US20100011685A1 - Sealant assemblies and methods - Google Patents

Sealant assemblies and methods Download PDF

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Publication number
US20100011685A1
US20100011685A1 US12/503,757 US50375709A US2010011685A1 US 20100011685 A1 US20100011685 A1 US 20100011685A1 US 50375709 A US50375709 A US 50375709A US 2010011685 A1 US2010011685 A1 US 2010011685A1
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US
United States
Prior art keywords
sealant
weight
amount
mating surface
color
Prior art date
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Abandoned
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US12/503,757
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English (en)
Inventor
Ronald J. Janoski
Mark C. Rundo
Jonathan A. Karas
Michael Lewis Kerman
Nicholas John Berard
Wayne Mazorow
Paul E. Snowwhite
Paul Ruede
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Adco Products Inc
Original Assignee
Adco Products Inc
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Filing date
Publication date
Priority claimed from US11/128,779 external-priority patent/US20060272249A1/en
Application filed by Adco Products Inc filed Critical Adco Products Inc
Priority to US12/503,757 priority Critical patent/US20100011685A1/en
Assigned to ADCO PRODUCTS, INC. reassignment ADCO PRODUCTS, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RUNDO, MARK C., KARAS, JONATHAN A., KERMAN, MICHAEL LEWIS, JANOSKI, RONALD J., BERARD, NICHOLAS JOHN, MAZOROW, WAYNE, RUEDE, PAUL, SNOWWHITE, PAUL E.
Publication of US20100011685A1 publication Critical patent/US20100011685A1/en
Assigned to GENERAL ELECTRIC CAPITAL CORPORATION, AS ADMINISTRATIVE AGENT reassignment GENERAL ELECTRIC CAPITAL CORPORATION, AS ADMINISTRATIVE AGENT SECURITY AGREEMENT Assignors: ADCO PRODUCTS, INC.
Priority to PCT/US2010/041494 priority patent/WO2011008642A1/en
Priority to EP10800355.9A priority patent/EP2454424A4/de
Priority to CA2767951A priority patent/CA2767951A1/en
Assigned to ADCO PRODUCTS, INC., ETERNABOND, INC., WTT SYSTEMS, LLC, MILLENNIUM ADHESIVE PRODUCTS, INC. reassignment ADCO PRODUCTS, INC. RELEASE OF SECURITY INTEREST Assignors: GENERAL ELECTRIC CAPITAL CORPORATION
Abandoned legal-status Critical Current

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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
    • E04D13/14—Junctions of roof sheathings to chimneys or other parts extending above the roof
    • E04D13/1407—Junctions of roof sheathings to chimneys or other parts extending above the roof for flat roofs
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/42—Polycondensates having carboxylic or carbonic ester groups in the main chain
    • C08G18/4288—Polycondensates having carboxylic or carbonic ester groups in the main chain modified by higher fatty oils or their acids or by resin acids
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4825—Polyethers containing two hydroxy groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/28—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the compounds used containing active hydrogen
    • C08G18/40—High-molecular-weight compounds
    • C08G18/48—Polyethers
    • C08G18/4833—Polyethers containing oxyethylene units
    • C08G18/4837—Polyethers containing oxyethylene units and other oxyalkylene units
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78—Nitrogen
    • C08G18/7806—Nitrogen containing -N-C=0 groups
    • C08G18/7818—Nitrogen containing -N-C=0 groups containing ureum or ureum derivative groups
    • C08G18/7831—Nitrogen containing -N-C=0 groups containing ureum or ureum derivative groups containing biuret groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78—Nitrogen
    • C08G18/7806—Nitrogen containing -N-C=0 groups
    • C08G18/7818—Nitrogen containing -N-C=0 groups containing ureum or ureum derivative groups
    • C08G18/7837—Nitrogen containing -N-C=0 groups containing ureum or ureum derivative groups containing allophanate groups
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G18/00—Polymeric products of isocyanates or isothiocyanates
    • C08G18/06—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen
    • C08G18/70—Polymeric products of isocyanates or isothiocyanates with compounds having active hydrogen characterised by the isocyanates or isothiocyanates used
    • C08G18/72—Polyisocyanates or polyisothiocyanates
    • C08G18/77—Polyisocyanates or polyisothiocyanates having heteroatoms in addition to the isocyanate or isothiocyanate nitrogen and oxygen or sulfur
    • C08G18/78—Nitrogen
    • C08G18/79—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates
    • C08G18/798—Nitrogen characterised by the polyisocyanates used, these having groups formed by oligomerisation of isocyanates or isothiocyanates containing urethdione groups
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J175/00—Adhesives based on polyureas or polyurethanes; Adhesives based on derivatives of such polymers
    • C09J175/04—Polyurethanes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G2190/00—Compositions for sealing or packing joints

