EP4731845A1 - Waterproof roof expansion joint systems and methods of forming same - Google Patents

Abstract

Roof expansion joint systems and methods of applying the same are provided herein. A roof expansion joint system may include a flexible waterproof membrane, a flexible sealing member comprising a flange structure and an expansion structure, and an adhesive layer, where each of the flexible waterproof membrane, the flexible sealing member, and the adhesive layer is cohesively favorable with one another.

Description

WATERPROOF ROOF EXPANSION JOINT SYSTEMS AND METHODS OF FORMING SAME

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of United States Provisional Application No. 63/510,157, filed June 26, 2023, which is incorporated herein by reference in its entirety.

FIELD

[0002] Described herein are roof expansion joint systems and methods of making the same.

BACKGROUND

[0003] Roof structures are exposed to many different environmental conditions, which can result in expansion and contraction of the roof structures due to changes in ambient conditions. For example, surface temperatures of a roof structure can vary widely depending on time of day and/or time of year. Various roof joint systems have been used in construction of large roofs to provide expansion joints to prevent buckling or deformation of the roof structure. Conventional roof joints systems have in some cases been cemented or fastened to roof panels or decks.

SUMMARY

[0004] The present disclosure is directed to a roof expansion joint system that comprises a flexible waterproof membrane, a flexible sealing member, and an adhesive layer. The flexible sealing member may comprise a flange structure and an expansion structure. The flexible waterproof membrane, the flexible sealing member, and the adhesive layer may be cohesively favorable with one another.

[0005] The present disclosure is further directed to a method of applying an expansion joint system. The method comprises dispensing an adhesive layer over a portion of a top surface of a first roof deck section and over a portion of a top surface of a second roof deck section, where the first roof deck section and the second roof deck section define a roof joint; installing a flexible sealing member comprising an expansion structure, a first flange portion, and a second flange portion such that the expansion structure is positioned above the roof joint; and dispensing a flexible waterproof membrane to a top surface of the flexible sealing member. In such methods, each of the adhesive layer, the flexible sealing member, and the flexible waterproof membrane may be cohesively favorable with one another.

BRIEF DESCRIPTION OF FIGURES

[0006] Figure 1 is a perspective view of a cutaway of a roof covering having a roof expansion joint system positioned on portions of a roof deck.

[0007] Figure 2 is cross-sectional view along axis A-A in Figure 1 showing portions of a roof expansion joint system described herein.

[0008] Figure 3A is a cross-sectional view a roof expansion joint system described herein.

[0009] Figure 3B is a cross-sectional view a roof expansion joint system described herein.

[0010] Figure 4A is a perspective view of a cutaway of a roof covering having a roof expansion joint system positioned on portions of a roof deck.

[0011] Figure 4B is a cross-sectional view along axis B-B of Figure 4A of a roof expansion joint system described herein.

[0012] Figure 5A is a perspective view of a cutaway of a roof covering having a roof expansion joint system positioned on portions of a roof deck.

[0013] Figure 5B is a cross-sectional view along axis C-C of Figure 5 A of a roof expansion joint system described herein.

[0014] Figure 6A is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0015] Figure 6B is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0016] Figure 6C is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0017] Figure 6D is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0018] Figure 6E is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0019] Figure 6F is a schematic of a cross-sectional view of one example of an expansion structure shape and configuration for use in an expansion joint system described herein.

[0020] Figure 7A is a portion of a flexible sealing member described herein. [0021] Figure 7B is a portion of a flexible sealing member showing a transition from horizontal orientation to vertical orientation as described herein.

[0022] Figure 8A is a portion of a flexible sealing member described herein.

[0023] Figure 8B is a portion of a flexible sealing member showing a transition from horizontal orientation to vertical orientation as described herein.

[0024] Figure 9 is a cross-sectional view of a roof expansion joint system described herein.

DETAILED DESCRIPTION

[0025] Provided herein are roof expansion joint systems and methods of applying roof expansion joint systems to a roof structure. The roof expansion joint systems can enable waterproof protection and/or inhibit ingress of water into a roof joint. The roof expansion joint systems may include portions that are cohesively favorable and provide a monolithic structure once bonded to inhibit ingress of water into a roof joint. The roof expansion joint systems described herein can provide a system that does not require mechanical attachment to a roof deck, for example, without the use of screws, nails, or other fasteners. In some cases, the roof expansion joint system can be applied to a roof structure in a manner that reduces installation time, for example, by spraying, pouring, and/or squeegeeing the layers.

