Composite roofing or other surfacing board, method of making and using and roof made thereby

A composite roofing board is provided, including a layer of bituminous core material having pieces or particles of shingles, rolled roofing, etc. that have been broken-up or comminuted therein, with the core material having layers of mat material on opposite surfaces thereof, also in layers, and with an adhesive applied to an outer surface of one of the layers of mat material, with a peelable and removable release liner layer covering the adhesive. The various layers are provided as a sandwich, to make the composite board. A plurality of composite boards may be applied to a roof deck or other roof structure, and they can be butt-joined and taped together with a joint tape. The method of making the composite board can be continuous.

BACKGROUND OF THE INVENTION

It is known in the roofing art to apply composite roofing boards to a roof deck, and to apply a roof covering material, such as shingles or roll roofing thereover.

THE PRESENT INVENTION

The present invention is directed to providing a composite board for use as a roofing or other surfacing material, having a novel construction, and to provide a roof or other surface made up of a plurality of composite boards applied over a roof or other structure, and then to cover the composite boards with shingles, tiles or a waterproofing membrane or other surfacing material. A method of making a composite board is also provided, as is a method of roofing a roof structure using such composite boards.

SUMMARY OF THE INVENTION

A composite board is provided for use as a roofing material or other surfacing material, that comprises a sandwich of a core material layer having layers of mat material on opposite surfaces thereof, one of which has a layer of adhesive secured thereto, which, in turn, has a removable layer of release liner covering the adhesive. The core material includes a solidified bituminous material having filler components of recycled roofing products that may be made from particles or pieces of shingles or other roofing materials such as roll roofing particles.

The release paper is removed to allow application of the composite board onto a roof deck or other structure, such that the adhesive layer can secure the composite boards to the roof deck or other structure.

Accordingly, it is a primary object of this invention to provide a novel composite board for use as a roofing material or other surfacing material, that comprises a core material layer that includes solidified bituminous material having filler components of recycled roofing products therein, with layers of mat material on opposite surfaces of the core material layer, and with the layer of adhesive on one of the layers of mat material, that in turn, is covered by a removable layer of release liner.

It is another object of this invention to accomplish the above object, wherein a roof is made, comprised of composite boards as described in the object immediately above, wherein the composite boards may or may not be laid on a roof adjacent each other, and may or may not have adjacent edges butt-joined together and secured together with joint tape.

It is yet another object of this invention to accomplish the objects recited above, wherein the step of making a composite board is provided by first supplying a layer of mat material, and then providing a non-solid core material layer that includes a bituminous material and pieces or particles of shingles and/or roll roofing material, then applying a second layer of mat material onto the other surface of the core material, allowing the core material to solidify, then applying a layer of adhesive to one of the layers of mat material, followed by the application of a removable layer of release liner to the layer of adhesive.

It is yet another object of this invention to accomplish the above object, wherein the steps of making the composite board are continuous.

It is a further object of this invention to provide a method of roofing a roof structure.

Other objects and advantages of the present invention will become readily apparent upon a reading of the following brief descriptions of the drawing figures, the detailed descriptions of the preferred embodiments, and the appended claims.

DETAILED DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring to the drawings now in detail, reference is first made toFIG. 1, wherein an apparatus20is shown for manufacturing composite boards in accordance with this invention.

The apparatus20includes a continuous conveyor belt21having upper and lower runs22and23, respectively, movable over rollers29, in the respective directions of arrows24,25, when suitably driven by a motor (not shown) or the like.

At the left end ofFIG. 1, a roll26of mat material27is provided, rotatable in the direction of arrow28, to be delivered onto the upper run22of the conveyor belt21, as shown.

As the lower layer27of mat passes beneath a hopper30, a bituminous material, such as somewhat molten asphalt31, carried in the hopper30is dispensed therefrom in the direction of the arrow33, out a discharge34thereof, to be delivered with its lower surface39onto the upper surface of the mat layer27in the form of a core layer35, to be delivered in the direction of the arrow36inFIG. 1.

Because the bituminous material31is in non-solid form, and is preferably heated to be somewhat molten, to carry a plurality of particles or pieces of shingles or roll roofing material that have been recycled as particles thereinto, the somewhat molten bituminous material31with the particles therein will preferably be allowed to cool and solidify. In this regard, a cooling unit37may deliver cooling air, gas or the like in the direction of the arrows38to the core layer35as shown, as the core layer35moves therepast in the direction of arrow36.