Definitions

  • the present invention relates to sealant assemblies and methods, and more particularly, to sealant assemblies and methods adapted to seal an interface between a surface and a projection extending from the surface.
  • roof surfaces designed to repel water and prevent water from leaking into interior areas of the building.
  • roof surfaces are also designed to accommodate one or more roof projections extending from the roof surface. For example, it is known to penetrate a roof surface with an exhaust pipe to allow venting of gases generated within the building. When roof projections are necessary, special care must be taken to avoid leak paths at the interface between the roof surface and the roof projection.
  • sealant assemblies are typically formed by circumscribing the exhaust pipe with a curb element to create a roof pocket about the exhaust pipe. Once the roof pocket is formed, a filling sealant is introduced into the roof pocket to complete the sealant assembly.
  • conventional sealant assemblies may fail due to environmental exposure.
  • conventional sealant assemblies include a curb element and a filling sealant that comprise different materials. Using different materials may result in an insufficient bond between the curb element and the filling sealant, leading to separation of the curb element and the filling sealant.
  • different materials often have substantially different coefficients of expansion. The differing coefficients of expansion can result in fracture of the interface between the curb element and the filling sealant as components of the assembly expand and contract at different rates during heating and cooling cycles.
  • forming the curb element and the filling sealant from different materials may discourage or prevent integral bonding that may further contribute to failure of any attachment interface between the curb element and the filling sealant. Separation at the interface limits the benefits of the curb element, leaving the filling sealant to seal the projection and the roof.
  • the side walls of many conventional pocket sealant assemblies contribute to water pooling at the juncture between the outer edge of the curb element and the roof.
  • Vertical or nearly vertical lower portions of the outer edge of the curb element allow water to flow down to the roof with little or no lateral momentum. Without lateral momentum, the water often pools next to the sealant pocket, increasing the chances of a leak.
  • a sealant assembly for sealing an interface between a surface and a projection extending from the surface.
  • the sealant assembly includes a flexible member circumscribing an area to form a sealant pocket.
  • the sealant assembly further includes a filling sealant at least partially filling the sealant pocket.
  • the filling sealant and the flexible member comprise substantially the same material.
  • a method of sealing an interface between a surface and a projection extending from the surface includes the step of positioning a flexible member on the surface with the flexible member circumscribing the projection and the projection extending through a sealant pocket defined by the flexible member and the surface.
  • the method further includes the step of adding a filling sealant into the sealant pocket, wherein the filling sealant subsequently solidifies such that the flexible member and the solidified filling sealant form a solid sealant assembly with the flexible member and the solidified filling sealant comprising substantially the same material.
  • a sealant assembly in accordance with still another aspect, includes a flexible member circumscribing an area to form a sealant pocket and a solidified filling sealant within the area and filling at least a portion of the sealant pocket. Sufficient plasticizer is included in the formulation to ensure that there is adequate flexibility in the flexible member such that it can conform to a slightly irregular roofing surface.
  • the sealant assembly is formed by a process including the step of positioning the flexible member on a surface with the flexible member circumscribing a projection extending from the surface. The process further includes the step of adding a filling sealant into the sealant pocket, wherein the filling sealant is substantially contained within the sealant pocket. Still further, the process includes the step of permitting the filling sealant to solidify such that the flexible member and the solidified filling sealant form a solid sealant assembly with the flexible member and the solidified filling sealant comprising substantially the same material.
  • FIG. 1A is a perspective view demonstrating an exemplary step of assembling a flexible member to circumscribe a projection extending from the surface;
  • FIG. 1B is a perspective view of an assembled flexible member
