Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1999-02-09
2001-02-27
Yao, Sam Chuan (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C052S535000, C052S540000, C052S746100
Reexamination Certificate
active
06193826
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to methods of roof construction, and more particularly relates to an improved method for adhering roof tiles to substrates using economical one-component adhesives, including one-component high-density polyurethane adhesive foams.
Roof construction, especially in residential construction, varies by location throughout the United States. In the northern climates, most roofs utilize a thin covering of tar paper-based shingles or thick wooden shingles as a final covering for the roof. In southern climates, tiles are used as the final covering of the roof. These roof tiles may be made from a variety of materials, including synthetic materials, such as plastics, and natural materials, such as stone, concrete, clay, ceramic and fired brick. In the application of these latter types of roof tiles, mortars or cementitious materials have been used in the past to apply the roof tiles to the roof substrate.
The use of mortars as roof tile adhesives is expensive because the mixing and application of the mortar is very labor intensive. Mortars are dense materials and their use as roof adhesives increases the load placed on the roof. The curing time for mortar may also be relatively long, thereby hampering quick completion of the roof. A need therefore exists for a lighter adhesive which is less labor intensive than mortar and which lends itself to efficient application of roof tiles.
Adhesives, and in particular adhesive foams, have been developed to replace mortars used in roof construction. U.S. Pat. No. 5,362,342, issued Nov. 8, 1994 describes the use of a two-component polyurethane foam to bond roof tiles to a substrate. This patent further describes the use of a bulky, complex pressurized dispensing system which is necessary to mix the two components together so that they may react to create a sufficient amount of foam with the desired adhesive characteristics. The aforesaid '342 patent further describes a particular method of using two-component foams to bond roof tiles to a roof substrate in which thick, linear beads of foam are applied to the entire length of the roof tiles.
One-component adhesives, such as those sold under the trade name INSTA-STIK by Insta-Foam of Joliet, Illinois have been utilized in the past, primarily for adhering roof insulation boards to roof substrates. These one-component adhesives are collapsible foams and are applied in long beads of foam for all or most of the entire length of the insulation boards to adhere the insulation boards to the roof. The use of long, linear beads of adhesives increases the cost of applications by using large amounts of adhesives and lengthening the application process.
The present invention is directed to a roof tile adhesion method which uses inexpensive one-component adhesives, and in a preferred embodiment one-component polyurethane adhesive foams, in a novel application pattern which significantly reduces the amount of adhesive used per roof tile without detracting from its adhesive strength.
It is therefore an object of the present invention to provide a method of adhering roof tiles to a roof substrate using economical one-component adhesives, including one-component adhesive foams.
Another object of the present invention is to provide a method for adhering roof tiles to a substrate using a modest amount of adhesive in a unique pattern which reduces the amount of adhesive used for application, yet provides sufficient adhesive strength between the roof tile and the substrate.
Yet another object of the present invention is to provide a method for adhering roof tiles to a substrate by applying a one-component, high-density polyurethane adhesive foam to opposing corners of the roof tile and placing the tiles into contact with the substrate, and letting the adhesive foam cure to adhere the roof tile to the substrate.
Still yet another object of the present invention is to provide an improved tiled roof construction having a substrate, a plurality of roof tiles adhered to the substrate, the roof tiles being adhered to the substrate by an adhesive deposited in alignment with opposing corners of the roof tiles, the adhesive deposits having a pad-like profile, the adhesive pads adhering opposite corners of the tile to the roof substrate and a preceding tile course, the adhesive pads further defining a discontinuous adhesive pattern which does not subdivide the space between the tile undersurfaces and the roof substrate into discrete spaces to restrict air circulation between the roof tile and the roof substrate.
SUMMARY OF THE INVENTION
In one principal aspect of the present invention, a roof construction method is provided in which successive courses of roof tile are adhered to a roof substrate by applying a one-component adhesive to the undersurface of the roof tiles; laying the tiles in successive courses on the roof; and, permitting the foam to cure.
In another principal aspect of the present invention and as exemplified in one preferred embodiment, a method for applying roof tiles to a roof substrate is provided which includes the steps of: providing a one-component adhesive, particularly a one-component adhesive foam; applying a first course of roof tile to a roof substrate by depositing the adhesive in a discontinuous pattern comprising two separate deposits in registration with opposite corners of the roof tiles; adhering the first course of roof tiles to the roof substrate by placing the first course of roof tiles onto the roof substrate to effect contact between the adhesive deposits, the roof tiles and the roof substrate; dispensing a series of second deposits of the adhesive in registration with opposite corners of the undersurfaces of a second course of roof tiles; placing the second course of roof tiles over the roof substrate and the first course of roof tiles such that the tail portions thereof and adhesive deposits aligned therewith contact the roof substrate and the head portions thereof and adhesive deposits aligned therewith overlie and contact the first course of roof tiles; and, permitting the adhesive to cure such that the first and second roof tile courses become adhered to roof substrate.
In another principal aspect of the present invention and as exemplified by another embodiment of the invention, a roof construction includes a roof substrate and a plurality of roof tiles attached to the substrate in successive courses, each of the tiles being attached to the roof substrate by discontinuous deposits of a one-component adhesive aligned with opposing corners of the undersurfaces of roof tiles, the adhesive foam deposits spacing the tiles partially away from the roof substrate so as to create an air channel therebetween.
These and other objects, features and advantages of the present invention will be apparent through a reading of the following detailed description, taken in conjunction with accompanying drawings, wherein like reference numerals refer to like parts.
REFERENCES:
patent: 2667131 (1954-01-01), Clarvoe et al.
patent: 3080683 (1963-03-01), Sallie
patent: 5362342 (1994-11-01), Murray et al.
patent: 5465547 (1995-11-01), Jakel
patent: 5582898 (1996-12-01), Kiser
Grunauer Gary
Starr Cris Damon
Insta-Foam Products Inc.
Vedder Price Kaufman & Kammholz
Yao Sam Chuan
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