[0026] In some cases, expansion joint systems can be used in the modular construction industry. In some cases, multiple modules can be premanufactured in a manufacturing setting before installation at a construction site. The modules can be positioned together, and in some cases require an expansion joint system. The expansion joint system can absorb thermal stress and/or prevent water leakages. In some cases, there can be more joints in a modular construction as compared to non-modular, more traditional construction of building structures. The expansion joint systems described herein can provide an expansion joint system that can improve productivity of modular construction projects.

[0027] Figure 1 shows a perspective view of a roof covering 100 having an illustrative roof expansion joint system positioned on portions of a roof deck. The roof covering 100 includes a first roof deck 101 and a second roof deck 102. The first roof deck 101 and second roof deck 102 can be made of any materials known to those in the ail of sufficient strength and durability to provide a roof covering for a building or structure. The first roof deck 101 and second roof deck 102 define a roof joint 103. Roof joint 103 is a space that allows expansion and contraction of a roof covering without causing damage to adjacent roof decks or other components of the roof covering, building, or structure. Roof joints arc often covered by bellow joints or other structures that allow for expansion and contraction of the roof joint. However, conventional structures may provide less desired systems to inhibit water from leaking through the roof joint and/or other portions of the roof covering due to methods and ways in which the conventional systems are positioned and affixed to the respective roof decks. The roof expansion joint system described herein and shown throughout the figures provides a system that inhibits water leakage through the roof joint and roof covering assembly. The roof expansion joint system and methods of applying such systems described herein may also provide improved and/or more efficient methods of applying the roof expansion joint systems to a roof structure.

[0028] The roof expansion joint system comprises a flexible sealing member 105 that is positioned over a roof joint 103. The flexible sealing member 105 may be waterproof. The flexible sealing member 105 can facilitate the installation of a waterproof layer on the outer surface of a roof deck. The roof expansion joint system can also include a flexible waterproof membrane 104 on the outer surface of the flexible sealing member 105. The roof expansion joint system can also include an adhesive layer 106 to affix the flexible sealing member 105 to a roof deck. In some cases, the flexible sealing member 105, flexible waterproof membrane 104, and adhesive layer 106 are cohesively favorable. When used herein, the term cohesively favorable generally refers to a quality of a portion of the roof expansion joint system that is capable of bonding and adhering to another portion of the roof expansion joint system without the need of a mechanical attachment or fastener, e.g., a screw or other fastener to withstand external deformation stresses and strains. When used herein, bonding refers to the formation of chemical or physical bonds between interface components. For example, bonding can be formed between two solid interfaces; a second interface as liquid spreading over and coming in intimate contact with a first solid interface; or two interfaces as liquids spreading wet-on-wet on each other and subsequently drying or curing together.

[0029] In some cases, materials or layers that are cohesively favorable are chemically compatible. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible because they comprise the same material. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible and comprise different materials, so long as the portions are capable of bonding and adhering to one another. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible because they comprise the same material, which can include for example, an isocyanate prepolymer. In some cases, the material can comprise a moisture cured isocyanate. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible because they comprise the same material, which can include for example, a polyurea. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible because they comprise the same material, for example, a polyurethane. Portions of the roof expansion joint system may be cohesively favorable and chemically compatible because they comprise the same material, for example, a combination of at least two of an isocyanate prepolymer, a polyurea, and a polyurethane. Portions of the roof expansion joint may be cohesively favorable and chemically compatible with other materials, such as an epoxy or methyl methacrylate. Each of the layers of the roof expansion joint system disclosed herein may independently comprise one or more of the foregoing materials.

[0030] Portions of the roof expansion joint system may be macroscopically homogeneous. When used herein, macroscopically homogeneous refers to materials with similar or the same chemical structures.

[0031] Portions of the roof expansion joint system may be structurally different but miscible to one another. For example, one layer of the roof expansion joint system may comprise polyphenylene oxide and a second layer of the roof expansion joint system may comprise a polystyrene. As another example, one layer of the roof expansion joint system may comprise poly(methyl methacrylate) and a second layer of the roof expansion joint system may comprise a styrene/acrylonitrile copolymer.