  • FIG. 1C is a perspective view demonstrating an exemplary step of adding a filling sealant into a sealant pocket
  • FIG. 1D is a perspective view of an exemplary sealant assembly in accordance with aspects of the present invention.
  • FIG. 2 is a sectional view of the sealant assembly taken at line 2 - 2 of FIG. 1D ;
  • FIG. 3 is a top plan view of an exemplary corner element in accordance with aspects of the present invention.
  • FIG. 4A is a sectional view of the corner element along line 4 A- 4 A of FIG. 3 ;
  • FIG. 4B is a sectional view of the corner element along line 4 B- 4 B of FIG. 3 ;
  • FIG. 5 is a left side elevational view of the corner element of FIG. 3 ;
  • FIG. 6 is a front elevational view of the corner element of FIG. 3 ;
  • FIG. 7 is an assembled flexible member in accordance with another exemplary embodiment of the present invention.
  • FIG. 8 is a sectional view of the flexible member along line 8 - 8 of FIG. 7 ;
  • FIG. 9 is another embodiment of a corner element in accordance with aspects of the present invention.
  • FIG. 10 is an isometric view of a flexible member in accordance with an embodiment of the present invention.
  • FIG. 11 is an isometric view of a unitary piece flexible member in accordance with an embodiment of the present invention.
  • FIG. 12A is a side view of a sealant assembly in accordance with an embodiment of the present invention.
  • FIG. 12B is a cutaway view of a connection on a flexible member.
  • FIGS. 1A-1D illustrate an exemplary method of providing a sealant assembly 20 adapted to seal an interface 204 between a surface 200 and one or more projections 202 extending from the surface 200 .
  • Sealant assemblies and methods herein may be applied in a wide range of applications. For instance, sealant assemblies may be used in applications where it is necessary to provide a fluid seal at an interface between a projection and a surface. In one example, the sealant assembly can be used to seal an interface between a roof surface and a vent pipe extending from the roof surface.
  • Sealant assemblies herein include a flexible member that may circumscribe a single projection or any plurality of projections in accordance with aspects of the present invention.
  • Flexible members may be provided in a wide variety of shapes and/or sizes depending on the particular application.
  • the flexible member is formed as a single piece.
  • the present invention also contemplates that the flexible member is formed from a plurality of pieces that can be assembled together to circumscribe the one or more projections.
  • the flexible member includes a continuous ring in a variety of shapes such as a continuous circular, oval, square, triangular, rectangular, or other continuous shape that can circumscribe a projection. The continuous ring can be placed over the top of the projection to circumscribe the projection adjacent the interface.
  • the ring may be split so that it is not necessary to place the ring over the top of the projection.
  • the ring may be split at a single location wherein the projection may be laterally inserted through the slit to enter the interior area of the ring.
  • the ring may be split at two locations, wherein the ring halves may be closed around the projection to circumscribe the projection.
  • the flexible member has a plurality of corner elements adapted to at least partially circumscribe the projection.
  • a flexible member 30 includes a plurality of corner elements 40 that are arranged to at least partially circumscribe the one or more projections 202 .
  • One exemplary corner element 40 is illustrated in FIGS. 3-6 .
  • the corner element 40 includes a first extension arm 42 extending along a first extension axis 42 a and a second extension arm 44 extending along a second extension axis 44 a .
  • the first extension axis 42 a and second extension axis 44 a are substantially perpendicular with respect to one another.
  • first and second extension axis may be located at different angular orientations depending on the shape of the flexible member.
  • the first and second extension axis might be located at an angle of 60 degrees from one another to form a triangular flexible member having three corner elements.
  • the illustrated corner element is shown to include relatively sharp corners.
  • the corner elements may comprise rounded corners to reduce stress points.
  • the corner element can comprise a first and second extension arm together with a rounded corner portion positioned between the first and second extension arm.
  • the entire corner element may comprise a rounded corner portion.
  • the extension arms 42 , 44 comprise the same length. It is contemplated that the extension arms, if provided, may be longer or shorter than the relative length illustrated in the figures. Moreover, it is contemplated that the extension arms might comprise different lengths in further embodiments.
