Abstract:
Exemplary embodiments generally relate to a method and device for assembling a plurality of different roof-covering membranes, herein known as fitments. The particular fitment is preferably designed for the particular roof on which it is to be used. The roof measurements may be provided to a factory which may create a unitary membrane from separate pieces which may be hot air bonded together. A single machine may be utilized to quickly, and repeatably assemble a plurality of different fitments.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a non-provisional patent application and does not claim priority to any co-pending applications. 
     TECHNICAL FIELD 
     Exemplary embodiments generally relate to a method and device for assembling a plurality of different roof-covering membranes, herein known as fitments. A single machine may be utilized to quickly, and repeatably assemble a plurality of different fitments. 
     BACKGROUND OF THE ART 
     Items such as vents, ductwork, air conditioning units, and the like commonly protrude from the surface of a roof. The size and location of these items is preferably provided to the factory which creates the membrane. With this information, the factory may make provisions for these items in the membrane. 
     Providing a water-tight seal around a protrusion in a roof presents a number of problems. U.S. Pat. No. 4,872,296 discloses a method and a fitment which have been used to cover the corners of protrusions. The fitment of this patent comprises a first generally rectangular member segment, a side being part-way split interjacent its ends, and a second member segment with a triangularly-shaped corner portion conformed to loop shape and having its marginal edges overlying portions of the first segment contiguous to the split and being welded thereto in a continuous weld seam. This method and fitment work best when the angle of the corner is a right angle and the angle between the roof and the protrusion is a right angle. 
     In many cases, however, the corner is not a right angle, the protrusion is not at a right angle to the roof, or there is some other irregularity in the protrusion, such as the bottom and the top being different sizes. In these situations, known fitments and methods do not provide satisfactory results. The membrane must be folded or “bunched” in order to conform the membrane to the underlying structure. The folding and bunching is unsightly, and water may collect in the folds which may have deleterious effects on the roofing membrane and/or may lead to localized leaks at seams and at other places in the membrane. In addition, folding can lead to cracking of the roof membrane over time due in part to stress induced by the fold lines. Therefore, a need exists for an adjustable fitment and roof membrane system that provides a smooth transition no matter what the shape or angle of the underlying protrusion and that eliminates the need to fold or bunch the fitment or the roof membrane. 
     U.S. Pat. No. 6,199,326 provides an embodiment of an adjustable roof membrane which includes a universal fitment. The disclosure of U.S. Pat. No. 6,199,326 is hereby incorporated by reference in its entirety. In this embodiment, the universal fitment is an adjustable corner fitment for a roof. The adjustable corner fitment is comprised of a top membrane and a bottom membrane. The top membrane has a cutout. The cutout extends from a side of the top membrane. The base membrane portion has a first side, a second side, a third side and a fourth side. The first side is connected to the second side at a first angle greater than 90 degrees, and the third side is connected to the fourth side at a second angle greater than 90 degrees. The base membrane portion is conformed to loop shape such that the first side and the second side underlie portions of the top membrane contiguous to the cutout. The first side of the base membrane may be completely welded to the top membrane prior to installation. However, the second side of the base membrane is adjustable relative to the top membrane prior to installation on the roof. Consequently, an installer is able to adjust the corner fitment to a corner in the field to eliminate unnecessary buckling of the corner fitment or the roof membrane. After adjusting the corner fitment to the corner, the installer may then completely weld the second side of the base membrane to the top membrane. 
     Further, U.S. Pat. Nos. 6,754,993 and 7,347,907 (both issued to Mayle et al.) disclose adjustable roof fitments and are herein incorporated by reference in their entirety. The fitments and methods for constructing the fitments disclosed in these patents are useful with roof membranes to cover exposed roof areas around a vertical protrusion in a roof. The fitments may be partially secured to a roof membrane, a boot, and/or a spanning strip prior to being positioned at the corner of a vertical protrusion. Alternatively, the fitment may be positioned independently of the other components at the corner of a vertical protrusion. After the fitment is positioned at the corner of a vertical protrusion, a floating portion of the fitment may be adjusted to fit the corner of the vertical protrusion so that there is minimal or no folding or bunching of the material of the fitment. In this adjusted position, the floating portion of the fitment may be dielectically welded, hot air bonded or otherwise secured to another portion of the fitment, and the fitment may be finally dielectrically welded, hot air bonded or otherwise secured to the roof membrane, the boot, and/or the spanning strips. 
