US1765796A - Sealed laminated roofing element - Google Patents

Description

June 24, 1930. l.. KIRSCHBRAUN 1,765,796

SEALED LAMINATED ROOFING ELEMENT Filed April 10, 1926 2 Sheets-Sheet l jwenar:

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` l azz v4 l vent lduction of relatively thick roofing material Patented June 24, 1930 UNITED STATESd PATENT vorf-'ICE LESTER KIRSCHBRA'UN, OIF LEONIA, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGNMENTS,

TO THE PATENT .AND LICENSING CORPORATION, OF

CORPORATION OF MASSACHUSETTS l SEAIIJIEJ) LAMINATED 'ROOFING ELEMENT lApplication led April 10,

{This invention relates to manufactured roofing and has for its chief object the pro' or units Which may be built up of laminas of any desired kinds and so treated as to presubsequ'ent delamination. Embodlments of my invention vmay include roong material comprising a variety of characteristics and materials, or units of various shapes.

Onefof the materials commonly used in the manufacture of rooting of this general paper-making machine.

v be readily saturated with bitumen, pitch or unsightly appearance.

equivalent substance, which can be rendered liquid by heat or otherwise. The felt, after saturation,is usually coated with high melting-point asphaltv or equivalent impervious material, this coatingl being then surfaced with grit or the like to protectit from the deteriorating action of the elements, or by a powder, such as pulverized mica or chalk, to render the surface of the coat non-sticky. Roofing units made in this Way are comparatively thin and limp, and when laid on a roof present a relatively flat and unsubstantial appearance. Many attempts have been made to produce a satisfactory thick material which would keep lits shape and resist the weather successfully. Attempts to produce such roofing by sticking or cementing sheets of roofing felt or similar'material together have been unsuccessful o n account of the tendency of the' bers ofthe felt to absorb and exude moisture through the ends exposed Where the finished unit was cut from the sheet of roofing materlal. The absorption of moisture, attended in seine seasons by freezing and thawing, and its exudation inI dry periods, tends to distort the laminas and to cause them t0 separate, thus greatly detracting from the protection afforded by the roof and giving the, roof an By my invention, delamination of the roofing units is effectually prevented and the units retain their shape 1926. Serial No. 101,097.

Weather. Not only may a plurality of -felted sheets be built up into a laminated structure, but there may be a Wide variety of combinations ofmaterials'` employed in -building up the vthick material. For example, afsheet of roofing felt may be combined with rigid materials, such as slabs of cement, clay, tile, gypsum, paper wallboards, corrugated board structures, or combinations of these or their equivalents. The lamination may be made more secure by the BOSTON, 'MASSACHUSETTS, A

use of suit-able fasteners, preferably metallic, which may be -in thel form of clips, staples, rivets, or the like, passing through some-or all the plies, or secured about the 4edges of the lamination. In carrying out the process of my invention with ordinary roofing materials or their equivalents', stock vof suitable Weights and materials, including if desired granular surfaced stocks, may be assembled with a layer of cementitigus material, such as hot asphalt or asphalt mastic, between the plies, the plies being pressed together while the cement is warm and held firmly until united. When the building up ofthe laminations has been completed and the individual roofing units have been partly or wholly cut from the sheet or otherwise formed to shape, the exposed face and edges off'each unit are completely coated,

with a layer ofimpervious material which may be surfaced if desired with any of the comminuted materials suitable for roofing, such 'as grit, crushed slate or tile, or other granular mineral, preferably opaque to protect the coating material from the deteriorating action of the suns rays. The coating of impervious material may be applied to cover not only the exposed edges and face of the unit, but lmay also extend over other portions thereof, vfor example, it may cover the whole 'of the upper face of the unit in cluding the portion to be lapped by the course laid next above the roof; or partor all of the under face of the -unit may be covered; or the whole unit may be completely enveloped, The essential pointl is to prevent delamination by protecting the exposed surface of the unit Whlch includes a portion of the upper face and all edges which are not lapped or sheltered by the course next above. Additional protection and security from the entrance of moisture may be obtained by extending the coating over more ofthe surface of the unit. If metallic fasteners are used to secure the ylaminae together, it is preferable to extend the coatingv to cover the fasteners so as to protect them from corrosion. ln applying the comminuted surfacing material to the coated areas, it is particularly desirable that the surfacing'be thoroughly applied to the coating on the butt edge of the unit and'on -the edges of slots or cutouts, if any. The

protection afforded by this surfacing layer is needed by the coating which seals the edges of the laminae as wellas by that on the exposed surface of the unit. The grit surfacing on the edges also adds to the appearance of the unit as a whole.