  • the first extension arm 42 can include a first end portion 46 a with a first substantially flat surface 48 a that is substantially perpendicular to the first extension axis 42 a .
  • the second extension arm 44 can include a second end portion 46 b with a second substantially flat surface 48 b that is substantially perpendicular to the second extension axis 44 a .
  • Providing the end portions with a substantially flat surface that is substantially perpendicular to the respective extension axis can facilitate connection of flexible member elements.
  • end portions with perpendicular surfaces can allow compression of the end portions without significant development of shear stress and without deforming the end portions away from the extension axis.
  • compression of diagonal surfaces can develop significant shear stresses and might wedge against each other to deform the end portions away from the extension axis and therefore interfere with the fastening process.
  • end portions of body components may have alternative configurations to facilitate connection of the components to one another.
  • FIG. 9 depicts a corner element 140 including a first end portion 146 a with a tongue 142 and a second end portion 146 b with a groove 144 .
  • the tongue 142 of one corner element may be inserted within a groove 144 of another corner element to link the corner elements to one another.
  • Providing a tongue and groove arrangement can facilitate fastening the end portions together and can increase the overall strength of the subsequently formed joint.
  • each corner element can include a substantially flat base 42 b , 44 b adapted to rest on a substantially flat surface 200 .
  • the corner elements further include boundary surfaces 42 c , 44 c adapted to at least partially define a perimeter boundary of the interior area 32 of the flexible member 30 .
  • the corner elements further include an outer surface 42 d , 44 d extending between the corresponding flat bases 42 b , 44 b and boundary surfaces 42 c , 44 c .
  • the outer surface, boundary surface, and flat base can form a triangular configuration although other configurations may be employed in accordance with aspects of the present invention.
  • FIG. 7 is an assembled flexible member 130 in accordance with another embodiment of the present invention.
  • the flexible member 130 includes at least a pair of intermediate segments 50 a , 50 b .
  • the intermediate segments 50 a , 50 b if provided, can extend at least one dimension of the flexible member 130 to create an enlarged sealant pocket 134 .
  • a second pair of intermediate segments 52 a , 52 b is also provided to extend a second dimension of the flexible member 130 to further enlarge the sealant pocket 134 .
  • the intermediate segments can include a wide variety of sizes to customize the size of the sealant pocket 134 .
  • the first pair of intermediate segments 50 a , 50 b may have a first length and the second pair of intermediate segments 52 a , 52 b may have a second length.
  • the first and second lengths may be equal or different from one another depending on the desired size of the flexible member 130 .
  • the intermediate segments 50 a , 50 b , 52 a , 52 b can have substantially identical lengths to form a substantially square shaped flexible member 130 .
  • first pair of intermediate segments 50 a , 50 b may have a different length than the second pair of segments 52 a , 52 b to form a substantially rectangular shaped sealant pocket 134 .
  • only one pair of segments is used to extend the length of the sealant pocket 134 in a single desired direction.
  • the flexible member 130 may be provided as a kit with four relatively long intermediate segments. The relatively long intermediate segments may be cut on site to provide a customized flexible member having an appropriate size. Customizing the flexible member can reduce the overall size of the flexible member wherein less filling sealant is necessary to fill the sealant pocket.
  • the intermediate segments may also have various shapes in accordance with aspects of the present invention. As shown in FIG. 8 , for example, the intermediate segment may have a triangular configuration that matches the configuration of the corner elements.
  • the intermediate segments can include a substantially flat surface 56 that is substantially perpendicular to the extension axis of the intermediate segment. Providing a perpendicular flat surface 56 can facilitate fastening of the intermediate segments between opposed corner elements.
  • the intermediate segments can also extend along a substantially straight axis but might extend along a substantially curved axis in further applications.
  • the flexible member 30 is positioned on the surface 200 with the flexible member 30 circumscribing the surface projections 202 .