     These prefabricated roofing fitments may be made from thermoplastic olefin (TPO), polyvinyl chloride (PVC), or any other suitable material. TPO material is much less expensive than other roof membrane material, but has not been used in the roofing industry in the past because TPO is non-conductive material and therefore, cannot be dielectrically welded. Material such as polyvinyl chloride (PVC) has been commonly used in the roofing industry since it can be easily dielectrically welded. However, PVC is much more expensive than TPO. Accordingly, PVC lends itself to dielectric welding or hot air bonding, while TPO lends itself to hot air bonding. With the hot air bonding apparatus and methods of the exemplary embodiment a fully TPO fitment is achieved. 
     An exemplary embodiment may utilize any material suitable for constructing the fitments described herein. Examples of the materials utilized in the fitments may be comprised of polyvinyl chloride (PVC), thermoplastic olefin (TPO), or rubber, and any mixtures thereof. The fitments may be made from or use any material that is heat bondable, glue bondable, or solvent bondable. The fitments may be made with or use a material that is compatible with dielectric welding, hot air bonding, solvent fusion, adhesive bonding, heat welding, melt bonding, vibration welding, ultrasonic welding, heat staking, or other methods commonly known to those experienced in the field of this art. 
     In addition to the novel features and advantages mentioned above, other objects and advantages are achieved, at least in the preferred embodiments, by the invention as shown and described below. 
     SUMMARY OF THE EXEMPLARY EMBODIMENTS 
     Exemplary embodiments relate to a device and method for constructing the roof fitments described herein. Embodiments provide a repeatable and efficient method for producing consistent roof fitments. The same base device may be used to create a plurality of different styles and shapes of fitments. 
     The foregoing and other features and advantages of the present invention will be apparent from the following more detailed description of the particular embodiments of the invention, as illustrated in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       A better understanding of an exemplary embodiment will be obtained from a reading of the following detailed description and the accompanying drawings wherein identical reference characters refer to identical parts and in which: 
         FIG. 1  is a perspective view of an embodiment of an adjustable roof membrane system; 
         FIG. 2  is a cross sectional view taken along line  2 - 2  of  FIG. 1 ; 
         FIG. 3A  is a top plan view of an exemplary embodiment of a base membrane portion; 
         FIG. 3B  is a top plan view of an exemplary embodiment of a base membrane portion which has a middle adjustment feature; 
         FIGS. 3C and 3D  are top plan views of an embodiment of the two components that form the base membrane portion with a middle adjustment feature of  FIG. 3B ; 
         FIG. 4  is a top plan view of an exemplary embodiment of a top membrane portion; 
         FIG. 5A  is a perspective view of an assembled fitment which lacks a seal along at least a portion of one of its edges; 
         FIG. 5B  is a perspective view of an assembled fitment which has both edges completely sealed; 
         FIG. 6  is a perspective view of an exemplary embodiment of a device for manufacturing roof fitments; 
         FIG. 7  is a perspective view of an embodiment for the bolster plate and heating element; 
         FIG. 8  is a perspective view of the bottom surface of the ram, showing the first and second dies; 
         FIG. 9  is another perspective view of the bottom surface of the ram, showing the insert; 
         FIGS. 10A and 10B  are perspective views of alternative embodiments of the heating element; 
         FIG. 11A  is a perspective view of an exemplary device for assembling roof fitments, where the heating element is transferring heat to the two membrane portions; 
         FIG. 11B  is a perspective view of the embodiment shown in  FIG. 11A  where the heating element has been retracted and the first and second dies are pressing overlapping portions of the membranes together. 
     
    
    
     DETAILED DESCRIPTION 
     Referring first to  FIGS. 1 and 2 , a polymer-membrane  10  is shown overlying a roof  20 . The roof  20  may have a surrounding parapet  22 . In addition, a protrusion  30  may extend from the roof  20 . An opening  12  in the membrane  10  preferably allows the sides  32 ,  34  of the protrusion  30  to extend through the membrane  10 . After the membrane  10  is in place on the roof  20 , a preferred embodiment of a fitment  40  may be installed to substantially prevent moisture from entering the roof  20  at a corner of the protrusion  30 . 
     In one type of adjustable roof membrane system, fitments  40  may be joined by spanning strips  50  as shown in  FIG. 1 . Each spanning strip  50  preferably has an upper portion  52  and a bottom portion  54 . The bottom portion  54  may be dielectrically welded, hot air bonded or otherwise sealed along its length to the membrane  10 , and the fitments  40  may be dielectrically welded, hot air bonded or otherwise sealed to the membrane  10  and the spanning strips  50  as shown at  60 ,  62 , and  70 . Although not shown in the figures, it should also be recognized that the fitments  40  may be positioned at the corners of a vertical protrusion such that they are overlapped by the spanning strips  50 . 
