United States Patent
`Mayle
`
`[19]
`
`US006021616A
`[11] Patent Number:
`[451 Date of Patent:
`
`6,021,616
`*Feb. 8, 2000
`
`[54]
`
`[76]
`
`ROOFING MEMBRANE WITH EXTERNAL
`TABS
`
`Inventor: Robert L. Mayle, 2047 Hyde Rd., Port
`Clinton, Ohio 43452
`
`[ * ] Notice:
`
`This patent is subject to a terminal dis-
`claimer.
`
`[21] Appl. No.: 09/173,054
`
`[22] Filed:
`
`Oct. 15, 1998
`
`Related U.S. Application Data
`
`[60] Continuation of application No. 09/063,550, Apr. 21, 1998,
`Pat. No. 5,850,719, which is a division of application No.
`08/679,682, Jul. 11, 1996, Pat. No. 5,775,052.
`
`Int. Cl.7 ........................................................ E04B 7/00
`[51]
`[52] U.S. Cl .............................. 52/408; 52/58; 52/746.11;
`52/557
`[58] Field of Search .................................... 52/746.11, 96,
`52/58, 60, 408, 409, 748.1,748.11, 521,
`557, 559
`
`[56]
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
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`4,603,517
`8/1986
`
`Blair et al ........................ 52/746.11 X
`Moeller ..................................... 52/521
`Peebles
`................................. 52/553 X
`Buckner .................................... 52/543
`White ................................. 52/748.1 X
`Freeman ...................................... 52/58
`Shearer .............................. 52/748.1 X
`Simpson ................................. 52/60 X
`Evans ........................................ 52/553
`Hinds ........................................ 52/521
`Coppola, Jr. .............................. 52/410
`Lyons, Jr ..................................... 52/60
`
`Vandemore ................................. 52/60
`1/1987
`4,635,409
`Sullivan ........................... 52/746.11 X
`6/1987
`4,671,036
`Triplett et al ............................. 52/408
`4,712,348 12/1987
`Russell et al ............................. 52/409
`4,718,211
`1/1988
`Janni ....................................... 52/58 X
`4,799,986
`1/1989
`Kelly ......................................... 52/410
`4,860,514
`8/1989
`Hart et al .................................. 52/409
`4,870,796 10/1989
`Janni ........................................... 52/58
`4,872,296 10/1989
`Purcell et al ......................... 52/410 X
`5,027,572
`7/1991
`Batch et al ............................. 52/58 X
`5,031,374
`7/1991
`Magid ......................................... 52/58
`5,065,553 11/1991
`McGady ...................................... 52/58
`5,077,943
`1/1992
`Ball ............................................. 52/62
`5,218,793
`6/1993
`Lassiter ..................................... 52/408
`5,365,709 11/1994
`Clapp et al ............................... 52/408
`9/1995
`5,452,553
`Balkins .............................. 52/748.1 X
`5,570,553 11/1996
`Tawzer .................................... 52/96 X
`5,586,414 12/1996
`Mayle ......................................... 52/60
`5,706,610
`1/1998
`Mayle
`.................................. 52/746.11
`5,775,052
`7/1998
`12/1998 Mayle ....................................... 52/408
`5,850,719
`
`OTHER PUBLICATIONS
`
`GenFlex Product Details for Field Fabricated Outside Cor-
`ner.
`Jan. 1, 1993, Technical product literature from Duro-Last,
`Inc.
`
`Primary Examiner~caura A. Callo
`Attorney, Agent, or Firm~tandley & Gilcrest LLP
`
`[571
`
`ABSTRACT
`
`A roofing membrane for installation on a roof or parapet.
`Tabs are affixed to the outside of the roofing material which
`fold back to allow insertion of a fastener. The ends of the
`roofing material are first fastened to the roof or parapet to be
`covered. The intervening portion of the roofing material is
`then fastened. The tabs affixed to the outside of the roofing
`material cover the fasteners and can be sealed shut to
`waterproof the roofing material.