  • the corner elements 40 are sufficient to circumscribe each of the surface projections 202 .
  • Double-sided tape 49 or other adhesive may be used to fasten together the flat end surfaces to maintain the desired shape of the assembled sealant pocket.
  • the complete flexible member 30 is formed as shown in FIG. 1B .
  • the boundary surfaces 42 c , 44 c of each extension arm of the completed flexible member cooperate to form a peripheral boundary defining the interior area 32 .
  • the boundary surfaces 42 c , 44 c of each extension arm cooperate with the surface 200 adjacent the interior area 32 to form a sealant pocket 34 .
  • the sealant pocket 34 is formed with the surface projections 202 extending through the sealant pocket 34 .
  • the flexible member 30 may also be sealed or fastened with respect to the surface 200 .
  • Providing a seal between the flexible member 30 and the surface 200 may help contain filling material within the sealant pocket as the filling material solidifies.
  • Fastening the flexible member 30 to the surface 200 can also help maintain the sealant pocket 34 in the desired location with respect to the one or more surface projections 202 .
  • tape 36 such as a Butyl tape, can be used to form a seal the flexible member 30 to the surface 200 and/or can help fasten the flexible member 30 with respect to the surface 200 .
  • an adhesive layer or other sealant layer may be used to aid in sealing and/or fastening of the flexible member.
  • filling sealant 60 may then be added into the sealant pocket 34 .
  • filling sealant 60 is added by pouring the filling sealant 60 into the sealant pocket with a bucket 70 .
  • the filling sealant 60 may be introduced with a hose or other container.
  • the filling sealant may be added without pouring.
  • filling sealant may be scooped into the cavity, shoveled into the cavity, packed into the cavity, or otherwise introduced into the cavity.
  • the filling sealant 60 may comprise a premixed sealant material or may comprise material of segregated components that are mixed just prior to adding the sealant to the pocket. Mixing just prior to adding the sealant can be conducted in a variety of ways.
  • two or more sealant components may be mixed in a container using a mixing paddle, stirring blade, or manually using a spatula or the like.
  • two or more sealant components may be segregated in a cartridge and mixed just prior to adding the filling sealant to the sealant pocket.
  • a cartridge may be provided with segregated sealant reservoirs that are in communication with a static mixing tip. When dispensing the components from the cartridge, the static mixing tip causes the components to mix as the filling sealant is added to the cavity. Sufficient filling sealant can be added until the level of filling sealant extends to a fill line 61 relative to the surface projections 202 .
  • the fill line 61 may be predetermined or may simply comprise the final level that the filling sealant 60 reaches with respect to the surface projections 202 .
  • the fill line 61 may be less than, equal to, or greater than the height of the flexible member 30 .
  • Providing a fill line 61 that is less than the height of the flexible member 30 can reduce the overall amount of filling sealant 60 necessary to complete the sealant assembly.
  • Providing a fill line 61 that is equal to the height of the flexible member 30 (as shown in FIG. 1D ), or greater than the height of the flexible member can avoid trapping water within unfilled portions of the sealant pocket.
  • providing the flexible member and the solidified filling sealant as the same material can cause the filling sealant 60 to be integrally bonded to the flexible member 30 at an interface 47 between the filling sealant and the flexible member. Integral bonding can occur as outer layers of the boundary surfaces of the flexible member 30 soften and blend with the filling sealant that is added into the sealant pocket. After a sufficient period of time, the filling sealant and softened and blended portions solidify wherein the filling sealant 60 is integrally bonded with the flexible member 30 at the interface 47 .
  • the corner elements, intermediate segments (if provided), and the filling material comprise substantially the same material to form a solid, sealed block around the roof protrusions 202 .
  • the assembled flexible member and the filling material have the same coefficient of expansion and therefore resist cracks or other failures that may otherwise occur due to temperature fluctuations.
  • forming the assembled flexible member and the filling material from substantially the same material can facilitate integral bonding at the interface between the flexible member and the filling sealant to further resist cracks or other failures of the connection between the flexible member and the filling sealant.