     A fitment  40  preferably has a top membrane portion  80  and a base membrane portion  90 . As illustrated in  FIG. 4 , the top membrane portion  80  is preferably substantially rectangular and may be comprised of quadrants  81 ,  82 ,  83 , and  84 . The top membrane portion  80  has a cutout  86 . The cutout  86  preferably divides quadrant  83  from quadrant  84 , and it preferably extends from about the middle of side  85  to about the center portion  89  of the top membrane portion  80 . As shown in  FIG. 4 , the cutout  86  may have substantially parallel sides  87 ,  88 . For one example of the cutout  86 , the sides  87 ,  88  may be separated by about one-half inch. However, the cutout  86  may increase in width as the cutout  86  extends from the center portion  89  towards the side  85 . 
     In addition to the embodiment shown in  FIG. 4 , the top membrane portion  80  may take the form of many different shapes. The shape of the top membrane portion  80  may vary depending on the application. For example, the top membrane portion  80  may have a different number of sides, it may have curved sides, or it may have sides of different lengths. For another example, the cutout  86  may extend from a portion of a side other than the middle, it may extend at an angle which is not perpendicular, or it may have a different shape, length, or width. 
     Referring back to  FIG. 1 , quadrants  81 ,  82  of the top membrane portions  80  and upper portions  52  of the spanning strips  50  may be secured by an adhesive or other suitable means to the sides  32 ,  34  of the protrusion  30 . A band  100  may be used to join the top edges of quadrants  81 ,  82  and upper portions  52 . In addition, an adhesive, a bead of mastic, a bead of sealant, or any similar material may be used to form a tight seal between the band  100  and the sides  32 ,  34  of the protrusion  30 . 
     Referring to  FIG. 3A , the base membrane portion  90  is preferably comprised of a first generally triangular portion  91 , a second generally triangular portion  94 , and a tab  97  which has a hole  98 . Sides  92 ,  93  of the first generally triangular portion  91  are preferably joined at a radiused corner. In addition, sides  92 ,  93  extend at an angle a which is greater than about 90 degrees. On the other hand, sides  95 ,  96  of the second generally triangular portion  94  are connected by the tab  97 . The sides  95 ,  96  extend at an angle b which is greater than about 90 degrees. By making the angles a, b greater than about 90 degrees, the fitment  40  is preferably adjustable. In other words, the angles a, b preferably help to substantially eliminate the need to fold or bunch the fitment  40  when the corner is not a right angle, when the protrusion  30  is not at a right angle to the roof  20 , or when there is some other irregularity in the protrusion  30 . 
     However, the base membrane portion  90  is not limited to the configuration as described above. The base membrane portion  90  may have any other shape that is suitable and may have side tabs  99   a , which may have a hole  99   b , on the corner between side  92  and side  95  and/or the corner between side  93  and side  96 . 
     Referring now to  FIGS. 3B-3D , in another embodiment the base membrane portion  90 ′ may be comprised of two separate triangular shaped portions  120 ,  124 . The first triangular shaped portion  120  may preferably be comprised of three sides  95 ′,  92 ′,  122 , a tab  97  which may have a hole  98 , and a side tab  99   a  which may have a hole  99   b . Side  95 ′ and side  122  are preferably connected by a tab  97 , while side  95 ′ and side  92 ′ are preferably connected by a side tab  99   a . The second triangular shaped portion  124  may preferably be comprised of three sides  96 ′,  93 ′,  126 , a tab  97  which may have a hole  98 , and a side tab  99   a  which may have a hole  99   b . Side  96 ′ and side  126  are preferably connected by a tab  97 , while side  96 ′ and side  93 ′ are preferably connected by a side tab  99   a . In an exemplary embodiment, the first triangular shaped portion  120  and the second triangular shaped portion  124  are arranged to form a base membrane portion  90 ′. 
     The base membrane portion  90 ′ may be substantially similar to base membrane portion  90 . However, base membrane portion  90 ′ has a middle adjustment feature  130  which allows the fitment  40  to be adjusted when sides  95 ′ and  96 ′ are sealed to the top membrane portion  80 . The middle adjustment feature  130  is preferably formed by the overlapping of side  122  on the first triangular shaped portion  120  and side  126  on the second triangular shaped portion  124 . 
