Seamless foam panel roofing system

• US 6,581,348 B2
• Filed: 12/18/2001
• Issued: 06/24/2003
• Est. Priority Date: 06/15/2001
• Status: Expired due to Fees

• Current Assignee: John P. Hunter Jr
• Original Assignee: John P. Hunter Jr
• Inventors: Hunter, John P. Jr.
• Primary Examiner(s): Friedman, Carl D.
• Assistant Examiner(s): Glessner, Brian E.
• Application Number:
  US10/022,612
• Publication Number:
  US 20020189185A1
• Time in Patent Office: 553 Days
• Field of Search: 524/08, 524/09, 524/12, 527/461.1, 527/471, 527/414, 527/450.6, 523/095, 523/098, 156/71, 156/78, 156/182, 428/319.1
• US Class Current: 52/408
• CPC Class Codes: E04C 2/246 combinations of materials fully covered by E04C2/16 and E04C2/20
• CPC Class Codes: E04D 3/38 Devices for sealing spaces or joints between roof-covering elements E04D3/36 takes precedence; sealing joints not restricted to roof-covering elements E04B1/68
• CPC Class Codes: Y10T 428/24999 Inorganic
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 442/647 Including a foamed layer or component

Abstract

A crush resistant seamless roofing system is formed by a layer of adjacent panels having loose joints filled by expanding rising foam adhesive, which is trimmed to remove excess foam adhesive above a top plane of the roofing system. The roofing system thus formed is covered by a fabric layer and a coating.

Claims

1. A method of installing roofing tiles comprising:

a) spraying a foam rising adhesive on a surface;

b) waiting for said foam rising adhesive to obtain a creamy consistency;

c) applying a first tile panel and an adjacent first subsequent tile panel to said surface;

d) waiting for said adhesive to cure and rise within a joint formed between said first tile panel and said first subsequent tile panel;

e) applying further tile panel and subsequent further tile panel to said surface;

f) waiting for said adhesive to cure and rise within further joints formed between said first subsequent tile and said further tile panel;

g) repeating steps “

c”

, “

d” and

“

e” and

“

f”

on next subsequent pairs of tile panels until said foam adhesive completes rising between said joints and accumulates as debris above a plane formed by said tile panels accumulated in a seamless configuration;

h) removing debris formed by said foam rising adhesive from the top surface of said tile panels; and

,

I) applying an elastomeric coat to the top surface of said joined, seamless accumulation of tile panels.

2. A method of installing roofing tiles according to claim 1, wherein said elastomer is an acrylic.

3. A method of installing roofing tiles according to claim 1, wherein said elastomer is a urethane.

4. A method of installing roofing tiles according to claim 1, wherein said elastomer is silicone based.

5. A method of installing roofing tile panels according to claim 2, wherein application of said first and said subsequent tile panels further comprises:

applying said first tile panel having a first length; and

applying said second tile panel having a second length,

wherein said second length of said second tile panel is different than said first length of said first tile panel.

6. A crush resistant and puncture resistant seamless waterproof roofing system comprising a plurality of adjacent cured foam panels attached to a roofing by a foaming adhesive bonding said panels to a substrate of said roof,

said adhesive rising between said panels, sealing said panels to each other by expansion through loose inter-panel joints between said panels,

said panels having an on-site coat of elastomeric sealing material thereon, said coat of elastomeric sealing material covering a fabric layer above each of said panels.

7. The roofing system as in claim 6 wherein said panels are polyurethane.

8. The roofing system as in claim 6 wherein said sealing material is a silicone.

9. The roofing system as in claim 7 wherein said polyurethane is a dense polyurethane foam having a strength of at least three pounds per cubic foot.

10. The roofing system as in claim 6 wherein said fabric is an integral top layer of non-woven 250 gram polyester fabric saturated by said foam.

11. The roofing system as in claim 10 wherein adjacent panels have tongue-in-groove edges fitting into adjacent tongue and groove edges of adjacent panels.

12. The roofing system as in claim 11 wherein said adhesive is low rise foam polyurethane adhesive, said adhesive seeping through loose tongue-in groove joints.

13. The roofing system as in claim 6 wherein said foaming adhesive used to both bond the said panels to a substrate and to rise between said panels, seals said panels to each other through loose inter-panel joints accommodating said risen adhesive therebetween, forming a seamless accumulation of said panels.

14. The roofing system as in claim 6 wherein said roof has panel seams which are staggered by using alternate whole panels as well as half panels upon said roof.

15. The roofing system as in claim 6 wherein said plurality of panels includes an edging bridging a wall under said roof, a support beam supporting said panels, and said panels.