  • the common material can comprise a wide variety of polymers, such as polymers and copolymers EPDM, Butyl rubber, Neoprene, SSBS, SEBS, Hypalon, Acrylic elastomers, CPE, PVC, CPVC, epichlorohydrin, ethylene acrylic elastomers, EPR, PIB, polybutadiene rubbers, polynorbomenes, polysulfide, one and two part urethane elastomers, and the like.
  • Other materials may be used as the common material to provide a sealant assembly with components having the same coefficient of expansion or components that form an integral bond with the filling material.
  • the flexible member and the filling sealant are formed of materials that include renewable polyols.
  • the filling sealant and the flexible member are each composed of a two part composition, a part A and a part B, as shown below in Table 1. More specifically, Table 1 lists each of the components of the composition and provides a percent by weight of each component in part A and in part B, respectively. Additionally, a preferred range of percents by weight of each component is shown. Part A and part B are each pre-mixed separately, and are blended together in substantially equal portions before application.
  • Examples of commercially available polyols for use in part A or part B include JEFFOL® PPG-400, JEFFOL® PPG-2000, JEFFOL® G31-23 (JEFFOL® products available from Huntsman Petrochemical Corporation of Austin, Tex.), PLURACOL® P-410, PLURACOL® P-726, PLURACOL® P-2010 (PLURACOL® products available from Wyandotte Chemical Corp. of Wyandotte, Mich.), and VORANOL® 220-56 available from Dow Chemical Company of Midland, Mi.
  • Examples of renewable polyols include SOYOL® R2-052-G available from Urethane Soy Systems Company of Volga, S. Dak., and POLYCIN® GR 53 available from Baker Castor Oil Company of Bayonne, N.J.
  • adhesion promoters include amino silanes.
  • Commercially available amino silanes include AP-32 and AP-33 available from Advanced Polymer, Inc. of Carlstadt, N.J., and DOW CORNING Z-6020® available from Dow Chemical Corporation of Midland, Mi.
  • Examples of UV stabilizers include hindered amines and substituted benzophenones.
  • Commercially available UV stabilizers include TINUVIN® 292 and TINUVIN® 328 available from Ciba-Geigy Corporation of Ardsley, N.Y., and CYASORB® UV-9, CYASORB® UV-24, and CYASORB® UV-531 available from Cytec Industries, Incorporated of West Paterson, N.J.
  • metal catalysts examples include dibutyltin dilaurate and dibutyltin diacetate, both available from Air Products and Chemicals Inc. of Allentown, Pa.
  • desiccants include molecular sieves (commercially available from W. R. Grace of Columbia, Md.), oxazolidenes (available from Dow Chemical Corp. of Midland, Mich.) and calcium oxide (commercially available from Mississippi Lime of St. Louis, Mo.).
  • plasticizer is included in the formulation to ensure that there is adequate flexibility in the flexible member such that it can conform to a slightly irregular roofing surface.
  • plasticizers include dioctyl phthalate (DOP), diisodecyl phthalate (DIDP), and diisononyl phthalate (DINP), available from Alfa Aesar, of Ward Hill, Mass.
  • isocyanates include allophanate-modified MDI, uretonimine-modified MDI, dimer-modified MDI, and mixed isomers of MDI, available from Bayer, BASF, Huntsman Chemical, and Dow Chemical.
  • part A and part B each contain a different color dye or pigment in a range of up to 4% by weight.
  • the two pigments create a new color indicative of proper blending of part A and part B.
  • the new color of the filling sealant is preferably substantially the same as a color of the flexible member.
  • a primary color pigment and a secondary color pigment are used, or a secondary or a primary color pigment may also be used with white pigment.
  • Primary color pigments in subtractive color systems are typically cyan, magenta, and yellow.
  • Secondary color pigments in subtractive color systems are typically violet, orange, and green.
  • part A may contain a red pigment and part B may contain a white pigment and upon mixing the composition has a pink color. It should be appreciated that other colors may be employed without departing from the scope of the present invention.
  • a generally rectangular flexible member 310 is shown on an imperfectly flat roof 302 in accordance with an embodiment of the present disclosure.
  • the flexible member 310 includes four corner pieces 312 , two short extension pieces 314 , and two long extension pieces 316 .
  • Each piece has a substantially triangular cross section and includes a first mating surface 320 , a second mating surface 322 opposing the first mating surface 320 , and a third mating surface 324 opposing the roof 302 .
  • the first mating surface 320 includes a projection 330 that extends substantially perpendicular to the first mating surface 320 and has an end that extends in a plane that is substantially parallel to the first mating surface 320 .
