being applied in a continuous application over the spray foam and on up and onto the parapet wall, thereby providing a continuous impermeable coating and seal for the roof and junction of the roof deck with the parapet wall.

Claim 8

Dependent Claim 45 words

A method of claim 5., wherein the adhesive material has characteristics for a tight bond between the upper surface of the roof deck and the membrane and further permits a pliability and expansion of the membrane during temperature variations without damage to the bond therebetween.

Claim 9

Dependent Claim 24 words

The method of claim 5., including the elastomer having elongation characteristics in excess of 500% of its thickness and further having ultra-violet resistant qualities.

Claim 10

Dependent Claim 40 words

The method of claim 5., wherein, during the application of the spray foam insulation, a cant is formed at the juncture of the parapet wall and the roof section whereby pocket information problems are precluded in the finished roof system.

Claim 11

Dependent Claim 57 words

The method of claim 5., wherein, during application of the spray foam insulation, the applicator forms the thickness of the insulation so as to provide a successive minimum slope of one-fourth per foot from the predetermined low point of the roof system to the other surfaces thereof, wherein pocket formations in the finished roof system are prevented.

Claim 12

Independent Claim 80 words

A method of fabricating a roof system on a roof deck comprising the steps of: providing a water impervious flexible membrane having a self-adhesive on one side; affixing said membrane to said deck by means of said adhesive; applying a layer of insulating foam in liquid form on top of said membrane; allowing said foam to solidify and become bonded to said membrane; and applying a layer of elastomeric water impervious material to the upper surface of the solidified foam.

Claim 13

Independent Claim 80 words

A method of fabricating a roof system on a roof deck comprising the steps of: providing a water impervious flexible membrane having a self-adhesive on one side; affixing said membrane to said deck by means of said adhesive; applying a layer of insulating foam in liquid form on top of said membrane; allowing said foam to solidify and become bonded to said membrane; and applying a layer of elastomeric water impervious material to the upper surface of the solidified foam.

Claim 14

Independent Claim 227 words

A method of preparing a building roof system having on its roof deck a prepared upper surface thereon, consisting of applying and affixing an impervious high strength heat resistant single sheet membrane to the adhesive primer and throughout the entire roof deck from rolls of material applied in successive parallel slightly overlapping rows so as to tightly and completely adhere the membrane to the roof deck, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, said membrane having on its lower surface an adhering material which immediately adheres to the upper surface of the roof deck as the membrane is unrolled and laid upon the roof deck, applying directly to the top surface of the affixed and placed membrane a spray insulating foam to produce when set an even distribution of rigid urethane of a predetermined thickness, said urethane thickness being related to specific requirements of a specified U-factor for said roof system and having an exposed upper surface, subsequently applying directly to the exposed surface of the set urethane insulation a liquid sealant to a thickness exceeding 40 mils and which coats the entire exposed set insulation surface and provides a seamless film having a thickness when set which becomes a waterproof weather protecting surface final coating for the roof system.

Claim 15

Independent Claim 227 words

A method of preparing a building roof system having on its roof deck a prepared upper surface thereon, consisting of applying and affixing an impervious high strength heat resistant single sheet membrane to the adhesive primer and throughout the entire roof deck from rolls of material applied in successive parallel slightly overlapping rows so as to tightly and completely adhere the membrane to the roof deck, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, said membrane having on its lower surface an adhering material which immediately adheres to the upper surface of the roof deck as the membrane is unrolled and laid upon the roof deck, applying directly to the top surface of the affixed and placed membrane a spray insulating foam to produce when set an even distribution of rigid urethane of a predetermined thickness, said urethane thickness being related to specific requirements of a specified U-factor for said roof system and having an exposed upper surface, subsequently applying directly to the exposed surface of the set urethane insulation a liquid sealant to a thickness exceeding 40 mils and which coats the entire exposed set insulation surface and provides a seamless film having a thickness when set which becomes a waterproof weather protecting surface final coating for the roof system.