[0032] The adhesive layer 106 may be cohesively favorable with the flexible sealing member 105 such that the adhesive layer can bond with the flexible sealing member 105 forming a waterproof seal. In some cases, the adhesive layer 106 can comprise the same material as other portions of the roof expansion joint system so that when portions are bonded together they form a waterproof monolithic structure. The adhesive layer 106 can be dispensed or installed in a variety of methods which may include pouring, rolling, spraying, application of preformed strips (such as an adhesive tape), application via squeegee, or other methods. In some cases, the adhesive layer 106 can be a pressure sensitive adhesive tape, for example, a double-sided tape comprising a polyurea. In some cases, the adhesive layer can be applied by spraying the material while it is in a substantially fluid state. Tn some cases, the adhesive layer may have a set time long enough to allow application of subsequent portions of the roof expansion joint system before the adhesive layer 106 sets, bonding the portions of the roof expansion joint system together. In some cases, the adhesive layer 106 can be 0.1 millimeters to 2.5 millimeters thick (e.g., from 1 to 2 millimeters or from 1 to 1.5 millimeters). The adhesive layer 106 can extend over at least a portion of the roof deck section 101, 102 and/or a structure on the roof deck section, such as blocking 108. Blocking 108 can comprise different dimensions and configurations, for example, different heights or angles. In some cases, the adhesive layer 106 can extend near the edge of the blocking 108 like that shown in Figure 1.

[0033] The flexible sealing member 105 can be installed as part of the roof expansion joint system. Figure 2 shows a cross-section view along axis A-A of Figure 1 of the roof expansion joint system. The flexible sealing member 105 comprises an expansion structure 120, a first flange 121, and a second flange 122. The first flange 121 and the second flange 122 are applied on the roof deck sections 101 and 102, respectively, and form the lower end of the flexible sealing member 105, and the expansion structure 120 extends upward and away from the top face of the flanges 121, 122. The flanges 121, 122 can be sized so that the flanges provide sufficient surface area for better shear and adhesive strength to the roof deck sections 101, 102. The flexible sealing member 105 can extend over at least a portion of the roof deck section 101, 102 and/or a structure on the roof deck section, such as blocking 108. The flexible sealing member 105 can extend near the edge of the blocking 108 like that shown in Figure 1 .

[0034] The flange portions 121, 122 on each side of the flexible sealing member 105 can be installed onto the adhesive layer 106, attaching either side of the flexible sealing member 105 to each roof deck section 101, 102 (or structures positioned on the roof deck, such as a blocking 108). The flexible sealing member 105 can be prefabricated before being brought to an installation site. The flexible sealing member 105 can be constructed in a mold in some cases. The material forming the flexible sealing member 105 can be sprayed into a mold and allowed to cure in the configuration of the mold. The flexible sealing member 105 can comprise a woven fabric or other textile material.

[0035] The flexible sealing member 105 can include an expansion structure 120 (see, for example, Figure 2). In some cases, the expansion structure 120 allows the flexible sealing member 105 to flex and/or stretch further than if the flexible sealing member 105 did not include expansion structure 120. The expansion structure 120 can allow a particular size and configuration of flexible scaling member 105 to be used in a variety of applications, which may include for example, different width roof joints 103. The expansion structure 120 can include a protrusion extending upward and away from the roof joint 103. The expansion structure 120 can include a protrusion extending downward into the roof joint 103 (see for example Figures 5A and 5B). The expansion structure 120 can include a shape preformed into the flexible sealing member 105. The expansion structure 120 can be configured to deflect, such that the width of the flexible sealing member 105 can vary depending on the width of the roof joint 103 without compromising the structural integrity or waterproof nature of the flexible sealing member 105. [0036] The shape of the expansion structure 120 may change during changes in the width of the flexible sealing member 105, for example, as shown in Figures 2, 3 A, and 3B. Figure 2 shows a first configuration of the expansion structure 120 when the roof joint 103 has a first width. Figure 3A shows a second configuration of the expansion structure 120 when the roof joint 103 has a second width, which is narrower than the first width. Figure 3B shows a third configuration of the expansion structure 120 when the roof joint 103 has a third width, which is wider than the first width. Figures 2, 3A, and 3B show examples of the deflection of the expansion structure 120 varying based on the width of the roof joint 103.

[0037] The expansion structure 120 can include a generally inverted V-shaped configuration in the flexible sealing member 105 as illustrated in Figures 2, 3 A, and 3B. The angle of the V- shape is inverted such that the point of the “V” is positioned upward and away from the roof joint 103. The expansion structure 120 can act like an accordion, collapsing into a tighter inverted V-shape when installed into a smaller roof joint 103 as illustrated in Figure 3A or expanding into a wider inverted V-shape when installed in a larger roof joint 103 as illustrated in Figure 3B. In some cases, the angle formed by the V-shape can change depending on the width of the roof joint 103. The expansion structure 120 can also be useful in maintaining a waterproof seal when the width of the roof joint 103 fluctuates during use, for example, during changes in temperature and environmental conditions.