`
`4 Claims, 2 Drawing Sheets
`
`~64
`
`62
`
`78
`
`66
`
`72
`
`///
`
`FAST FELT 2019, pg. 1
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Feb. 8,2000
`
`Sheet 1 of 2
`
`6,021,616
`
`I
`
`12
`
`62
`
`6O
`
`IIO
`
`72
`
`90
`
`84
`
`5O
`
`2O
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`I0
`
`///
`
`///
`
`Fig. I
`
`(PRIOR ART)
`
`Fig.
`
`FAST FELT 2019, pg. 2
`Owens Coming v. Fast Felt
`IPR2015-00650
`
`

`
`U.S. Patent
`
`Feb. 8,2000
`
`Sheet 2 of 2
`
`6,021,616
`
`Ii
`
`FAST FELT 2019, pg. 3
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`6,021,616
`
`1
`ROOFING MEMBRANE WITH EXTERNAL
`TABS
`
`This application is a continuation of application Ser. No.
`09/063,550, filed Apr. 21, 1998, now U.S. Pat. No. 5,850, 5
`719 which is a divisional of application Ser. No. 08/679,682,
`filed Jul. 11, 1996 now U.S. Pat. No. 5,775,052.
`
`BACKGROUND AND SUMMARY OF THE
`INVENTION
`
`This invention relates to a method of attaching roofing
`material in sheet form to horizontal roof decks (substrates)
`and vertically extending roof structures or walls (i.e.,
`parapet) requiring less manpower and time-consumption,
`while achieving the desired result of securely attaching
`roofing material that is water-tight and wind-resistant.
`Known methods of installing roofing material are time-
`consuming and require the use of two or more installers. In
`known methods, tabs are attached to the inside surface of the
`roofing material. Each tab is installed to the roofing material
`via a fastener, or anchor (e.g., a screw, nail, or any other
`equivalent fastening means). A fastener is driven through the
`tab and into the roofing substrate thereby securely attaching
`the material to the roof. The first fastener is installed on the
`horizontal roof substrate just before the material makes a
`right angle turn to climb the parapet. One or more installers
`are required to hold the roofing material up, or away, from
`the roof substrate and/or the parapet while another worker is
`required to pull the tab taut against the roof substrate. In this
`position, an additional worker can then fasten the tab to the
`roof substrate. As discussed, this process requires at least
`two to three workers. Additionally, this method requires a
`significant amount of time as the process is inherently
`cumbersome. Accordingly, a new and reliable process of
`installing roofing material is needed which can be performed
`by one installer, thereby significantly decreasing the cost and
`time of installing roofing material.
`The method of the present invention for installing roofing
`material involves the use of a roof membrane which is
`comprised of a sheet of roofing material which may have
`tabs affixed to its outer surface. The ends of the roofing
`material are first fastened to the wall or roof substrate to be
`covered. The ends of the roofing material are fastened by
`tabs which are affixed to the underside of the roofing
`material. The portions of the roofing material between the
`fastened ends are fastened to the wall or roof substrate by
`installing fasteners directly through the roofing material into
`the wall or roof substrate to be covered. Tabs are affixed to
`the outer surface of the roofing material which can be folded
`back so that fasteners can be installed directly through the
`roofing material. Once fastened, the tabs can be folded back
`into place to cover the fasteners. The tabs may then be
`welded, or otherwise sealed, shut so that the roofing material
`is protected from rain, water, and other elements. The
`present method of installing roofing material saves signifi-
`cant time since the tabs affixed to the outside surface allow
`the roofing material to be fastened by one worker (there is
`no need for another worker to lift and hold the roofing
`material while fastening). Additionally, the roof membrane
`of the present invention can be pulled taut one sheet at a
`time, whereas the known methods require each tab to be
`pulled taut for each intervening tab.
