[특허]Panelized roofing system and method

Huber Engineered Woods LLC

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특허 상세정보

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내보내기 페이스북 공유 트위터 공유 카카오톡 공유

Panelized roofing system and method

특허상세정보
국가/구분	United States(US) Patent 등록
국제특허분류(IPC7판)	E04B-002/02 E04D-006/00
미국특허분류(USC)	052/789.1; 052/408; 052/177; 052/417
출원번호	UP-0029293 (2005-01-04)
등록번호	US-7721506 (2010-06-14)
발명자 / 주소	Bennett, John L. Barker, Joel F. Jordan, Rick D. Schuman, Thomas L. Ou, Nian Swiacki, Neil C.
출원인 / 주소	Huber Engineered Woods LLC
대리인 / 주소	Ades, Patricia L.
인용정보	피인용 횟수 : 11 인용 특허 : 46

초록
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The panelized roof sheathing construction system includes a plurality of panels attached to a building frame structure in substantially abutting relationship. Each panel includes a water resistant barrier layer secured atop the outward facing surface of the panel. The water resistant barrier layer includes a skid resistant surface. Joints between panels are sealed by strips of water resistant tape or the like. The panels are made of lignocellulosic material. The water resistant and skid resistant surface may include indicia for aligning strips of tape or for aligning fasteners. A method for manufacturing the water resistant building panels is also disclosed and includes the steps of feeding a roll of paper onto a forming belt, depositing lignocellulosic material and the binding agent onto the forming belt so as to form a lignocellulosic mat, cutting the mat and paper into segments of predetermined lengths, transferring the segments onto a loading screen, subjecting the segments to heat and pressure so as to impart the skid resistant surface on the paper, and cutting the segments into panels of predetermined sizes. A method of drying-in a building using the panels of the invention is also contemplated.