[0038] A flexible waterproof membrane 104 can be applied over the top of the flexible sealing member 105. The flexible waterproof membrane 104 may be cohesively favorable with the flexible sealing member 105 and bond to the flexible sealing member 105 to form a waterproof seal. The flexible waterproof membrane 104 may comprise the same material as the flexible sealing member 105 such that when the portions are bonded together, they form a waterproof monolithic structure. The flexible waterproof membrane 104 may extend past the end of the flexible sealing member 105 and over at least a portion of the roof deck section 101, 102 and/or a structure on the roof deck section, such as blocking 108. The flexible waterproof membrane 104 can bond to the roof deck section 101, 102, blocking 108, or other membrane that may have been previously applied. The flexible waterproof membrane 104 can help to inhibit the ingress of water through the roof joint 103. The flexible waterproof membrane 104 can be dispensed or installed in a variety of methods which may include pouring, rolling, spraying, application of preformed strips, application via squeegee, or other methods. The flexible waterproof membrane can be applied by spraying the material while it is in a substantially fluid state. The flexible waterproof membrane 104 can be 1 to 5 millimeters thick (e.g., from 1.5 to 5 millimeters or from 2 to 4 millimeters, or a range defined by any two of the foregoing values). The flexible waterproof membrane 104 can be greater than 5 millimeters thick. The roof expansion joint system can omit a flexible waterproof membrane, for example, like flexible waterproof membrane 104.

[0039] The roof expansion joint system can include additional coatings or membranes applied at the outermost layer, for example, coating layer 107. For example, a polyurea top coating layer 107 can be dispensed and applied on the flexible waterproof membrane 104. The coating layer 107 can comprise a silicone and/or an acrylic material. The coating layer 107 can comprise a reactive silicone component in an amount up to 7 weight %, for example, up to 1 wt %, up to 2 wt %, up to 3 wt %, up to 4 wt %, up to 5 wt %, or up to 6 wt %, or can be included in a range defined by any two of the foregoing values. The reactive silicone component can aid in the repelling of water and/or dirt. The top coating layer 107 can comprise a cyanoamine, such as cyanoethyl amine. The cyanoamine can aid in the repelling of mildew. The top coating layer 107 can comprise at least one of solar-reflecting granules, UV absorbers, and hindered amine light stabilizers (HALS) that may enhance weatherability and/or longevity of the layers between the top coating layer 107 and the substrate.

[0040] The additional coating or membrane (e.g., coating 107) can provide additional performance properties and characteristics such as good and/or improved flame-resistance, chemical resistance, abrasion resistance, sealing properties, color retention, ease of cleaning, increased lifespan of the flexible waterproof membrane and/or other properties and characteristics.

[0041] The coating layer 107 can have a tensile elongation of at least 300% as measured according to test method described in ASTM D638 (2014) measured at room temperature and a test speed of 500 mm I min. The coating layer (e.g., layer 107) can have a tensile Young’s modulus of less than 150 MPa as measured according to test method described in ASTM D638 (2014) measured at room temperature. Such properties may provide increased sand resistance for the system.

[0042] Different portions of the roof expansion joint system can comprise materials compatible with one another, allowing them to be chemically bonded together, forming a seal inhibiting the entry of water. The portions can include for example, the flexible waterproof membrane 104, the flexible sealing member 105, the adhesive layer 106, and/or the additional coating layer 107. Different portions of the roof expansion joint system can independently comprise an elastomer, an epoxy, a urethane, a fiberglass, a carbon fiber, an isocyanate prepolymer, a moisture-cured isocyanate, a polyurea, a polyurethane, or a combination thereof. For example, one or more layers can comprise a two-component elastomeric aliphatic polyurea coating. One or more layers can essentially or completely omit rubber and/or neoprene.

[0043] When bonded together, the different portions of the roof expansion joint structure may form a monolithic structure, inhibiting the entry of water. Where portions of the roof expansion joint system are not cohesively favorable with other portions of the roof expansion joint system, a primer or an intermediary member such as a plate may be used to achieve strong adhesion and a waterproof seal.

[0044] The expansion structure 120 can additionally or alternatively include a generally inverted U-shaped configuration in the flexible sealing member 105 as illustrated in Figures 4A, 4B. Much like the inverted V-shape, the inverted U-shaped expansion structure 120 can act like an accordion, collapsing into a tighter inverted U-shape when installed into a smaller roof joint 103 or expanding into a wider inverted V-shape when installed in a larger roof joint 103. The arc formed by the U-shape can change depending on the width of the roof joint 103.