`In addition to the features mentioned above, objects and
`advantages of the present invention will be readily apparent
`upon a reading of the following description.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`Novel features and advantages of the present invention, in
`addition to those mentioned above, will become apparent to
`
`2
`those skilled in the art from a reading of the following
`detailed description in conjunction with the accompanying
`drawings wherein similar reference characters refer to simi-
`lar parts and in which:
`
`FIG. 1 is a cross-sectional view of a parapet showing the
`installation of roofing material on a parapet and a portion of
`the horizontal roof deck substrate using a known method;
`
`FIG. 2 is a cross-sectional view of a parapet showing the
`installation of roofing material on a parapet and a portion of
`the horizontal roof deck substrate according to the method of
`this invention;
`FIG. 3 is a cross-sectional view of roof layer showing the
`installation of roofing material on a horizontal roof deck
`substrate using a method known in the art;
`
`FIG. 4 is a cross-sectional view of a roof layer showing
`the installation of roofing material on a horizontal roof deck
`substrate according to the method of this invention;
`
`10
`
`15
`
`2O
`
`FIG. 5 is a cross-sectional view of a plate and fastener in
`use in fastening the roofing material to the roof substrate;
`and
`
`FIG. 6 is a cross-sectional view of a fastener in use in
`fastening the roofing material to a parapet.
`
`25
`
`3o
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENT
`
`The preferred system herein described is not intended to
`be exhaustive or to limit the invention to the precise forms
`disclosed. They are chosen and described to explain the
`principles of the invention, and the application of the method
`to practical uses, so that others skilled in the art may practice
`the invention.
`
`FIG. 1 illustrates the installation of roofing material on a
`35 wall (or parapet) using a method known in the art whereby
`the first fastener is installed at 10 and subsequent fasteners
`are installed in sequence at predetermined intervals 20, 30,
`40 and 50. All fasteners are inserted through tabs which are
`attached to the underside surface of the roofing material
`4o closest to the roof or wall being covered. (Reference number
`12 refers to a tab on the underside surface of a known roofing
`material.) These previously known methods of roofing
`require at least two workers to install the roofing material.
`For proper installation, since all the tabs of the known
`45 roofing materials are located on the underside of the roofing
`material, at least one worker is needed to pull the roofing
`material taut against the roof substrate and/or the wall to be
`covered, while another worker must position himself so as
`to be able to insert a fastener through the tab and drive the
`50 fastener into the roof substrate or wall. (An additional
`worker is often needed to hold the roofing material up or
`away from the worker pulling the tab.)
`The method of roofing of the present invention may be
`accomplished with a pre-fabricated sheet of roof membrane
`55 92 of the present invention. A pre-fabricated sheet of roof
`membrane 92 is comprised of: a sheet of roofing material 62;
`tabs 74, 76 affixed to the underside surface 78 of the roofing
`material 62; and tabs 84 affixed to the exterior surface 72 of
`the roofing material 62, where the tabs 74, 76, 84 are
`6o positioned at a predetermined distance in relation to each
`other. Additionally, as illustrated in FIGS. 2 and 4, the tabs
`84 affixed to the exterior surface 72 of the roofing material
`62 are placed along a length of the roofing material 62 and
`between the tabs 74, 76 affixed to the underside surface 78
`65 of the sheet of roofing material 62.
`The length and width of the pre-fabricated sheet of roof
`membrane 92 will vary based on the width or height of the
`
`FAST FELT 2019, pg. 4
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`6,021,616
`
`roofing surface. The sheet of roof membrane 92 can also be
`standardized to a no material waste standard size that a
`contractor can fit in the center of a roof, while making the
`appropriate fitting measurements at the perimeters of the
`roof. This process will standardize the sheets and cut mate-
`rial costs. Various known materials can be used to manu-
`facture the sheet of roof membrane 92 of the present
`invention.
`FIG. 2 illustrates the installation of a roof membrane 92
`onto a parapet (or wall 66) using the method of this
`invention. The first fastener is installed at 60 and the second
`at 70 using via the tabs 74, 76 attached to the underside of
`the material 62. A predetermined number of intervening
`fasteners are installed directly through the roofing material
`62 into the wall 66 at 80, 90, 100 and 110. (The number of
`intervening fasteners required may vary depending on the
`particular installer, the thickness and length of the roofing
`material 62, and the type of roofing material 62 and fastener
`used.) Once the intervening fasteners are driven into the wall
`66, tabs 84, or plates, affixed to the exterior surface 72 of the
`roofing material 62, are folded down on the fasteners. The
`perimeters of the tabs 84 are then field-welded, or otherwise
`sealed, closed to prevent moisture from penetrating the hole
`made by the fastener.