  • the second mating surface 322 has a recess 332 configured to receive the projection 330 .
  • the projection 330 has a trapezoidal shape, however other shapes may be used without departing from the scope of the present disclosure.
  • the flexible body member 310 may conform to slight changes of direction on the roof 302 .
  • the flexible member 310 conforms to an arced portion 334 of roof 302 .
  • Arced portion 334 of roof 302 is generally an overlap section or standard irregularity in the roof. The overlap section is a part of a roof, whether built-up or single ply, that is raised above the plane of the main body of the roof.
  • the flexible member 310 is adhered to the roof 302 by an adhesive 336 .
  • the adhesive 336 is the same composition as the flexible member or the filling sealant as shown in table 1. However, the adhesive 336 may be any sealant or adhesive suitable for adhering sealant assemblies to a roof 302 .
  • the flexible member 410 has a generally square shape; however, the flexible member 410 may have other shapes without departing from the scope of the present disclosure.
  • the flexible member 410 includes a unitary body piece 412 having a generally triangular cross section. The hypotenuse of the generally triangular cross section is coextensive with the outer face 440 of the unitary body piece 412 .
  • the outer face 440 directs water away from the juncture between the flexible member 410 and the roof to which it is sealed by allowing the water to build lateral momentum as it travels down the outer face 440 .
  • the outer face 440 includes a rounded lower edge 442 and a rounded upper edge 444 .
  • the flexible member 410 includes a first mating surface 420 and a second mating surface 422 .
  • the first mating surface 420 includes a projection 430 that extends substantially perpendicular to the first mating surface 420 and has an end 431 that extends in a plane that is substantially parallel to the first mating surface 420 .
  • the projection 430 has a trapezoidal shape, however other shapes may be used without departing from the scope of the present disclosure.
  • the second mating surface 422 has a recess 432 including an interference portion 433 configured to receive the projection 430 .
  • the interference portion 433 of the recess 432 engages the end 431 of the projection 430 , resisting axial separation of the first mating surface 420 and the second mating surface 422 .
  • the projection 430 is preferably inserted into the recess 432 along an axis B.
  • the first mating surface 420 and the second mating surface 422 may be pulled apart along a separation arc A.
  • the first mating surface 420 and the second mating surface 422 are separated by a separation distance 450 and are separable by a maximum separation distance 452 .
  • the maximum separation distance 452 is greater than a width or dimension of the projection the flexible member 410 is to encompass.
  • a bead of adhesive 535 is disposed in the recess 532 .
  • a method of sealing an interface between a roof projection and a roof using a flexible member including a unitary body piece will now be described.
  • the roof is first cleared of loose gravel, dirt, granules, or other foreign substances that may interfere with adhesion between a filling sealant and the roof.
  • a first mating surface and a second mating surface of the unitary body piece are separated by an amount corresponding to a dimension of the projection.
  • the unitary body piece is placed around the roof projection by passing the roof projection between the first mating surface and the second mating surface.
  • a mark is traced around the edges of the unitary body piece, and the unitary body piece is removed from around the roof projection.
  • An interface between the roof projection and the roof is sealed with a sealant, and a bead of sealant is applied to the inside of the traced mark.
  • a bead of sealant is then applied within a recess of the second mating surface.
  • the unitary body piece is then placed around the roof projection, and a projection on the first mating surface is engaged with the recess on the second mating surface.
  • the engaged unitary body piece is then placed onto the bead of sealant on the roof and pressure is applied.
  • excess sealant is removed from the outside of the unitary body piece.
  • a test amount of a filling sealant is preferably dispensed to confirm a proper mix of components comprising the filling sealant.
  • the sealant pocket created by the unitary body piece is then filled with the filling sealant.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Sealing Material Composition (AREA)
US12/503,757 2005-05-13 2009-07-15 Sealant assemblies and methods Abandoned US20100011685A1 (en)