A roll40of mat material, rotating in the direction of arrow41, delivers another layer of mat material42onto the upper surface43of the core material layer35, to be adhered thereto, prior to the upper surface43becoming permanently solidified.

Thereafter, an adhesive45, preferably in somewhat molten form, is delivered from a hopper46, dispensed therefrom in the direction of arrow49, to form a layer47that adheres to the upper surface of the mat layer42, as the adhesive layer47moves in the direction of the arrow48, rightward as shown inFIG. 1.

Thereafter, a roll50of release liner51, rotating in the direction of arrow52, is applied to the upper surface of the adhesive layer47shown inFIG. 1.

It will be understood that the bituminous material31will preferably be an asphalt, that is heated in the hopper30, to be somewhat molten, for ease of application onto the layer27of mat material. The core material will include pieces or particles of shingles, roofing products such as roll roofing or the like that have been comminuted, to be dispersed throughout the bituminous material31in the hopper30, to be delivered onto the layer27of mat material preferably in a continuous manner as is schematically shown inFIG. 1. The roofing shingles or particles in the bituminous material31will preferably be particles having asphaltic materials or other bituminous materials therein, some fiber materials, some granules, etc., as would normally be obtained by comminuting or grinding up shingles, roll roofing, etc.

The mechanism37for solidifying the bituminous material with particles therein, can be a refrigerating mechanism, a fan blowing ambient air thereon, or even the simple presence of ambient air applied to the layer35of core material over some predetermined distance, or any other means for solidifying the layer35of core material. The mat materials delivered as layers27,42, from rolls26,40respectively, can include fiberglass mat, organic felt, scrim, or any other suitable mat material.

The adhesive45provided from hopper46, could be an asphalt material, or any other type of adhesive as may be desired, such as butyl, SBS, SIS, rubber resin or other adhesives.

The release liner or layer51provided from roll50, can be any type of release material known in the art that can readily be removed from the adhesive layer47, at the site of installation of the composite boards applied to a roof deck or other roof structure. The release liner51can be comprised of silicone coated plastic film or paper, or any other readily removable release liner.

As an alternative process, the adhesive could be applied to the release liner and then the adhesive on the liner could be laminated to what would become the bottom side of the composite board.

With reference now toFIG. 2, it will be seen that the end product emanating from the right side ofFIG. 1is illustrated in inverted form, such that the core layer has a mat layer27on its upper surface and a mat layer42on its lower surface, with the adhesive layer47disposed against the lower surface of the mat layer42, and with the layer51of release liner disposed thereagainst. The left end of the layer of release liner is shown, at53, to be peelable away from the adhesive layer47, by grasping the same and moving it in the direction of the arrow54, when the composite board55for use as a roofing material is adapted to be used by applying it to a roof structure, roof deck, or the like. In some embodiments the release liner may have a pull tab or extension (not shown) beyond an edge of the composite board, to facilitate removal of the release liner.

It will also be understood that, as used herein, the roof structure to which the composite boards55can be applied, may comprise a roof deck of any particular construction, with or without a tarpaper or other waterproof liner disposed thereon.

With reference now toFIG. 3, it will be seen that a building structure60is illustrated, having a roof61, with a plurality of composite boards62-67applied thereto, such composite boards being made in accordance with this invention as described above.

The composite boards62and63are shown being butt-joined together along the dotted line68, shown beneath the layer70of joint tape that overlies the abutting edges of the composite boards62,63that meet along joint line68, and with the joint tape70being adhesively secured to the composite boards62,63, securing them together, and adding an additional waterproofing feature.

With reference now toFIG. 4, it will be seen that the roof deck61has the composite boards62and63shown adhesively secured thereto, by means of the adhesive layers47securing the boards62,63thereto, and in the enlargement ofFIG. 4, it is seen that the butt-joined edges of the boards,62,63, come together at the joint line68, and are adjacent to each other, with their adjacent edges being held together by the layer of joint tape70.

InFIG. 5, the roof61of the structure60is shown, with joint tape strips70,71and72being illustrated, applying the joint tape over a plurality of butt-joined edges of adjacent composite boards,62-67, as described above.

Referring now toFIG. 6in detail, it will be seen that a roof deck80is illustrated fragmentally, having a pair of roofing boards81and82in accordance with this invention applied thereto. Adjacent thin edges83,84, overlap each other, and are capable of bending to accommodate the lap, when installed, thereby undergoing a deformation. A seam tape (not shown) may be provided, also covering the lapped joint.