`Referring to FIG. 2 in more detail, the roofing method of
`the present invention is accomplished by: first fastening the
`roof membrane 92 of the present invention to the top 64 of
`a wall 66; then fastening the roofing material 62 at a location
`68 near the bottom of the wall 66; and then fastening the
`roofing material 62 to the intervening portion of the wall 66
`by fastening means, where the fastening means securing the
`intervening portion of the roofing material 62 are installed
`directly through the exterior surface 72 of the roofing
`material 62 and into the wall 66. The intervening portion of
`the wall 66 merely refers to the portion of the wall 66
`between the top 64 and bottom areas 68 of the wall 66. The
`location 68 near the bottom of the wall where the roofing
`material 62 is fastened is preferably a portion of the roof
`substrate 82 just beyond the point where the wall 66 and the
`roof substrate 82 meet (e.g., tab 76 in FIG. 2).
`The roofing material 62 is fastened to the top 64 of the
`wall 66 and to a location 68 near the bottom of the wall 66
`by installing a fastening means through the tabs 74, 76
`affixed to the underside surface 78 of the roofing material 62.
`The present method of roofing can be performed by one
`worker. For example, once the tab 74 is secured at the top 64
`of the wall 66, the worker may allow the roofing material 62
`to hang down to the bottom of the wall 66. When a screw,
`or fastener, is installed at the location 68 near the bottom of
`the wall 66, the roofing material 62 will draw taut. Since the
`fastening means securing the intervening portion of the
`roofing material 62 is installed directly through the exterior
`surface 72 of the roofing material 62, an additional worker
`is not required to lift and hold, or pull, the roofing material
`62 while the fastening means is installed.
`As illustrated in FIGS. 2 and 4, the roofing material 62 of
`the present invention is comprised of tabs affixed to the
`exterior surface 72 of the roofing material 62. The tabs 84
`may be folded back so that a fastener can be installed
`directly through the roofing material 62. (The arrow 101 in
`FIG. 2 shows the direction in which the tab 84 at location
`100 may be folded back.) The roofing material 62 may be
`fastened to the intervening portion of the wall 66 by first
`folding back the tabs 84 before installing the fastening
`means directly through the exterior 72 surface of the roofing
`material 62 and into the wall 66. Subsequently, the tabs 84
`
`5
`
`4
`may be folded back into position to cover the fastening
`means. The tabs 84 may be welded, or otherwise sealed (e.g.
`by glue), shut for purposes of waterproofing the roofing
`material 62.
`Once the wall 66 (or parapet) is covered with the roofing
`material 62, the roof substrate 82 may also be similarly
`covered. FIG. 3 illustrates the known method of installing
`roofing material on a horizontal roof substrate. The known
`roofing method is accomplished by fastening the roofing
`s0 material at locations 120, 122, 124, 126, 128, and 132
`whereby all fasteners are inserted through tabs located on
`the interior surface of the roofing material. The fasteners are
`then driven into the roof substrate 82. Again, as discussed
`above, these known roofing methods require at least two to
`25 three workers to complete; one for holding back the roofing
`material, another for pulling the tab taut, and an additional
`worker for fastening the roofing material to the substrate.
`FIG. 4 illustrates another embodiment of the present
`invention showing the installation of a roof membrane 92 on
`2o a roof substrate 82 according to the method of this invention.
`
`Normally, the roof substrate 82 will be in the horizontal
`plane. If the roof substrate 82 is connected to a wall 66 (or
`parapet) which has been covered with the roof membrane
`92, as discussed above, the fastener at 70 will already have
`25 been installed (see FIG. 5). In this instance, the roofing
`
`material 62 would then be fastened to the roof substrate 82
`at location 134 (or at the far end of the roof substrate 82 in
`relation to the wall 66). The roofing material 62 would then
`be fastened to the intervening portion of the roof substrate 82
`3o as will be described below.
`
`40
`
`The roof substrate 82 can also be covered with a roof
`membrane 92 by the method of the present invention,
`independently of the covering of an attached wall 66, if any.