Among the various forms and embod i-\ ments my invention may take, some are illustrated in the drawing in which: A v

Figure 1 represents a slab of rlaminated roofing'materials before coating.

Figure 1a is a section of a completed unit. Figure 2 indicates a method of dividing a sheet of material into units.Y I

Figure 2a is a fragmentary plan of a plurality o'f units showing another method of.

cuttingl them from the sheet. v

' Figure 3 suggests one of the effects which may be obtained in laying t-he finished units taken from a sheet as in Figure 2. I

Figure 4 indicatesin cross section the structure of a tapered roong unit.- A

Figure 5 indicates in cross section a roofing material built on a corrugated base.

. repellant felted fibrous stock 10 or roofing base, such as is commonly used in manufactured roofing. Instead of the felt stock, any similar'ory equivalent material, such as for example treated corrugated straw-board, may be used. In the form illustrated, the desired thickness may be obtained by the use of suitable materials between vthe sheets of .the felted fibrous material. A convenient way to assemble such a sheet is to apply a layer l1 of blown asphalt, or other similar coating material, to each sheet 10. While the coating material is still hot and sticky, 4al bulky material, such for example as comminuted cork, may be applied to the surface so as to form a layerw 12 lof considerable thickness. The surfaced faces of the sheets `10 may now be pressed together with a la er 13 of asphalt or' other adhesive material etween them until all the layers are irmly united. This Vcompletes thestructure shown in Figure 1. In order to secure thelaminae more firmly together, suitable fasteners, such as metal staples-14:, may be clinched therethrough, thus adding to the mechanical strength of the material. It is obvious that in place of the staples shown, any form of clips,.rivets or edge clamps may be used, or the lamin may be sewed with wire or any suitable strand. After the laminated sheet.

4sheet may be cut on lines 15 to form double units of varying width which may be broken or torn apart as on the line 16, thus Amaking more or less ragged edges, which willgive an artistic effect tothe roof Awhen the elements are laid, as shown in Figure 3. An.-

other method of forming the individual units is indicated in Figure 2a. By this method, the sheet is preferably divided into strips as along the line-16 (Figure 2),.then slots 'l5EL are cut in the strip extending from the butt edge entirely across the portion of the strip which will be exposed when the elements to be cut therefrom are laid on a roof.' The slots 15a are preferably 'just Wide enough to permit thorough coating and slating of the cut edges thereof. This enables the handling of the elements in a continuous connected strip or groups of convenient size, the individual elements being cut from the strip or groups after coating and slating, as on lines 15. The coating should be applied on the exposed face and edges of each element, but may also be extended to the lower face of the element or the whole upper surface or may completely lenvelop the entire element. If the elements are cut as indi-y cated in Figure. 2a, the edges formed by the cuts 15 will be uncoated, unless subsequently coated by an additional'step, but as these Y edges are protected, when the element is laid bythe course above, the lack of coating thereon is not as important. For coating material, asphalt of relatively high melting point, such as oxidized petroleum residuum, has been found satisfactory, but any equivalent waterproof material may be used instead. While the coating is still tacky, the coated areas of one or both faces and the edges are preferably -surfaced with comminuted material. such as crushed slate, or a combination of various such materials, as desired, to impart to the shingle a further which may be inserted a third slab 20 of the saine or differentinaterial, the latter being tapered or not, as desired. The slab 20, however; is preferably of about half the length of the slabs 19 so that the butt portioii of the element will be thicker and .heavier than the head portion. It is preferable to cement the slabs 19 and 20 with a layer 21 of suitable cementitious material, such as blown asphalt or its equivalent, and a metal clip 22- may be clamped about tlie butt edge of the shingle to provide additional strength thereto and to prevent delamination at that point. Metallic fasteners (not shown) may also be passed through the the delaminating leffect of-"moisture slabs 19 and 2O in the same manner asrillustrated in Figure 1. If preferred, the

lamiiiae 19 and 20, instead of being pre-cut the outer plies 26 being plane. Additional thickness may be obtained by building up a multiple corrugated board with two or more 'corrugated plies 25 alternating with plane plies 26. The plies may be of any desired and suitable material as dry felt, pre-saturated felt or other fibrous stock, to which may be added, if desired, a hydrocarbon emulsion like that described in my Patent No. 1,417,835 issued May 30, 1922. The corrugated board may be dipped into a liquefied cementitious saturating or coating compound, preferably waterproof, such as as phalt, which beside coating the exterior surfaces of the board, will also enter the cellular spaces and coat all the inner free surfaces,

