Method and apparatus for seaming wide panels of EPDM membrane to form a composite EPDM roofing membrane

• US 6,615,892 B2
• Filed: 11/20/1998
• Issued: 09/09/2003
• Est. Priority Date: 11/20/1998
• Status: Expired due to Term

• Current Assignee: Firestone Building Products Company LLC (Bridgestone Corporation)
• Original Assignee: OMNOVA Solutions Incorporated
• Inventors: Verrocchi, Anthony, Kelly, Walter J., Weinert, Raymond J., Hubbard, Michael J.
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): Haran, John T.
• Application Number:
  US09/197,140
• Publication Number:
  US 20020003026A1
• Time in Patent Office: 1,754 Days
• Field of Search: 156/71, 156/428, 156/494, 156/543, 156/544, 156/546, 156/549, 156/516, 156/555
• US Class Current: 156/428
• CPC Class Codes: B29C 65/10 using hot gases (e.g. combustion gases) or flames coming in contact with at least one of the parts to be joined
• CPC Class Codes: B29C 65/4815 Hot melt adhesives, e.g. thermoplastic adhesives
• CPC Class Codes: B29C 65/54 between pre-assembled parts
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/435 Making large sheets by joining smaller ones or strips together
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/83413 cooperating rollers, cylinders or drums
• CPC Class Codes: B29C 66/8432 Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29C 66/874 Safety measures or devices
• CPC Class Codes: B29C 66/8746 Detecting the absence of the articles to be joined
• CPC Class Codes: B29K 2023/04 Polymers of ethylene
• CPC Class Codes: B29K 2023/10 Polymers of propylene
• CPC Class Codes: B29K 2023/16 EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
• CPC Class Codes: Y10T 156/1317 Means feeding plural workpieces to be joined
• CPC Class Codes: Y10T 156/1715 Means joining indefinite length work edge to edge
• CPC Class Codes: Y10T 156/172 Means applying fluid adhesive to work edge
• CPC Class Codes: Y10T 156/1727 Plural indefinite length or running length workpieces

Abstract

A method and apparatus for continuously seaming cured EPDM membrane to form a composite sheet of predetermined width and indefinite length. The method includes the steps of providing at least two rolls of cured EPDM membrane having longitudinal marginal edges and feeding the cured EPDM membrane from the at least two rolls in a first direction. The longitudinal marginal edges of the cured EPDM membranes are positioned in an overlapping relationship as the cured EPDM membranes are fed in the first direction and then the overlapping longitudinal marginal edges are continuously seamed to form a composite sheet of indefinite length.

Claims

1. An apparatus for continuously seaming wide panels of cured EPDM membrane to form a composite roofing membrane of predetermined width and indefinite length comprising:

at least two supply stations, each supply station including a supply roll of cured EPDM membrane wound on a mandrel positioned in overlapping relation to an adjacent mandrel for supplying and simultaneously positioning indefinite length cured EPDM membrane in an overlapping relationship;

a seaming station including a frame member supporting a press assembly and a device for seaming the overlapping cured EPDM membranes, the press assembly including opposing pinch rollers to continuously compress the overlapping edges of the cured EPDM membranes as the EPDM membranes pass between the pinch rollers thereby continuously securing the overlapping cured EPDM membranes together to form a continuous seam and a composite roofing membrane of predetermined width and indefinite length; and

a storage station for continuously reeling the composite roofing membrane.

2. The apparatus of claim 1 wherein the supply station includes a supply roll containing cured EPDM membrane of indefinite length and selected width and a tensioning device to maintain a constant tension on the cured EPDM membrane as the membrane is fed from the supply roll to the seaming station.

3. The apparatus of claim 2 wherein the tensioning device includes a support roll that supports the cured EPDM membrane as the membrane is fed from the supply roll and a tensioning roll pivotally connected to the supply station to maintain a downward pressure on the cured EPDM membrane between the supply roll and the support roll.

4. The apparatus of claim 3 wherein the supply stations are arranged in an alternating overlapping arrangement.

5. The apparatus of claim 3 wherein the supply stations are arranged in a step-wise arrangement.

6. The apparatus of claim 1 wherein the device includes a plurality of hot air guns to heat the area of overlap to weld the overlapping cured EPDM membranes together and form a seam.