[0045] The flexible sealing member 105 can include a plurality of expansion structures, some of which may extend in different directions. For example, Figures 5A, 5B shows a roof expansion joint system having expansion structure 520 (similar to the expansion structure 120 shown in Figure 2) and a second expansion structure 530. The second expansion structure 530 can extend downward and into the roof joint 103. The first expansion structure 520 and second expansion structure 530 can define a void 540. A material, such as a foam, can be supplied in void 540 (as shown in Figures 5A, 5B). Foam can used to provide additional thermal management for the structure. Foam may be injected into such voids to repair the roof expansion structure and/or repair leaks in a nondestructive manner. The void 540 may remain empty, for example, when the void is filled only with air.

[0046] As shown in Figures 5A and 5B, the flexible sealing member 105 comprises a first flange 121 and a second flange 122 on the upper most portion of the flexible sealing member 105 and a third flange 521 and a fourth flange 522 on the lower most portion of the flexible sealing member 105. The third flange 521 and the fourth flange 522 form the lower most portion of the flexible sealing member 105, and the expansion structure 530 extends downward and away from the top face of the flanges 521, 522. The flange portions 521, 522 on each side of the flexible sealing member 105 can be installed onto the adhesive layer 106, attaching either side of the flexible sealing member 105 to each roof deck section 101, 102 (or structures positioned on the roof deck, such as a blocking 108).

[0047] The flexible sealing member 105 can be configured with an expansion structure of various sizes and shapes. Non-limiting examples of flexible sealing members 105 having various combinations of expansion structures, in terms of shape and quantity, are shown in Figures 6A- 6F. The expansion structure can include a V-shaped configuration, where the V-shape is oriented to create a trough-like configuration. The configuration and number of expansion joints can be modified to attain the desired performance for a particular application. For example, the number of expansion structures and the shape of any such expansion structure can be modified to reduce wind noise and/or maximize cyclic movement (as measured according to ASTM International Standard E- 1399-97 (Reapproved 2022), entitled “Standard Test Method for Cyclic Movement and Measuring the Minimum and Maximum Joint Widths of Architectural Joint Systems”).

[0048] Figures 6D-6F show examples where the flexible sealing member 105 includes a plurality of expansion structures. Each of the expansion structures can be similar to the expansion structure 120 shown in Figure 2 (see for example Figure 6D). The plurality of expansion structures can act like an accordion, collapsing into a tighter inverted shape when installed into a smaller roof joint or expanding into a wider inverted shape when installed in a larger roof joint. The plurality of expansion structures may permit the flexible sealing member to span a greater range of roof joints.

[0049] The shape(s) of the expansion structure can be formed by configuring the manufacturing of the flexible sealing member 105. For example, the flexible sealing member 105 can be made by any one of molding process (e.g., reaction injection molding, open molding, or closed molding), additive manufacturing, or robotic spraying at gradient thickness to allow the material to cure and shrink to the desired shape.

[0050] The flexible sealing member 105 can be 1 to 5 millimeters thick (e.g., from 1.5 to 4 millimeters or from 1.5 to 2.5 millimeters).

[0051] The flexible sealing member 105 can be adapted to fit a variety of applications, including both small and large width roof joints. The flexible sealing member 105 can be capable of sealing roof joints up to 9 inches wide (for example, roof joints being 1, 2, 3, 4, 5, 6, 7, or 8 inches wide), but may also be used to seal a joint up to 24 inches wide (e.g., up to 10, 12, 14, 16, 18, 20, or 22 inches wide). Accordingly, the flexible sealing member 105 can be configured to seal a joint having a width within a range with endpoints defined by any two of the foregoing values.

[0052] The flexible sealing member 105 can have a tensile elongation property that permits the flexible sealing member to absorb any thermal expansion mismatch or differences between the substrate (e.g., a roof deck section) and/or other layers of the expansion joint system (e.g., a flexible waterproof member 104, adhesive layer 106, and/or coating layer 107). The tensile elongation of the flexible sealing member 105 can aid in any expansion joint movement as described herein. The flexible sealing member 105 can have a tensile elongation of at least 300% as measured according to test method described in ASTM D638 (2014) measured at room temperature and a test speed of 500 mm / min.