that is, the surfaces not in mutual contact. p

The excess material may be allowed to drain therefrom, leaving air spaces within the board anda coating 27 covering and saturating the surfaces of the corrugations as Well as the surfaces of the plane plies 2b, thus sealing the board inside and out; or if a 4heavier Weight of roofing is desired, the ends o f the corrugations may be crimped, plugged or otherwise closed inv any suitable wayso as to keep the spaces or cells within t0 Size, may Vl0@ Supliliedieinntheiorrn-ocoIi- Ytlieboard-fulhof asphalticmaterialf The tinuous isllpsillldnmaybelbrought togetheli-nature -of the Ytreatmentewilhdependfonthe Y. e

'with cementing material between them as a continuous operation, the individual ele- 'ments thereafter being cutor shaped from the laminated strip. When each element has been formed orcut to shape and separated from the sheet completely or to the extent indicated in Figure 2, impervious coating material is then applied to the exposed surface of each element, that is the portion of the upper face and the edges to which rain and sunlight will have access when thev element is laid on a roof with other elements in lapped courses. In. addition to the exposed surface, the coated areas may include asmuch more of the faces and edges of the element as desired. The ,exposed surface, including the ex osed edges, is the minimum surface the sealing of which with an iinpervious coat will afford protection against Further security from the entrance of moisture into the fibrous body 'of the element may be obtained by extending the impervious coat over more of the upper face of the element and/or over part or all of the lower face. An outer sur acing 24 of any desired kind or kinds of comminuted material is prefer bly applied to the exposed coated areas for ad itioiial protection and to vproduce any artistic effect desired. ff

Figure 5 shows in cross section a roofing' material which may be vused to make up units or` elements, such as hea shingleswsimulating tiles, or the like. yhis form ofjroofing material comprises as a base corrugated board, the Icentral ply 25 being corrugated,

l29. "The material used for/the coatin character of the product which it is desired to vmake. If the advantages of comparatively light weight and insulating air spaces are desired, the cell spaces will be drained.. If a heavier or more rigid material is ydesired, the cells will be allowed toremain full of the coating material. Instead of using asphalt to fill the air cells, a slurry of Portland cement, gypsum, or the like may be employed with a suitable filler. The sheet may then be cut or divided into individual elements, the exposed surfaces of which are then sealed with a coating of impervious material 28, which may also extend over as much more of the element as desired, and

surfaced bysuitable comiiiinuted material is preferably thermoplastic, such 'as meltin -point asphalt, the temperature of whichl is, so regulated that thematerial will c be'comparatively viscous and sluggish so asf not to enter to any material extent into the' cell spaces, but nevertheless sulicieiitly fluid 'to form an impermeable coating over the exterior of the unit to which grit or equivalent surfacing material may be readily aiiixed.

Instead of corrugated board, boards or l, sheets of certain materials can be made hav'- ing similar properties of light weight, rigidity and insulating qualities. Among such materials are unreiined bagasse, ax, or' straw fibers, which may boards of any desired thickness. The coarse unrefined fibers are naturally water-repellent but 4may be superficially saturated with be made up into fluid bitumen, and in either event may be encased in4 any envelope ofl hi h meltingpoint asphalt or its equivalent, t e resultant product being highly resistant tothe action of theweather. Slabs or tiles of such material may be formed in units as illustratedvi'n f Figure 3, the units after being suitably sur-V faced with grit having the general appearany suitable material, such as the usual felted fibrous roong base or its equivalent. After the waves have been formed in the lamina 31, it may be secured to the lamina as by metallic or other fasteners indicated at 32.

'. The two laminae may be formed and combined in any desired way. As shown the waves of the lamina 31 are tapered slightly to permit their butt portions to fit closelyover the head portions of corresponding waves in the course below which are lapped thereby. The two laminas 30, 31are also preferably offset laterally so that when adj acent strips in the samecourse are laid abutting one another, the joints of the lamina 30, as 'at 33, will not vregister with the joints ofthe undulate lamina 31, as at 34. The lamina 31 is also preferably offset downward with respect'to the plane lamina 30, so that the buttportion thereof projects below the butt edge of the lamina 3() leaving a part 35 of the head portion of the lamina `30 lexposed. In laying the strips, the butt edge 36 ofthe lamina 30L is placed against the upper edge 37 of the lamina 31 of the course below lapping the exposed head portion 35 of the plane lamina 30 of the course below and permitting the projecting butt portions vof the waves to lap over the head portions4 of the waves in the course below. Such con'- lstruction producesa roof having an artistic n tiled appearancewi-th the additional rotection afforded by the lapped plane laminaebe-l neath. Strips made up in this way are also easily and accurately` laid. When the strip has been formed and the laminae secured together, the whole strip may thenbe dipped 1n a coating compound which envelops sub-n stantially all the free surfaces of the strip (1'. e. the surfaces not in mutual contact),

Y both inside and out, and comminuted suroov facin material may 'thereafter be applied if an as desired.