InFIG. 7, a pair of adjacent roofing boards90and91are mounted on a roof deck92, also fragmentally shown, and their adjacent edges93,94are shown in shiplapped relation to each other, with a strip of seam tape95also covering the joint.

InFIG. 8, adjacent roofing boards100and101cover a roof or other deck102, with their edges103,104essentially abutting each other, and wherein cover layers105,106of mat, foil or film, carried by the boards100,101provide the overlapping function. Optionally, a strip of seam tape107may also be used, covering the edges of the cover layers105,106.

InFIG. 9, the adjacent roofing boards110,111, are applied to a roofing deck112, or other structure, also with their adjacent edges113,114abutting each other, and also with cover layers of mat, foil or film115,116applied thereover, again with an optional seaming tape117overlapping the lapped edges of the cover layers115,116. In the embodiment ofFIG. 9, beneath the overlapping right end of the cover layer115, there is a strip of adhesive118, with a release liner120therebeneath, with the release liner being removable upon installation, to allow the adhesive118to adhere the right edge of the cover layer115to the uncovered left edge of the board111.

Referring now toFIG. 10, a roof deck or other structure130is shown, with adjacent roofing or other surfacing boards131,132applied thereto, being butt-joined at133, as shown. It will be understood that the junction133could in the alternative be any of those set forth inFIGS. 6 through 9, or otherwise, within the spirit and scope of the invention.

The roofing or other surfacing boards131,132may have respective photovoltaic layers139,134, appropriately wired at135,136, for electrical connection to a power system, battery, electrical grid, or the like, and preferably with a protective covering137for the junction138where the photovoltaic layers139,134come together, and also for protecting the electrical wiring135,136.

The roofing or other surfacing boards in accordance with this invention may optionally have a surfacing layer applied thereto, to form a radiant barrier, flame retardant or resistant barrier, a barrier for ultraviolet radiation protection, or the like, or for any other form of protection, as is disclosed in U.S. application Ser. No. 12/056,766, filed Mar. 27, 2008, the complete disclosure of which is herein incorporated by reference.

With respect to the photovoltaic feature of this invention, that is discussed more specifically with respect toFIG. 10, photovoltaic elements or layers may be incorporated into the roofing board or other surfacing board in accordance with this invention, in accordance with the disclosure of U.S. application Ser. No. 12/339,943 filed Dec. 19, 2008, the complete disclosure of which is also herein incorporated by reference.

Also, in accordance with this invention, a surface of the roofing or other surfacing board could be a parchment, a metallized plastic film, a metal foil, a waterproofing layer, or other protective layers, as may be desired, or combinations thereof.

It will thus be seen that the present invention discloses a semi-rigid recovery board that includes an asphalt or other bituminous material having particles of recycled shingles or rolled products or other roofing materials embedded therein, with a core thereof being sandwiched between two layers of mat material, such that the board can be applied to a roof structure such as a roof deck or other covering on the roof structure or other structure by means of a factory-supplied self adhesive attachment.

The composite boards of this invention can also provide a waterproofing layer for plastics, parking garages or building floors, especially those that include a cementitious substrate, by providing a surfacing structure therefor, to be adhesively secured to the cementitious substrate disposed therebeneath after removal of the release liner, and can have applied thereover at least one additional cementitious layer, on top of the composite boards. In such a construction, the composite boards can act as a waterproofing layer. The same type of surfacing structure can be used on various floor surfaces, bridges or the like, and therefore provides a composite board for use a building product, for both roof and non-roof structures.

It will also be understood that the adhesive layer47, while preferably being continuously applied to a surface of a mat layer, could, in the alternative, be discontinuous and could be applied in the shape of dots, strips, or in any other manner. In each case, the adhesive layer can be protected by means of a peelable release liner.

The present invention thus allows an economic advantage, in making use of recycled roofing material, such as recycled shingles, roofing roll products, and the like, and can be applied to a roof without requiring an on-site application of hot asphalt. It creates a clean, solid, even, stable surface for next-overlying layers of shingles, roofing tiles, membranes, or the like.

It will be understood that various modifications can be made in the details of construction as well as in the use and application of the composite boards of this invention, all within the spirit and scope of the invention as defined in the appended claims.