Roofing systems with improved wind performance of roofing tiles and methods of installing thereof

Inventors: Ming-Liang Shiao (Basking Ridge, NJ); Brian Lee (Linden, NJ); Daniel E. Boss (Morris Township, NJ); Ramil Marcelo L. Mercado (Waxahachie, TX)

Assignee: BMIC LLC

E04D1/36 E04D1/12 E04D1/28 E04D1/2928

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Quick Facts

Patent No.: US 12,024,888
App. No.: 18/310,912
Granted: Jul 2, 2024
Kind: B2

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Abstract

This invention, in embodiments, relates to a roofing system comprising (a) a roofing substrate having a roofing surface, (b) a first roofing tile overlying the roofing surface, the first roofing tile having a front surface, a back surface, a top edge, and a bottom edge, and (c) a second roofing tile overlying the first roofing tile, the second roofing tile having a front surface, a back surface, a top edge, and a bottom edge. At least one sealant line is applied to (i) the back surface of the second roofing tile in an area that overlays the first roofing tile, (ii) the front surface of the first roofing tile in an area in which the second roofing tile overlays the first roofing tile, or (iii) both (i) and (ii). The at least one sealant line is configured to adhere the second roofing tile to the first roofing tile.

Claims (27)

1. A roofing tile comprising:

(a) a front surface;

(b) a back surface that is opposite to the front surface;

(d) a second side edge that is opposite to the first side edge;

(e) a top edge;

(f) a bottom edge that is opposite to the top edge;

(g) at least one sealant line configured to adhere the roofing tile to another roofing tile, the at least one sealant line being applied to (i) the back surface of the roofing tile, (ii) the front surface of the roofing tile, or (iii) both (i) and (ii); and

(h) a release agent, wherein the release agent is applied to (i) the front surface of the roofing tile in only an area that is opposite to the at least one sealant line, (ii) the back surface of the roofing tile in only an area that is opposite to the at least one sealant line, or (iii) both (i) and (ii),

wherein the roofing tile comprises a non-interlocking, synthetic tile, with the roofing tile being non-interlocking along the first side edge and the second side edge, and

wherein the roofing tile comprises a thermoplastic material and a filler.

2. The roofing tile according to claim 1 , wherein the at least one sealant line is applied to (i) the back surface of the roofing tile in an area that is adjacent to the bottom edge of the roofing tile, (ii) the front surface of the roofing tile in an area that is adjacent to the top edge of the roofing tile, or (iii) both (i) and (ii).

3. The roofing tile according to claim 1 , wherein the at least one sealant line comprises at least one of (i) a heat-activated sealant or (ii) a self-activated sealant.

4. The roofing tile according to claim 1 , wherein the thermoplastic material comprises at least one of a thermoplastic polymer, an elastomer, a rubber, a copolymer, a polyolefin, or a combination thereof.

5. The roofing tile according to claim 1 , wherein the filler comprises at least one of sand, calcium carbonate, stone dust, wood dust, or a combination thereof.

6. The roofing tile according to claim 1 , further comprising an additive.

7. The roofing tile according to claim 6 , wherein the additive comprises at least one of a fire retardant, a colorant, a pigment, a stabilizer, an impact modifier, a UV absorber, an anti-oxidizer, a processing aid, or a combination thereof.

8. The roofing tile according to claim 1 , wherein the release agent has a low affinity to the at least one sealant line.

9. The roofing tile according to claim 1 , wherein the release agent comprises one or more of a silicone, siliconate dispersions, a fluoropolymer, a soap, a wax, a metal salt, or a surface with a texture to create a low surface energy effect.

10. The roofing tile according to claim 1 , wherein the front surface of the roofing tile is free of a sealer.

11. The roofing tile according to claim 1 , wherein the at least one sealant line comprises a discontinuous line.

12. The roofing tile according to claim 1 , wherein the at least one sealant line has a thickness of from 5 mils to 200 mils.

13. The roofing tile according to claim 1 , wherein the at least one sealant line exhibits a minimum activation temperature (° F.) (tan δ>1) of less than 40° F.

14. The roofing tile according to claim 1 , wherein the at least one sealant line comprises a heat-activated sealant that exhibits an activation temperature between 70° F. and 140° F.

15. The roofing tile according to claim 1 , wherein the at least one sealant line comprises at least one of an asphaltic sealant, a polymer modified asphaltic sealant, a butyl adhesive, an acrylic adhesive, a polyurethane adhesive, a pressure sensitive adhesive, an epoxy, a foam adhesive, a hot melt adhesive, and combinations thereof.

16. The roofing tile according to claim 1 , wherein the top edge of the roofing tile extends from the first side edge to the second side edge of the roofing tile, and the bottom edge of the roofing tile extends parallel to the top edge from the first side edge to the second side edge of the roofing tile.

17. The roofing tile according to claim 16 , wherein the first side edge of the roofing tile extends parallel to the second side edge of the roofing tile from the top edge to the bottom edge of the roofing tile.