[0053] The flexible sealing member 105 can have a white color. In such cases, the flexible sealing member 105 can reflect sunlight that may penetrate different layers in the expansion joint system, for example, the flexible waterproof layer 104 (as shown in Figure 1), or other layers, e.g., adhesive layer 106, and/or additional coating layer 107. The reflection of sunlight can reduce heat buildup within the expansion joint system. The flexible sealing member 105 can have a black color. In such cases, the flexible sealing member 105 can absorb heat and maintain better flexibility for a structure in a cold climate. [0054] The flexible sealing member 105 can comprise a non-planar configuration. For example, while Figure 7A shows a perspective view of a portion of a flexible scaling member 105 in a single horizontal plane, Figure 7B shows a perspective view of a portion of a flexible sealing member 105 having a first section in a first plane (e.g., horizontal), which then transitions to a second section oriented in a second plane (e.g., vertical).

[0055] Figures 8A and 8B show additional examples of a flexible sealing member 805 (comprising multiple expansion structures) oriented and configured in more than one plane. Such configurations can aid in the positioning of an expansion system on a non-planar structure as the transition in a continuous flexible sealing member 105, 805 reduces portions of the structure more susceptible to leaks as well as provides a structure that may be more easily installed on a roof structure. The multi-planar oriented flexible sealing member 105, 805 can provide an improved system to transition around edges of structures. The flexible sealing member 105, 805 may also transition along the same plane at a specified angle, for example at a 90° angle.

[0056] The roof expansion joint system can include an expansion structure oriented to create a trough-like configuration, for example in a V-shape or U-shape configuration or plurality of V- shape or U-shape configurations. Figure 9 shows one example of such a roof expansion joint system. The expansion structure 120 in Figure 9 extends downward and into the roof joint 103. The flexible sealing member 105 comprises a first flange 121 and second flange 122. The flange portions 121, 122 on each side of the flexible sealing member 105 can be installed onto the adhesive layer 106, attaching either side of the flexible sealing member 105 to each roof deck section 101, 102 (or structures positioned on the roof deck, such as blocking 108). Figure 9 shows that a closed-cell backer rod 940 may be positioned within the trough or channel created by the expansion structure 120.

[0057] The backer rod 940 can provide a physical structure to provide height for the roof joint, for example to promote appropriate drainage and water flow. The backer rod 940 can be comprised of a compressible material that adapts to the expansion and contraction of the roof joint when the width of the roof joint 103 fluctuates during use, for example, during changes in temperature and environmental conditions.

[0058] Figure 9 also shows that a bond breaker tape layer 950 can be positioned as a layer on top of the backer rod 940 and portions of the flexible sealing member 105. The bond breaker tape layer 950 can be short enough to not extend to the edges of the flexible sealing member 105. In some cases, the bond breaker tape layer 950 may extend to further or lesser than that shown in Figures 9 (c.g., closer to the edge of the flexible scaling member 105). Other example configurations disclosed herein may also include a bond breaker tape layer 950.

[0059] In some cases, the bond breaker tape 950 can be electrically conductive. In such cases, electricity can be applied to electrically conductive bond break tape 950 to aid in the removal of joint expansion system. In some cases, a mechanical force, for example being pulled by a machine, can be applied to the bond breaker tape 950 to remove the joint expansion system. [0060] The bond breaker tape 950 can provide a portion of the layers that inhibits adhesion of the flexible waterproof member 104 to the flexible sealing member 105 in the area where the bond breaker tape 950 is applied. Such a configuration may increase the amount of area that the flexible waterproof member 104 may move during the expansion and contraction of the roof joint while still maintaining a sealed roof joint.

[0061] A flexible waterproof membrane 104 may be positioned on the outer surface of the bond breaker tape layer 950 and the flexible sealing member 105. The flexible waterproof layer 104 can be applied such that slack exists within the layer as it spans the roof joint 103 to allow the flexible waterproof member 104 to move without stretching. Such configurations can be useful to minimize fatigue of the flexible sealing membrane 104 over repeated cycles of use. Figure 9 also shows a top coating layer 107 (as described herein) applied on the flexible waterproof membrane 104.

[0062] As discussed in connection with Figures 5 A, 5B, the V-shape expansion structure 120 of Figure 9 can provide a channel that can be easier to conduct non-destructive repairs, for example via injection of material into the channel or trough created by the expansion structure 120.