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What is claimed is: 1. A panelized roof sheathing construction system for a building comprising: building frame structure; a plurality of wood or wood composite panels attached to said frame structure in substantially abutting relationship so as to form joints therebetween, each one of said plurality of panels further comprising a first inward facing surface, a second outward facing surface and a peripheral edge; each one of said plurality of panels comprising a substantially bulk water resistant barrier layer secured to at least the second outward facing surface of said panel by an adhesive layer, said plurality of substantially bulk water resistant barrier layer further comprising a substantially skid resistant embossed textured outward facing surface; a plurality of water-resistant sealing means, each of said means sealing at least one of said joints between adjacent panels; and wherein said panels with substantially bulk water resistant barrier layers are characterized by a water permeability in the range from about 0.1 U.S. perms to about 1.0 U.S. perms as determined by ASTM E96 procedure A, and further wherein said panels with substantially bulk water resistant barrier layers are characterized by a water vapor transmission rate from about 0.7 to about 7 grams/m2/24 hrs as determined by ASTM E96 procedure A (at 73° F.—50% RH), a water vapor permeability from about 0.1 to about 12 perms as determined by ASTM E96 procedure B (at 73° F.—100% RH), and a liquid water transmission rate from about 1 to about 28 grams/100 in2/24 hrs via Cobb ring according to the test method described in ASTM D5795. 2. The panelized roof sheathing construction system of claim 1 wherein said skid resistant textured outward facing surface comprises a plurality of major textured features and a plurality of minor textured features. 3. The panelized roof sheathing construction system of claim 2 wherein said plurality of major textured features are disposed in a first direction and wherein said plurality of minor textured features are disposed in a second direction. 4. The panelized roof sheathing construction system of claim 3 wherein each of said plurality of major textured features is larger than each of said plurality of minor textured features. 5. The panelized roof sheathing construction system of claim 4 wherein said plurality of major textured features comprise a plurality of major channels and wherein said plurality of minor textured features comprises a plurality of minor indentations. 6. The panelized roof sheathing construction system of claim 3 wherein said first direction and said second direction are substantially orthogonal to one another. 7. The panelized roof sheathing construction system of claim 5 wherein said major channels are substantially parallel. 8. The panelized roof sheathing construction system of claim 5 wherein said major channels are continuous. 9. The panelized roof sheathing construction system of claim 5 wherein said major channels are discontinuous. 10. The panelized roof sheathing construction system of claim 5 wherein said major channels are characterized by an undulating configuration. 11. The panelized roof sheathing construction system of claim 5 wherein said major channels have a width of about 0.1694 cm (0.0667 inches) to about 0.508 cm (0.200 inches). 12. The panelized roof sheathing construction system of claim 5 wherein said major channels have a depth of about 5 to about 20 mils. 13. The panelized roof sheathing construction system of claim 5 wherein said plurality of minor indentations are disposed substantially orthogonally with said major channels. 14. The panelized roof sheathing construction system of claim 13 wherein said minor indentations have a substantially elongated configuration. 15. The panelized roof sheathing construction system of claim 13 wherein said minor indentations are of a length of about 0.0508 cm (0.020 inches) to about 0.254 cm (0.100 inches). 16. The panelized roof sheathing construction system of claim 13 wherein said minor indentations are of a width of about 0.0254 cm (0.010 inches) to about 0.254 cm (0.100 inches). 17. The panelized roof sheathing construction system of claim 13 wherein said minor indentations are of a density of about 10 to about 35 indentations per inch as measured in a direction parallel with said major channels. 18. The panelized roof sheathing construction system of claim 13 wherein said minor indentations are at least partially disposed on one or more of a corresponding major channel. 19. The panelized roof sheathing construction system of claim 1 wherein one or more of said plurality of panels is comprised of reconstituted lignocellulosic furnish. 20. The panelized roof sheathing construction system of claim 19 wherein one or more of said plurality of panels further comprises a structural panel. 21. The panelized roof sheathing construction system of claim 20 wherein one or more of said plurality of panels further comprises oriented strand board. 22. The panelized roof sheathing construction system of claim 20 wherein one or more of said plurality of panels is comprised of plywood. 23. The panelized roof sheathing construction system of claim 19 wherein one or more of said plurality of panels is comprised of particleboard. 24. The panelized roof sheathing construction system of claim 19 wherein one or more of said plurality of panels is comprised of medium density fiber board. 25. The panelized roof sheathing construction system of claim 20 wherein one or more of said plurality of panels is comprised of waferboard. 26. The panelized roof sheathing construction system of claim 1 wherein said plurality of water-resistant sealing means comprises a plurality of strips of water-resistant tape, said strips of tape comprising a backing and an adhesive layer and further wherein the thickness of said backing is from about ½ to about 1/30 the thickness of said adhesive layer. 27. The panelized roof sheathing construction system of claim 1 wherein said plurality of strips of water-resistant tape comprises a backing of a thickness of about 1.0 mils to about 4.0 mils and an adhesive layer disposed on said backing of a thickness of about 2.0 mils to about 30.0 mils. 28. The panelized roof sheathing construction system of claim 26 wherein said strips of tape have a dry coefficient of friction of at least about 0.6. 29. The panelized roof sheathing construction system of claim 1 wherein each of said panels is of a thickness in a range from about 0.635 cm (0.25 inches) to about 3.175 cm (1.25 inches). 30. The panelized roof sheathing construction system of claim 1 wherein each of said barrier layers substantially covers the entire outward facing surface of a corresponding one of said panels. 31. The panelized roof sheathing construction system of claim 29 wherein said barrier layers are comprised of a paper having a dry weight of about 75.05 g/m2 (16 lbs./msf) to about 365.85 g/m2(75 lbs./msf). 32. The panelized roof sheathing construction system of claim 31 wherein said paper comprises resin-impregnated paper having a resin content up to about 80% by dry weight, in a preferred range of about 20% to about 70% by dry weight. 