Priority Applications (4)

Application Number Priority Date Filing Date Title
US12/503,757 US20100011685A1 (en) 2005-05-13 2009-07-15 Sealant assemblies and methods
PCT/US2010/041494 WO2011008642A1 (en) 2009-07-15 2010-07-09 Sealant assemblies and methods
EP10800355.9A EP2454424A4 (de) 2009-07-15 2010-07-09 Dichtungsmittelbaugruppen und verfahren dafür
CA2767951A CA2767951A1 (en) 2009-07-15 2010-07-09 Sealant assemblies and methods

Applications Claiming Priority (2)

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US11/128,779 US20060272249A1 (en) 2005-05-13 2005-05-13 Sealant assemblies and methods
US12/503,757 US20100011685A1 (en) 2005-05-13 2009-07-15 Sealant assemblies and methods

Related Parent Applications (1)

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US11/128,779 Continuation-In-Part US20060272249A1 (en) 2005-05-13 2005-05-13 Sealant assemblies and methods

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US20100011685A1 true US20100011685A1 (en) 2010-01-21

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US (1) US20100011685A1 (de)
EP (1) EP2454424A4 (de)
CA (1) CA2767951A1 (de)
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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110203201A1 (en) * 2010-02-19 2011-08-25 Lechuga Gabriel V Insulated pipe and duct mounting arrangement
US20120208957A1 (en) * 2009-07-02 2012-08-16 Adco Products, Inc. Two-part foamable adhesive with renewable polyol
US8875455B1 (en) * 2014-05-28 2014-11-04 Zep Solar, Llc Ramp mounting system for a flat roof solar array
US20180298610A1 (en) * 2016-07-27 2018-10-18 Gabriel V. Lechuga Wall Mounted Receiver
TWI663929B (zh) * 2014-03-31 2019-07-01 羅恰 傑拉爾德 可展開接觸扣件

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Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20120208957A1 (en) * 2009-07-02 2012-08-16 Adco Products, Inc. Two-part foamable adhesive with renewable polyol
US20110203201A1 (en) * 2010-02-19 2011-08-25 Lechuga Gabriel V Insulated pipe and duct mounting arrangement
US9091377B2 (en) * 2010-02-19 2015-07-28 Gabriel V. Lechuga Insulated pipe and duct mounting arrangement
US10422134B2 (en) * 2010-02-19 2019-09-24 Gabriel V. Lechuga Wall mounted receiver
TWI663929B (zh) * 2014-03-31 2019-07-01 羅恰 傑拉爾德 可展開接觸扣件
US8875455B1 (en) * 2014-05-28 2014-11-04 Zep Solar, Llc Ramp mounting system for a flat roof solar array
US8984819B1 (en) * 2014-05-28 2015-03-24 Zep Solar, Llc Ramp mounting system for a flat roof solar array
WO2015183971A1 (en) * 2014-05-28 2015-12-03 Solarcity Corporation Ramp mounting system for a flat roof solar array
US20180298610A1 (en) * 2016-07-27 2018-10-18 Gabriel V. Lechuga Wall Mounted Receiver
US10151112B2 (en) * 2016-07-27 2018-12-11 Gabriel V. Lechuga Wall mounted receiver

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EP2454424A1 (de) 2012-05-23
WO2011008642A1 (en) 2011-01-20
CA2767951A1 (en) 2011-01-20
EP2454424A4 (de) 2016-12-07

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