[0063] Also described herein are methods of applying an expansion joint system to a roof structure. The method can include dispensing an adhesive layer over a portion of a top surface of a first roof deck section and over a portion of a top surface of a second roof deck section. The first roof deck section and the second roof deck section can define a roof joint. The method further includes installing a flexible sealing member that comprises an expansion structure, a first flange portion, and a second flange portion over the roof joint. The flexible sealing member can be positioned such that the expansion structure spans the roof joint. The first flange portion can be installed by placing a bottom surface of the first flange portion on the portion of the first roof deck section having an adhesive layer dispensed thereon, and the second flange portion can be installed by placing a bottom surface of the second flange portion on the portion of the second roof deck section having an adhesive layer dispensed thereon. The method can also include dispensing a flexible waterproof membrane to a top surface of the flexible sealing member. In such methods, each of the adhesive layer, flexible sealing member, and flexible waterproof membrane is cohesively favorable with one another. For example, the adhesive layer, flexible sealing member, and flexible waterproof membrane may each comprises an isocyanate prepolymer, a moisture-cured isocyanate, a polyurea, a polyurethane, or combination thereof. The methods can provide a roof expansion joint system that forms a monolithic structure once bonded together that inhibits entry of water into a roof expansion joint.

[0064] The adhesive layer and waterproof flexible membrane can be dispensed or installed in a variety of methods which may include pouring, rolling, spraying, application of preformed strips, application via squeegee, or other methods. The adhesive layer and waterproof flexible membrane can be applied while they are in a substantially fluid state.

[0065] The methods can include dispensing additional layers or coatings to the flexible waterproof membrane, for example, dispensing a top coating layer on the flexible waterproof membrane as described herein. The coating layer can comprise a polyurea, silicone, and/or an acrylic material.

[0066] As used herein, unless otherwise expressly specified, all numbers such as those expressing values, ranges, amounts or percentages may optionally be read as if prefaced by the word “about”, even if the term does not expressly appear. When the term “about” (or similar terms such as “approximately” or “substantially”) is used in conjunction with a stated amount, value, or condition, it may be taken to mean an amount, value or condition that deviates by less than 10%, less than 5%, less than 1%, less than 0.1%, or less than 0.01% of the stated amount, value, or condition.

[0067] Any numerical range recited herein is intended to include all subranges subsumed therein. When ranges are given, any endpoints of those ranges and/or numbers within those ranges can be combined with the scope of the present disclosure. Plural encompasses singular and vice versa. When ranges are given, any endpoints of those ranges and/or numbers within those ranges can be combined within the scope of the present disclosure. Including and like terms means “including but not limited to”. The word “comprising” and forms of the word “comprising” as used in this description and in the claims does not limit the disclosure claimed to exclude any variants or additions.

[0068] As used herein, the terms “on”, “applied on/over”, mean formed or provided on but not necessarily in contact with the surface. Each of the characteristics and examples described above and below, and combinations thereof, may be said to be encompassed by the present disclosure.

[0069] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0070] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to”) unless otherwise noted.

[0071] Although the disclosure has been described in terms of “comprising”, “consisting essentially of’ or “consisting of’ are also within the scope of the present disclosure. In this context, “consisting essentially of’ means that any additional components will not substantially affect the size, shape, or functionality of the roof expansion joint system.

[0072] While this specification describes the composition being applied to a roof structure or covering, a person of ordinary skill in the art would understand that the system can be applied to other structures. Some non-limiting examples of structures include joints between two wall structures, wall to roof deck, a roof deck to a door sill, floor structures having two sections, or other joints which seek to include a waterproof joint and joint structure that accounts for the varying of the width of a joint.

[0073] Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the disclosure are approximations, numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard variation found in their respective testing measurements.

[0074] The disclosure will be further described by reference to the following examples.

EXAMPLES

[0075] Six different expansion joint systems were manufactured with flexible sealing members having expansion structures respectively corresponding to those shown in Figures 6A- 6F. Each of the manufactured expansion joint systems utilized the layers shown and described in relation to Figures 1 through 3B. That is, each of the manufactured expansion joint systems included an adhesive layer on cither side of the joint, a flexible scaling member with flanges attached to the corresponding portions of the adhesive layer and with the expansion structure spanning the joint, a waterproof membrane applied over the flexible sealing member, and a coating layer applied over the waterproof membrane. In these examples, the adhesive layer, flexible sealing member, and waterproof membrane were formed from a polyurea/polyurethane hybrid. The coating layer was a polyurea material. As disclosed above, other materials such as polyurea, polyurethane, or hybrids thereof may be utilized and are expected to provide similar efficacy to these examples. A coating layer comprising or consisting of silicone is also expected to provide similar efficacy.

[0076] Each expansion joint system was sanded down using commercially available Norton E-Z Flex Metalite P60 grit paper until any textured spots were dulled. A 10-mm plastic pull-off stub was glued to each of the sanded areas using 3M Scotch-Weld DP 460 NS Epoxy Adhesive. The adhesive was allowed to cure for 48 hours. Each stub was then separately installed to a PATTI Quantam Digital Adhesion Tester unit with an inlet air pressure of 150 psi. The adhesion of the expansion joint systems was measured according to ASTM D4541 (2022). Each measurement resulted in an adhesion value of higher than 400 psi, which reflects adhesion measurements across all interfaces of the expansion joint systems.