       FIGS. 5A and 5B  show examples of fitments  40  prior to installation. In an exemplary embodiment, preferably only one of the sides  95 ,  96  may be completely sealed to the top membrane portion  80  prior to installation on the roof  20 . Preferably, only a portion, if any at all, of the other side  95 ,  96  may be sealed to the top membrane portion  80  prior to installation. This preferably enables the fitment  40  to be adjusted in the field to a corner that is not a right angle, a protrusion  30  that is not at a right angle to a roof  20 , and/or an irregularly-shaped protrusion  30 . In a fitment  40  that has a middle adjustment feature  130 , both sides  95 ′ and  96 ′ may be sealed to the top membrane portion  80  prior to installation. However, the middle adjustment feature  130  is not sealed prior to installation and enables the fitment  40  to be adjusted in the field to the corner or protrusion  30  on the roof  20 . It should be noted that after sealing, the base membrane portion  90  remains substantially flat. 
     Although it may be advantageous to leave one of the sides  95  or  96  unsealed or provide an adjustment feature  130 , these are not required. Exemplary fitments may lack an adjustment feature  130  and may be completely sealed on both sides  95  and  96 . An exemplary device for making the fitments disclosed herein would be capable of manufacturing each type of sealing arrangements for the various fitments. 
     During installation, after the fitment  40  is adjusted to the roof  20  and to the protrusion  30  in the field to substantially eliminate any folding or bunching, if there is an unsealed side, the unsealed side  95  and/or  96  may be sealed along its entire length to the top membrane portion  80  or the middle adjustment feature  130  may be sealed. 
       FIG. 6  shows an exemplary device  100  for making the various fitments described herein. An exemplary device may be comprised of a ram  103 , bolster plate  101 , and heating element  102 . 
       FIG. 7  provides another view of the bolster plate  101  and heating element  102 . The bolster plate  101  contains one or more securing mechanisms  111  along with one or more suction devices  110 ; both elements may be used to hold the top membrane portion  80  in position during the fabrication process. Alternatively, only securing mechanisms or only suction devices may be used to secure the top membrane portion. The bolster plate  101  has three main surface areas. First area  183  accepts quadrant  83  of the top membrane portion  80 . Second area  184  accepts quadrant  84  of the top membrane portion  80 . Third area  180  accepts quadrants  82  and  81  of the top membrane portion  80 . 
       FIG. 8  provides a detailed view of the bottom surface of the ram  103 , which contains a first die  104  and a second die  105 . The first die  104  is actuated by the main ram actuator assembly  200  (see  FIG. 11B ) and the second die  105  is actuated by an auxiliary actuator assembly  201  (see  FIG. 11B ). The ram  103  may contain one or more suction devices  112  and pins  198  and  199  for securing the bottom membrane portion  90  during fabrication of the fitment. In alternative embodiments, only suction devices or only pins may be used. Hole  98  in the bottom membrane portion corresponds to pin  198  in the ram while holes  99   b  in the bottom membrane portion correspond with pins  199  in the ram. 
     The first die  104  is utilized to create a seal along edge  95  and at least a portion of  96 . Edge feature  109  is contained within the first die  104  and is used to create a seal along edge  95 . A portion of the first die  104  may comprise an insert  106 , so that the same die may be used to create both fitments where the entire edge  96  is sealed and also where only a portion of the edge  96  is sealed. By changing out the insert  106 , the points of contact between the first die  104  and the bolster plate  101  may be changed without having the change the entire die or use an entirely different machine. The second die  105  contains an edge feature  107  to further seal at least a portion of edge  96 . The second die  105  also contains a concave feature  108  which interfaces with third area  180  of the bolster plate  101 . The concave feature  108  is used to form the seal around radius  134  to create pucker  140 . 
       FIG. 9  is another view of the bottom surface of the ram  103 . Suction devices  112  are again shown along with insert  106 . Also shown is the second die  105  which contains the concave feature  108  and pin  198 . 
       FIGS. 10A and 10B  show two embodiments for the heating element  102 . These embodiments may be utilized when hot air bonding is the chosen method for creating the seals between the base  90  and top  80  membrane portions. For the embodiment shown in  FIG. 10A , air exhausts are located along edges  195  and  196   a , along with radius  234 . For the embodiment shown in  FIG. 10B , air exhausts are located along edges  195  and  196   b , along with radius  234 . As can be observed, edge  196   b  does not run the length of the heating element, where  196   a  from  FIG. 10A  does. Thus, the embodiment shown in  FIG. 10B  would be utilized when the entirety of edge  96  between the membranes is not required to be sealed. Both embodiments may force hot air over the overlapping areas of edges  96 ,  95 , and radius  134 . As shown below, the heating element  102  is sandwiched between the base  90  and top  80  membrane portions prior to contacting the portions with one another. Thus, an exemplary device would force hot air in both the upward and downward directions in order to heat the overlapping edges of both the base  90  and top  80  portions simultaneously. 
