Tpo roofing membrane fastening system and method

Abstract

This invention relates to an improved fastening technique for single ply roofing membranes comprised of thermoplastic polymer material. In one embodiment, a method of installing a roof on a structure may comprise providing a single-ply roofing membrane comprising thermoplastic polymer material, and periodically securing rigid strips over a roofing deck. In such embodiment, the rigid strips have thermoplastic polymer material on corresponding exterior surfaces thereof. The method may further include laying the roofing membrane over the roofing deck, where the rigid strips are located between the roofing deck and the roofing membrane. Then the method may include heating the roofing membrane and the rigid strips simultaneously, perhaps using a heat induction technique, such that thermoplastic polymer material on the exterior surfaces of the rigid strips fuses directly with the thermoplastic polymer material of the roofing membrane.

1 . A method of installing a roof on a structure, the method comprising:
 providing a single ply roofing membrane comprising thermoplastic polymer material;   periodically securing rigid strips over a roofing deck, the rigid strips having thermoplastic polymer material on corresponding exterior surfaces thereof;   laying the roofing membrane over the roofing deck, the rigid strips located between the roofing deck and the roofing membrane; and   heating the roofing membrane and the rigid strips simultaneously such that thermoplastic polymer material on the exterior surfaces of the rigid strips fuses directly with the thermoplastic polymer material of the roofing membrane.   
   
   
       2 . A method according to  claim 1 , further comprising mounting insulating boards directly on the roofing deck, the rigid strips located on exterior surfaces of the insulating boards, and wherein the laying comprises laying the roofing membrane directly on the rigid strips and portions of the insulating boards. 
   
   
       3 . A method according to  claim 2 , wherein securing the rigid strips comprises incorporating the rigid strips into the exterior surfaces of the insulating boards, the exterior surfaces of the rigid strips exposed beyond the exterior surface of the insulating boards. 
   
   
       4 . A method according to  claim 2 , wherein securing the rigid strips comprises laying the rigid strips directly on top of the exterior surface of the insulating boards, the rigid strips also comprising thermoplastic polymer material on corresponding interior surfaces facing the insulating boards, and wherein the heating further comprises thermoplastic polymer material on the interior surfaces of the rigid strips adhering the rigid strips to the insulating boards. 
   
   
       5 . A method according to  claim 2 , wherein the insulating boards comprise a metal coating on their exterior surfaces, and wherein the securing the rigid strips comprises adhering the rigid strips directly on top of the metal coating of the insulating boards using an adhesive. 
   
   
       6 . A method according to  claim 2 , wherein the insulating boards comprise polyisocyanurate foam. 
   
   
       7 . A method according to  claim 1 , wherein the rigid strips comprise metal therein, the thermoplastic polymer material disposed on the metal. 
   
   
       8 . A method according to  claim 1 , wherein the thermoplastic polymer material comprises thermoplastic olefin. 
   
   
       9 . A method according to  claim 1 , further comprising passing mechanical fasteners through the roofing membrane and the rigid strips so as to secure the roofing membrane and the rigid strips to the roofing deck. 
   
   
       10 . A method according to  claim 9 , wherein the rigid strips comprise preformed holes therethrough configured to received the mechanical fasteners. 
   
   
       11 . A method according to  claim 1 , wherein the roofing membrane comprises at least two membrane portions, and wherein laying the membrane further comprises laying at least one of the overlapping edges of the at least two membrane portions directly on at least one rigid strip. 
   
   
       12 . A method according to  claim 1 , further comprising placing an underlayment between the roofing deck and the roofing membrane, the rigid strips incorporated into the exterior surface of the underlayment, and wherein laying the membrane comprises laying the membrane directly on the rigid strips and portions of the underlayment. 
   
   
       13 . A method according to  claim 1 , wherein the heating comprises a heat induction technique. 
   
   
       14 . A method according to  claim 13 , wherein the heat induction technique comprises a heated roller or a heated flat iron. 
   
