Non-cellular adhesive for composite roof structure

Abstract

A composite roof structure, and a corresponding method of fabricating the structure, are disclosed which includes use of a layer of non-cellular adhesive material (preferably a two-component non-cellular polyurea polyurethane adhesive material), roof insulation panels, along with a flexible roof membrane, preferably made of thermoplastic olefin rubber, including a rubber-like sheet having a fleece-like matting secured to the underside thereof. The non-cellular adhesive is preferably sprayed onto a roof substrate and prior to complete solidification thereof the roof membrane or roof insulation is pressed into the adhesive so that the matting becomes embedded therein.

1 . A composite roof structure adapted to be supported by a roof substrate and comprising: 
 a layer of non-cellular adhesive material adapted to be secured to said substrate; and    a flexible membrane including a sheet of flexible material having fleece-like matting secured to the underside thereof, said membrane being attached to said adhesive material with at least a portion of said matting being imbedded within the adhesive material.    
   
   
       2 . The composite roof structure as defined in  claim 1 , said adhesive material is non-foamed, non-cellular synthetic resin adhesive material.  
   
   
       3 . The composite roof structure as defined in  claim 2 , said adhesive material is non-cellular two component synthetic resin adhesive material.  
   
   
       4 . The composite roof structure as defined in  claim 2 , said adhesive material is non-cellular polyurea polyurethane adhesive material.  
   
   
       5 . The composite roof structure as defined in  claim 3 , said adhesive material is non-cellular two component polyurea urethane adhesive material.  
   
   
       6 . The composite roof structure as defined in  claim 5 , said non-cellular two component polyurea polyurethane adhesive material including polyol and a diisocyanate components.  
   
   
       7 . The composite roof structure as defined in  claim 2 , said layer having a thickness of at least about 1/16 inch.  
   
   
       8 . The composite roof structure as defined in  claim 7 , said thickness being from about 1/16 inch to ¼ inch.  
   
   
       9 . The composite roof structure as defined in  claim 1 , said adhesive material being initially in the form of a liquid and having an initial solidification time from about 30 seconds to 5 minutes.  
   
   
       10 . The composite roof structure as defined in  claim 1 , said sheet of flexible material comprising a synthetic rubber.  
   
   
       11 . The composite roof structure as defined in  claim 1 , said synthetic rubber being thermoplastic olefin rubber.  
   
   
       12 . The composite roof structure as defined in  claim 1 , said synthetic rubber being ethylene propylene diene monomer rubber.  
   
   
       13 . The composite roof structure as defined in  claim 10 , said synthetic rubber sheet having a thickness of about 40 mils to 70 mils.  
   
   
       14 . The composite roof structure as defined in  claim 1 , wherein said fleece-like matting comprising polyester matting.  
   
   
       15 . The composite roof structure as defined in  claim 14 , said polyester matting having a thickness of about 40-80 mils or membrane with an underside prepared for adhesive attachment.  
   
   
       16 . A method for forming a composite roof structure upon a roof substrate, said composite roof structure comprising a flexible roof membrane including a flexible sheet having a fleece-like matting secured to the underside thereof, said method comprising the steps of: 
 providing an initially flowable non-cellular adhesive material;    applying a layer of said initially flowable non-cellular adhesive material onto said substrate;    after said adhesive material is applied, applying a flexible roof membrane thereto by placing said fleece-like matting in contact with said layer of said adhesive material prior to complete solidification thereof causing said matting to become at least partially embedded within the adhesive material; and    allowing the adhesive material to solidify.    
   
   
       17 . The method as defined in  claim 16 , wherein said adhesive material is non-foamed, non-cellular synthetic resin material.  
   
   
       18 . The method as defined in  claim 17 , wherein said adhesive material is two component non-cellular synthetic resin adhesive material.  
   
   
       19 . The method as defined in  claim 17 , wherein said adhesive material is non-cellular polyurea polyurethane adhesive material.  
   
   
       20 . The method as defined in  claim 28 , wherein said adhesive material is non-cellular two component polyurea urethane adhesive material.  
   
   
       21 . The method as defined in  claim 20 , wherein said non-cellular two component polyurea urethane adhesive material including polyol and a diisocyanate components.  
   
   
       22 . The method as defined in  claim 18 , wherein said layer having a thickness of at least about 1/16 inch.  
   
   
       23 . The method as defined in  claim 22 , wherein said thickness being from about 1/16 inches to ¼ inches.  
   
   
       24 . The method as defined in  claim 16 , wherein said non-cellular adhesive material being initially in the form of a liquid and having an initial solidification time of from about 30 seconds to 5 minutes.  
   
   
       25 . The method as defined in  claim 16 , wherein said flexible sheet comprising a synthetic rubber.  
   
   
       26 . The method as defined in  claim 25 , wherein said synthetic rubber being thermoplastic olefin rubber.  
   
   
       27 . The method as defined in  claim 25 , wherein said synthetic rubber being ethylene propylene diene monomer rubber.  
   
   
       28 . The method as defined in  claim 25 , wherein said flexible sheet having a thickness from about 40 mils to 70 mils.  
   
   
       29 . The method as defined in  claim 16 , wherein said fleece-like matting comprising polyester matting.  
   
   
       30 . The method as defined in  claim 29 , said polyester matting having a thickness from about 40 mils to 80 mils or membrane with an underside prepared for adhesive attachment