[0077] Whereas various examples of the disclosure have been described in fulfillment of the various objectives of the disclosure, it should be recognized that these examples are merely illustrative of the principles of the present disclosure. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the present disclosure as defined in the following claims.

Claims

WHAT IS CLAIMED IS:

1. A roof expansion joint system comprising: a flexible waterproof membrane; a flexible sealing member comprising a flange structure and an expansion structure; and an adhesive layer, wherein each of the flexible waterproof membrane, the flexible sealing member, and the adhesive layer is cohesively favorable with one another.

2. The roof expansion joint system of claim 1, wherein the flexible waterproof membrane, the flexible sealing member, and the adhesive layer each comprises a polyurea.

3. The roof expansion joint system of claim 1, wherein the flexible waterproof membrane, the flexible sealing member, and the adhesive layer each comprises an isocyanate prepolymer, a polyurea, a polyurethane, or a combination thereof.

4. The roof expansion joint system of any one of claims 1-3, wherein each of the flexible waterproof membrane, the flexible sealing member, and the adhesive layer is chemically compatible with one another.

5. The roof expansion joint system of any one of claims 1-4, wherein the roof expansion joint system forms a monolithic structure once bonded together to thereby inhibit entry of water into a roof expansion joint.

6. The roof expansion joint system of any one of claims 1-5, wherein the flexible sealing member comprises a first flange and a second flange, wherein the first flange is configured to be adhered on a top surface of a first roof deck section by the adhesive layer and the second flange is configured to be adhered to a top surface of a second roof deck section by the adhesive layer.

7. The roof expansion joint system of any one of claims 1-6, wherein the expansion structure comprises a shape preformed into the flexible sealing member, such as an inverted V-shape.

8. The roof expansion joint system of claim 7, wherein an angle formed by the inverted V-shape can change depending on the width of the roof joint.

9. The roof expansion joint system of any one of claims 1-8, wherein the expansion structure is configured to be installed over a roof joint and extend upward and away from the roof joint.

10. The roof expansion joint system of any one of claims 1-9, wherein the expansion structure is configured to deflect such that the width of the flexible sealing member can be varied depending on the width of the roof joint.

11. The roof expansion joint system of any one of claims 1-10, wherein the flexible sealing member comprises a plurality of expansion structures.

12. The roof expansion joint system of any one of claims 1-11, wherein the flexible waterproof membrane is applied to a top surface of the flexible sealing member and the adhesive layer adheres to a bottom surface of the flexible scaling member.

13. The roof expansion joint system of any one of claims 1-12, further comprising a top coating layer disposed over the flexible waterproof membrane.

14. The roof expansion joint system of any one of claims 1-13, further comprising a bond breaker tape layer positioned between the flexible waterproof membrane and the flexible sealing member.

15. A roof structure comprising the roof expansion joint system of any one of claims 1-14.

16. A method of applying an expansion joint system to a roof structure, the method comprising: dispensing an adhesive layer over a portion of a top surface of a first roof deck section and over a portion of a top surface of a second roof deck section, wherein the first roof deck section and the second roof deck section define a roof joint; installing a flexible sealing member comprising an expansion structure, a first flange portion, and a second flange portion such that the expansion structure is positioned above the roof joint; and dispensing a flexible waterproof membrane to a top surface of the flexible sealing member, wherein each of the adhesive layer, flexible sealing member, and flexible waterproof membrane is cohesively favorable with one another.

17. The method of claim 16, wherein the adhesive layer, the flexible sealing member, and the flexible waterproof membrane each comprises an isocyanate prepolymer, a polyurea, a polyurethane, or a combination thereof.

18. The method of any one of claims 16 or 17, wherein the adhesive layer, the flexible sealing member, and the flexible waterproof membrane form a monolithic structure once bonded together thereby inhibiting entry of water into the roof joint.

19. The method of any one of claims 16-18, wherein the first flange portion is installed by placing a bottom surface of the first flange portion on the portion of the first roof deck section having an adhesive layer dispensed thereon, and wherein the second flange portion is installed by placing a bottom surface of the second flange portion on the portion of the second roof deck section having an adhesive layer dispensed thereon.

20. The method of any one of claims 16-19, further comprising dispensing a top coating layer on the flexible waterproof membrane.