   
       15 . A method of installing a roof on a structure, the method comprising:
 providing a single ply roofing membrane comprising thermoplastic polymer material;   mounting insulating boards directly on the roofing deck, the insulating boards having exterior surfaces opposite the roofing deck;   periodically locating rigid strips directly on the exterior surfaces of the insulating boards, the rigid strips having thermoplastic polymer material on interior surfaces facing the insulating boards and on exterior surfaces opposite the interior surfaces;   laying the roofing membrane directly on the exterior surfaces of the rigid strips and portions of the exterior surfaces of the insulating boards; and   heating the roofing membrane and the rigid strips simultaneously such that thermoplastic polymer material on the exterior surfaces of the rigid strips fuses directly with the thermoplastic polymer material of the roofing membrane, and thermoplastic polymer material on the interior surfaces of the rigid strips adheres the rigid strips to the insulating boards.   
   
   
       16 . A method according to  claim 15 , wherein the insulating boards comprise polyisocyanurate foam. 
   
   
       17 . A method according to  claim 15 , wherein the rigid strips comprise metal therein, the heat-weldable thermoplastic material disposed on the metal. 
   
   
       18 . A method according to  claim 15 , wherein the heat-weldable thermoplastic polymer material comprises thermoplastic olefin. 
   
   
       19 . A method according to  claim 15 , further comprising passing mechanical fasteners through the roofing membrane, the rigid strips and the insulating boards so as to secure the roofing membrane, the rigid strips and the insulating boards to the roofing deck. 
   
   
       20 . A method according to  claim 19 , wherein the rigid strips comprise preformed holes therethrough configured to received the mechanical fasteners. 
   
   
       21 . A method according to  claim 15 , wherein the roofing membrane comprises at least two membrane portions, and wherein laying the membrane further comprises laying at least one of the overlapping edges of the at least two membrane portions directly on at least one rigid strip. 
   
   
       22 . A method according to  claim 15 , wherein the heating comprises a heat induction technique. 
   
   
       23 . A method according to  claim 22 , wherein the heat induction technique comprises a heated roller or a heated flat iron. 
   
   
       24 . A roof installation on structure, comprising:
 a single ply roofing membrane comprising thermoplastic polymer material laid over a roofing deck;   rigid strips having thermoplastic polymer material on corresponding exterior surfaces, the rigid strips periodically spaced over the roofing deck between the roofing deck and the roofing membrane; and   wherein the rigid strips are secured to the roofing deck, and thermoplastic polymer material on the exterior surfaces of the rigid strips is fused directly with the thermoplastic polymer material of the roofing membrane.   
   
   
       25 . A roof installation according to  claim 24 , further comprising insulating boards mounted directly on the roofing deck, the rigid strips located on exterior surfaces of the insulating boards and the roofing membrane laid directly on the rigid strips and portions of the insulating boards. 
   
   
       26 . A roof installation according to  claim 25 , wherein the rigid strips are incorporated into the exterior surface of the insulating boards, the exterior surfaces of the rigid strips exposed beyond the exterior surface of the insulating boards. 
   
   
       27 . A roof installation according to  claim 25 , wherein the rigid strips also comprise thermoplastic material on corresponding interior surfaces facing the insulating boards, and wherein the rigid strips are laid directly on top of the exterior surface of the insulating boards. 
   
   
       28 . A roof installation according to  claim 25 , wherein the insulating boards comprise a metal coating on their exterior surfaces, and wherein the rigid strips are adhered directly on top of the metal coating of the insulating boards using an adhesive. 
   
   
       29 . A roof installation according to  claim 25 , wherein the insulating boards comprise polyisocyanurate foam. 
   
   
       30 . A roof installation according to  claim 24 , wherein the rigid strips comprise metal therein, the thermoplastic polymer material disposed on the metal. 
   
   
       31 . A roof installation according to  claim 24 , wherein the thermoplastic polymer material comprises thermoplastic olefin. 
   
   
       32 . A roof installation according to  claim 24 , further comprising mechanical fasteners passing through the roofing membrane and the rigid strips so as to secure the roofing membrane and the rigid strips to the roofing deck. 
   
   
       33 . A roof installation according to  claim 32 , wherein the rigid strips comprise preformed holes therethrough configured to received the mechanical fasteners. 
   
   
       34 . A roof installation according to  claim 24 , wherein the roofing membrane comprises at least two membrane portions, at least one rigid strip located directly under at least one overlapping edge of the at least two membrane portions. 
   
   
       35 . A roof installation according to  claim 24 , further comprising an underlayment located between the roofing deck and the roofing membrane, the rigid strips incorporated into the exterior surface of the underlayment, and the roofing membrane laid directly on the rigid strips and portions of the underlayment.