Claim 16

Dependent Claim 165 words

An improved roof system comprising a roof deck, said roof deck having a lower surface and an upper surface, a high strength flexible membrane applied and adhering to the upper surface of the roof deck to form a continuous membrane thereupon, self-adhering adhesive means on the lower surface of said membrane for forming adhesion between the membrane and the upper surface of the roof deck, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, a continuous spray foam insulation layer immediately on top of the membrane and having bonding characteristics to form a permanent bond between said spray foam layer and the upper surface of the membrane, an elastic coating applied to the upper surface of the spray foam and covering the entire upper surface thereof and said coating having permanent stretching characteristics and being a material resistive to normal atmospheric conditions and erosion problem characteristic to exposed roof surfaces.

Claim 17

Dependent Claim 165 words

An improved roof system comprising a roof deck, said roof deck having a lower surface and an upper surface, a high strength flexible membrane applied and adhering to the upper surface of the roof deck to form a continuous membrane thereupon, self-adhering adhesive means on the lower surface of said membrane for forming adhesion between the membrane and the upper surface of the roof deck, said membrane having integral therein a supportive and strengthening mesh throughout and said mesh further being substantially intermediate of the surfaces of the membrane, a continuous spray foam insulation layer immediately on top of the membrane and having bonding characteristics to form a permanent bond between said spray foam layer and the upper surface of the membrane, an elastic coating applied to the upper surface of the spray foam and covering the entire upper surface thereof and said coating having permanent stretching characteristics and being a material resistive to normal atmospheric conditions and erosion problem characteristic to exposed roof surfaces.

Claim 18

Dependent Claim 35 words

The roof system as defined in claim 12., wherein the means for forming the adhesion between the membrane and upper surface of the roof deck comprises a self-adhesive bonding material formed integral with the membrane.

Claim 19

Dependent Claim 39 words

The roof system as defined in claim 12., wherein the flexible membrane has puncture resistive properties and is pliable during temperature varying conditions, and wherein the elastic coating has a stretching characteristic in excess of 500% of its thickness.

Claim 20

Dependent Claim 47 words

The roof system as defined in claim 12., wherein the roof deck is constructed to have a minimum slope from its low point throughout thereof of one-fourth inch slope per foot to preclude pocketing of ice or water on the top finished surface of the roof system.

Claim 21

Dependent Claim 48 words

The roof system as defined in claim 12., wherein the flexible membrane is comprised of successive rolls of material applied in an overlapping relation, said overlapping of rolled membrane material being of such overlapping width as to provide a permanent moisture resistive seal for the applied membrane strips.

Claim 22

Dependent Claim 104 words

A roof system comprising: a roof deck having an upper surface; a flexible water impervious membrane overlying said deck and comprising a supportive and strengthening mesh having a self-adhering adhesive substance on its lower surface for effecting adhesion of said membrane to said upper surface of said deck and having its upper surface adapted for bonding to insulating foam; a rigid layer of insulating foam foamed in situ overlying said membrane and having its lower surface bonded to said upper surface of said membrane; and a layer of elastomeric material overlying and adhering to the upper surface of said rigid layer of insulating foam.

Claim 23

Dependent Claim 104 words

A roof system comprising: a roof deck having an upper surface; a flexible water impervious membrane overlying said deck and comprising a supportive and strengthening mesh having a self-adhering adhesive substance on its lower surface for effecting adhesion of said membrane to said upper surface of said deck and having its upper surface adapted for bonding to insulating foam; a rigid layer of insulating foam foamed in situ overlying said membrane and having its lower surface bonded to said upper surface of said membrane; and a layer of elastomeric material overlying and adhering to the upper surface of said rigid layer of insulating foam.

Claim 24

Dependent Claim 14 words

A system according to claim 17 wherein said adhesive substance is rubberized self-adhesive asphalt.

Claim 25

Dependent Claim 14 words

A system according to claim 18 wherein said membrane is approximately .065 inches thick.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1980-04-04	1980-10-04	1981-04-05	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1984-04-04	1984-10-04	1985-04-05	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1988-04-04	1988-10-04	1989-04-05	$7700.00	Window Closed / Lapsed

Method and construction of roof system

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