In Figures 7 and 8 is illustrated a further example of laminated roofing units made of 'any material suitable for use as a roofing base. In this form, the reinforcing lamina 38 1s .preferably secured to the butt portion only of the shingle 39 (which may be ofv conventional shape as shown) by cementing the two laminasI together with a layer 40 ofl any desired adhesive material or by fasteners 41, or both. The built-up unit is substantially enveloped in a coating 42 of impervious material, and a surfacing 45 of" granular material may be applied Ito the upper face of the lamina 39. The laminae' may be built up in laterally offset relation, as shown on the drawing, so as to provide for an overlap of adjacent shingles or units in the same course, thereby making a tighter roof. Suchoffset construction results in a projection lof a portion 44 of the upper ,lamina which will lap the exposed portion 43 of the lower lamina of the next adjacent unit. The faces of these-portions 43, 44 are p preferably left without grit in order to permit a closer engagement and alsov in order that black lines, simulatin spaces or shadows may show between adjacent shingles if laid slightl spaced laterally.

It will e apparent that the examples shown and described herein are illustrative only and that many others may be constructed which will .fall within the purview. of my invention. I therefore do not wish to be limited to the s eciiic forms shown but only by the scope of) the claims hereinafter ap,- pended.

I claim;

1. A roofing unit having a structure comprisig a plurality of laminae of sheet material, a layer of binder between successive laminae, fasteners passing through said! laminae and layers, and a sealing coat of waterproof substance enveloping the expised portion of said structure vincluding e ges.

2. Sheet roofing material comprising at least one corrugated ply, a plane facing ply cemented thereto, a coating of waterproof compound over all free inner and outer surfaces of said plies, and a surface layer of grit on one side of the material.

3. A roofing unit comprising a corrugated ply, a plane facing ply cemented thereto, and a coating of waterproof compound impregnating all of said plies and cover- 4. A rooin unitv comprising a corrugated ply, a acing ply cemented thereto, said plies being of fibrous stock impregnated with waterproofing material and forming between them tubular air spaces within the k unit, a sealing coat of waterproofing compound lcoverin the 'exposed surface and edges of the unit, and a layer of grit adhering to said coat.

ing all free inner and outer surfaces there- 5. A roofing unit comprising a corrugated ply of fibrous material, a plane facing ply cemented to said ply, a coating of. waterproofing compound. impregnatingall of said plies and covering all free inner and outer surfaces thereof, an additional coat of waterproofing material covering and substantially confined to the entire exterior surface and edges of saidfunit, and a layer of comminuted material adhering to one face `of said unit and the exposed edges.

6. A roo-ling unitcom rising a plane layer of roofing base, an undhlate layer of roofing base attached thereto, ,and a sealing coat of Waterproof compound covering all the free surfaces of said unit.

7. A roong unit comprising' a plane layer of roofing base, an undulate layer of roofing base secured thereto, said undulations being tapered,` and acoating of im ervious material enveloping substantially all the A free surface of the unit.

8. A rooting unit comprising a plane layer of roofing base, an undulate layer of roofing base attached thereto, said undulations being tapered, metal fasteners gripping both said plies, and afsealing coat of waterproof compound covering substantially all the freev surface of said unit. l

l9. A roofing unit comprisin a plane layer of roofing base, an undu ate layer of roofing base superposed thereon, metal fasteners passing through the two layers at points of mutual contact, and a'coating of waterproofin material covering all the free 4 surfaces of oth layers, said layers being A mutually offset so that the head portion of the plane layer projects beyond that of the undulate layer while the butt portion of the undulate layer projects beyond the' butt portion of the plane layer.

10. A roofing unit comprising a plane layer of rooingbase, a second layer of roofing 40 base superposed thereon, said-second layer being formed with a series of undulations tapering toward the head of the unit, metal fasteners passing through said layers at points of mutual contact, and a coating of Waterproofing material covering all the free surfaces of both layers, said layers being mutually offset so thatthe head ortion of: the plane layer projects beyond t at of the second layer Wlule the butt portion of the second layer projects beyond the butt portion of the planelayer.

Intestimony whereof I have aiiixed my signature. LESTER KIRSCHBRAUN.

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