`35 The roofing material 62 is first fastened to the roof substrate
`82 at one end (either location 70 or 134) of the roofing
`material 62. The roofing material 62 is then fastened to the
`roof substrate 82 at the second end (either 70 or 134
`whichever has not yet been fastened) of the roofing material
`62. Once the ends 70, 134 have been fastened, the roofing
`material 62 is fastened to the intervening portion of the roof
`substrate 82 by fastening means installed directly through
`the roofing material 62 and into the roof substrate 82.
`(Again, the intervening portion of the roof substrate 82 is
`45 merely the portion of the roof substrate 82 between the end
`locations 70, 134.)
`Again, as illustrated in FIGS. 2 and 4, the roof membrane
`92 is comprised of roofing material 62 which is further
`comprised of tabs 84 placed on its exterior surface 72. The
`50 tabs 84 may be folded back to expose the exterior surface 72
`of the roofing material 62. The roofing material 62 may be
`fastened to the intervening portion of the roof substrate 82
`by first folding back the tabs 84 before installing the
`fastening means directly through the roofing material 62 and
`55 into the roof substrate 82. Subsequently, the tabs 84 can then
`be folded back into position to cover the fastening means.
`The tabs 84 may then be field-welded, or otherwise sealed,
`shut for purposes of waterproofing the roofing material 62.
`All remaining fasteners at locations 136, 138, and 140 may
`6o be installed according to this method. Accordingly, the
`method of the present invention saves considerable time and
`money from the known roofing techniques by enabling one
`worker to pull the roofing material 62 taut one-time per sheet
`as opposed to one tab at a time.
`FIG. 4 illustrates a roof layer, or deck sheet 94 (i.e., a roof
`substrate 82 which has been covered with a prefabricated
`sheet of roof membrane 92) of the present invention. The
`
`65
`
`FAST FELT 2019, pg. 5
`Owens Corning v. Fast Felt
`IPR2015-00650
`
`

`
`6,021,616
`
`deck sheet 94, is comprised of a roof substrate 82 and a sheet
`of roof membrane 92 covering the roof substrate 82. The
`roof substrate 82 may be comprised of a deck layer 96 and
`an insulation layer 98.
`FIGS. ~ and 6 illustrate cross-sectional views of different 5
`types of fasteners, in use, that may be used to fasten the
`roofing material 62 to a roof substrate 82 or wall 66.
`Having shown and described a preferred embodiment of
`the invention, those smiled in the art will realize that many
`variations and modifications may be made to affect the
`described invention and still be within the scope of the
`claimed invention. Thus, many of the elements indicated
`above may be altered or replaced by different elements
`which will provide the same result and fall within the spirit
`of the claimed invention. It is the intention, therefore, to 25
`limit the invention only as indicated by the scope of the
`claims.
`What is claimed is:
`1. A roof membrane, comprised of:
`a sheet of roofing material;
`at least one tab affixed to an underside surface of said
`sheet of roofing material;
`at least one tab affixed to an exterior surface of said sheet
`of roofing material, wherein said tab affixed to an 25
`exterior surface of said sheet of roofing material is
`
`2O
`
`adapted to be folded away from said roofing material to
`allow the installation of a fastener through said roof
`membrane and wherein said tab affixed to an exterior
`surface may be welded to said roofing material to cover
`said fastener installed through said roof membrane.
`2. Aroof membrane according to claim 1, wherein said tab
`affixed to an exterior surface of said sheet of roofing material
`is adapted to be heat welded to said sheet of roofing material.
`3. A roof membrane according to claim 1 wherein said
`tabs are placed along a length of said roofing material.
`4. A roof membrane, comprised of:
`a sheet of roofing material;
`at least one tab affixed to an exterior surface of said sheet
`of roofing material, wherein said tab is adapted to be
`folded away from said roofing material to allow the
`installation of a fastener through said roof membrane
`and wherein said tab is adapted to allow welding of said
`tab to said roofing material to cover said fastener
`installed through said roof membrane; and
`a tab fixed to an underside portion of said roofing
`material, said tab fixed to an underside portion of said
`roofing material being attached to an end of said sheet
`of roofing material.
`
`FAST FELT 2019, pg. 6
`Owens Corning v. Fast Felt
`IPR2015-00650