     An exemplary method for making a fitment may begin by placing the top membrane portion  80  on the bolster plate  101  and placing the base membrane portion  90  on the bottom surface of the ram  103 . The top membrane portion  80  may be secured in place by using one or more securing mechanisms  111  along with one or more suction devices  110 . The base membrane portion  90  may be secured in place by using one or more suction devices  112  and pins  198  and  199 . When securing the top membrane portion  80  to the bolster plate  101 , the quadrants of the membrane and bolster plate should preferably be aligned as described above. First area  183  accepts quadrant  83  of the top membrane portion  80 . Second area  184  accepts quadrant  84  of the top membrane portion  80 . Third area  180  accepts quadrants  82  and  81  of the top membrane portion  80 . Third area  180  is a concave surface and when aligning the top membrane portion  80 , the quadrants  82  and  81  should follow the surface without substantial wrinkles or buckles. The edges  87  and  88  of the top membrane portion  80  should be aligned so that when the ram  103  lowers, these edges overlap edges  95  and  96  of the base membrane portion  90 . 
     Once the membrane portions are properly placed and secured,  FIG. 11A  shows what may be the next step in an exemplary process. The ram  103  is lowered so that the two membrane portions are in relatively close proximity to one another. The heating element  102  is placed between the two membrane portions and forces hot air along the seams which are to be sealed. Preferably, the heating element forces hot air along the seam areas of both the top and base membrane portions  80  and  90  respectively. As noted above, a plurality of different heating elements  102  may be interchangeable with an exemplary device so that a single device is capable of making a plurality of different fitments. 
     Once the membrane portions are adequately heated,  FIG. 11B  shows what may be the next step in an exemplary process. The heating element  102  is removed and the ram  103  is further lowered so that the membrane portions are adjacent to one another. For sealing the desired edges, the ram  103  lowers the first  104  and second dies  105  so that pressure is created along the desired edges which were previously heated by the heating element  102 . In an exemplary embodiment, the pressure is created through two actuations. The first die  104  is actuated first by the main ram actuator assembly  200  and then the second die  105  is actuated by an auxiliary actuator assembly  201 . However, one continuous actuation may be used. 
     In a preferred embodiment, the first die  104  is used to create the seal along edges  95  and  96 , while the second die  105  is used to create the seal near the radius  134  and possibly a portion of edges  95  or  96 . As noted above, the second die  105  contains a concave feature  108  which interfaces with third area  180  of the bolster plate  101 . The concave feature  108  is used to form the seal around radius  134  to create pucker  140 . 
     As noted above, an insert  106  may be used so that a plurality of edge-seal orientations may be accomplished through the same machine. Thus, both edges  95  and  96  may be sealed, only a portion of each edge may be sealed, edge  95  may be sealed while only a portion of edge  96  is sealed, edge  96  may be sealed while only a portion of edge  95  is sealed, or any other combination. Thus, inserts may be used more places and with different geometry than the insert shown in  FIGS. 8 and 9 . 
     In exemplary embodiments, the fitment  40  may be made from thermoplastic olefin (TPO), polyvinyl chloride (PVC) and any other suitable material. TPO material is much less expensive than other roof membrane material, but has not been used in the roofing industry in the past because TPO is non-conductive material and therefore, cannot be dielectrically welded. Material such as polyvinyl chloride (PVC) has been commonly used in the roofing industry since it can be easily dielectrically welded. However, PVC is much more expensive than TPO. TPO material may be used because it may be easily and efficiently hot air bonded to form a seal, as described above. Additionally, using TPO material greatly reduces the cost associated with the adjustable fitments and roof membrane system. PVC material may be because it may easily be dielectrically welded or hot air bonded. Accordingly, PVC and any other suitable material may be used in the method(s) of forming a fitment  40  that use dielectric welding or hot air bonding, while TPO and any other suitable material may be used in the method(s) of forming a fitment  40  that use hot air bonding. 
     PVC, TPO and other suitable material may be used when the assembly of the component portions of the fitment  40  uses a mode for attachment other than hot air bonding and dielectric welding, such as caulking or adhesives. 
     The preferred embodiments herein disclosed are not intended to be exhaustive or to unnecessarily limit the scope of the invention. The preferred embodiments were chosen and described in order to explain the principles of the present invention so that others skilled in the art may practice the invention. Having shown and described preferred embodiments, those skilled in the art will realize that many variations and modifications may be made to affect the described invention. Many of those variations and modifications will provide the same result and fall within the spirit of the claimed invention. It is the intention, therefore, to limit the invention only as indicated by the scope of the claims.