33. The panelized roof sheathing construction system of claim 1 wherein said water resistant barrier layer further comprises an applied coating layer. 34. The panelized roof sheathing construction system of claim 33 wherein said coating layer comprises an acrylic resin. 35. The panelized roof sheathing construction system of claim 33 wherein said coating layer comprises an asphalt base. 36. The panelized roof sheathing construction system of claim 1 wherein said system further comprises a UV-resistant overlay. 37. The panelized roof sheathing construction system of claim 1 wherein one or more of said plurality of panels further comprises a radiant reflective layer. 38. The panelized roof sheathing construction system of claim 32 wherein said resin impregnated paper comprises a glueline layer in a range up to about 243.90 g/m2(50 lbs./msf). 39. The panelized roof sheathing construction system of claim 38 wherein said resin-impregnated paper comprises a glueline layer of a preferred range from about 9.75 g/m2 (2 lbs./msf) to about 58.53 g/m2(12 lbs./msf). 40. The panelized roof sheathing construction system of claim 39 where said glueline layer comprises at least one of a phenol-formaldehyde resin, a hot-melt, and a PVA resin. 41. The panelized roof sheathing construction system of claim 39 where said glueline layer is isocyanate based. 42. The panelized roof sheathing construction system of claim 26 wherein each of said strips of tape is applied by a tape applicator to at least one joint between adjacent panels to form a substantially moisture-resistant seam. 43. The panelized roof sheathing construction system of claim 42 wherein at least some of said strips of tape form a moisture-resistant seam with roofing accessory materials. 44. The panelized roof sheathing construction system of claim 32 wherein said barrier layers are adapted to receive fasteners in a substantially moisture resistant manner. 45. The panelized roof sheathing construction system of claim 1 wherein said water-resistant barrier layer comprises a textured surface, said textured surface adapted to provide a wet coefficient of friction that is substantially the same or better than the dry coefficient of friction of said textured surface. 46. The panelized roof sheathing construction system of claim 1 wherein said textured surface is adapted to provide a wet coefficient of friction in a range of from about 0.8 to about 1.1 as measured by an English XL Tribometer per ASTM F1679-04 and said textured surface adapted to provide a dry coefficient of friction of at least about 0.8 as measured by an English 5 XL Tribometer per ASTM F1679-04. 47. The panelized roof sheathing construction system of claim 1 wherein said skid-resistant surface is an anti-skid coating. 48. The panelized roof sheathing construction system of claim 1 wherein adjacent panels are linked together via at least one of a tongue and groove configuration, a ship lap configuration, an H-clip configuration, or a mating square edge configuration. 49. The panelized roof sheathing construction system of claim 46 wherein a first edge of a panel is parallel with a corresponding second edge of a panel, each of said first and second edges having contiguous sections of equal length, each section having a groove and a tongue compatible with a corresponding groove and tongue. 50. The panelized roof sheathing construction system of claim 49 wherein the length of the first edge of each panel is a multiple of the length of a section. 51. The panelized roof sheathing construction system of claim 50 wherein the length of the tongue in each section measured in the longitudinal direction of an edge is less than or equal to the length of the grooves in each section. 52. The panelized roof sheathing construction system of claim 51 wherein a third edge and a fourth edge of each of said panels are parallel. 53. The panelized roof sheathing construction system of claim 52 wherein the first and second edges of a panel are substantially perpendicular with adjacent third and fourth edges, and further wherein in each panel the grooves and tongues of the sections of the first edge are alternately disposed with a groove adjacent the third edge and a tongue adjacent the fourth edge; and the grooves and tongues of the sections of the second edge are alternately disposed with a tongue adjacent the third edge and groove adjacent the fourth edge. 54. The panelized roof sheathing construction system of claim 53, wherein the length of the tongue in each section measured in the longitudinal direction of an edge is less than or equal to the longest grooves in each section. 55. The panelized roof sheathing construction system of claim 54, wherein the length of the tongue in each section is at most ½ the length of the length of the longest grooves in each section. 56. The panelized roof sheathing construction system of claim 1 wherein each water-resistant barrier layer further comprises indicia for positioning fasteners, said fasteners being adapted to secure said panels on said building frame structure. 57. The panelized roof sheathing construction system of claim 56 wherein said indicia further comprises alignment guides for applying said strips of tape. 58. A method for drying-in a building prior to applying roofing shingles comprising the steps of: attaching a plurality of panels to a building frame structure, each of said panels comprising lignocellulosic material and further comprising an inward facing surface, an outward facing surface and a peripheral edge, said panels further each comprising a barrier layer adhesively secured to the outward facing surface of said panel by an adhesive layer, said barrier layer further comprising a substantially bulk water resistant and a substantially skid resistant embossed textured outward facing surface; and further wherein said barrier layers are comprised of resin-impregnated paper having a basis weight of about 78.05 g/m2(16 lbs./msf) to about 365.85 g/m2 (75 lbs./msf; and further wherein said panels with said barrier layers are characterized by water permeability in a range from about 0.1 U.S. perms to about 1.0 U.S. perms as determined by ASTM E96 procedure A, and further wherein said panels with said barrier layers are characterized by a water vapor transmission rate from about 0.7 to about 7 grams/m2/24 hrs as determined by ASTM E96 procedure A (at 73° F.—50% RH), a permeability from about 0.1 to about 12 perms as determined by ASTM E96 procedure B (at 73° F.—100% RH), and a liquid water transmission rate from about 1 to about 28 grams/100 in2 /24 hrs via Cobb ring according to the test method described in ASTM D5795; said panels attached atop said building frame structure in substantially abutting relationship so as to form joints therebetween; and sealing the joints between adjacent panels with lengths of tape each of said lengths of tape overlapping at least one of said joints between adjacent panels, said tape comprising a backing and an adhesive layer disposed on said backing.

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Panelized roofing system and method

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