7. The apparatus of claim 1 wherein the device includes an adhesive applicator for applying adhesive between the overlapping wide panels of cured EPDM membrane.

8. The apparatus of claim 1 wherein the storage station includes a rotatable take-up roll onto which the composite roofing membrane is rolled for storage purposes.

9. An apparatus for continuously seaming wide panels of cured EPDM membrane to form a composite roofing membrane of predetermined width and indefinite length comprising:

at least two supply stations for providing a selected length of cured EPDM membrane in the direction of a seaming station, each supply station including a supply roll of cured EPDM membrane wound on a mandrel positioned in overlapping relation to an adjacent mandrel for supplying and simultaneously positioning indefinite length cured EPDM membrane in an overlapping relationship along the length of the EPDM membrane;

wherein the seaming station includes a frame member supporting a press assembly and a device for seaming the overlapping length of cured EPDM membranes, the press assembly including opposing pinch rollers to continuously compress the overlapping edges of the cured EPDM membranes as the EPDM membranes pass between the pinch rollers thereby continuously securing the overlapping cured EPDM membranes together to form a continuous seam and a composite roofing membrane of predetermined width and indefinite length; and

a storage station for continuously reeling the composite roofing membrane.

10. The apparatus of claim 9 wherein the supply station includes a supply roll containing cured EPDM membrane of indefinite length and selected width and a tensioning device to maintain a constant tension on the cured EPDM membrane as the membrane is fed from the supply roll to the seaming station, wherein the tensioning device includes a support roll that supports the cured EPDM membrane as the membrane is fed from the supply roll and a tensioning roll pivotally connected to the supply station to maintain a downward pressure on the cured EPDM membrane between the supply roll and the support roll.

11. The apparatus of claim 9 wherein the supply stations are arranged in an alternating overlapping arrangement.

12. The apparatus of claim 9 wherein the supply stations are arranged in a step-wise arrangement.

13. The apparatus of claim 9 wherein the apparatus includes a plurality of hot air guns to heat the area of overlap to weld the overlapping length of cured EPDM membranes together and form a seam.

14. The apparatus of claim 9 wherein the apparatus includes an adhesive applicator for applying adhesive between the overlapping wide panels of cured EPDM membrane.

15. An apparatus for continuously seaming wide panels of cured EPDM membrane to form a composite roofing membrane of predetermined width and indefinite length comprising:

at least two supply stations, each supply station including a supply roll of cured EPDM membrane wound on a mandrel positioned in overlapping relation to an adjacent mandrel for supplying and simultaneously positioning indefinite length cured EPDM membrane in an overlapping relationship along the length of the EPDM membrane;

a seaming station including a frame member supporting a press assembly and a device for seaming the length of the overlapping cured EPDM membranes, the press assembly including directly opposing pinch rollers to continuously compress the overlapping edges of the cured EPDM membranes as the EPDM membranes pass between the pinch rollers thereby continuously securing the overlapping cured EPDM membranes together to form a continuous seam and a composite roofing membrane of predetermined width and indefinite length; and

a storage station for continuously reeling the composite roofing membrane.

16. The apparatus of claim 15 wherein the supply station includes a supply roll containing cured EPDM membrane of indefinite length and selected width and a tensioning device to maintain a constant tension on the cured EPDM membrane as the membrane is fed from the supply roll to the seaming station, wherein the tensioning device includes a support roll that supports the cured EPDM membrane as the membrane is fed from the supply roll and a tensioning roll pivotally connected to the supply station to maintain a downward pressure on the cured EPDM membrane between the supply roll and the support roll.

17. The apparatus of claim 15 wherein the supply stations are arranged in an alternating overlapping arrangement.

18. The apparatus of claim 15 wherein the supply stations are arranged in a step-wise arrangement.

19. The apparatus of claim 15 wherein the apparatus includes a plurality of hot air guns to heat the area of overlap to weld the overlapping length of cured EPDM membranes together and form a seam.

20. The apparatus of claim 15 wherein the apparatus includes an adhesive applicator for applying adhesive between the overlapping wide panels of cured EPDM membrane.