INTERLOCKING VAPOR BARRIER SYSTEM

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the priority of U.S. Provisional Patent Application Serial No. 61/092,706 filed August 18, 2009, U.S. Provisional Patent Application Serial No. 61/248,653 filed October 5, 2009, and U.S. Patent Application Serial No. 12/770,073 filed April 29, 2010, the contents of each are incorporated herein by reference.

FIELD OF THE INVENTION

[0002] The present invention is generally concerned with the construction of a seamless covering, including membrane and insulation, associated with a roof and which includes both ductwork and piping which penetrates through a hole in the roof surface. More specifically, the present invention discloses a plurality of heat welded and continuous PVC membrane sheets, such as supported upon exterior rooftops. Additional subassemblies are configured for applying about running lengths of ductwork, as well as particularly to piping and which are formed into a series of interlocking sections to create an impermeable vapor barrier system in which a break in a given section does not otherwise compromise the integrity of the remaining sections.

BACKGROUND OF THE INVENTION

[0003] Building facilities include such as those providing food processing abilities requiring the use of coolers and freezers, the associated equipment required for running these typically circulating liquids at a number of different temperatures ranging from below to above freezing at a given ambient atmospheric pressure. Piping extending between associated items of equipment can further extend over long running lengths both above and below an associated rooftop of the facility.

[0004] As is further known, such pipes require an over-layering of insulation in order to maintain its interior (usually chilled) temperature. Given the physical nature of a cold exterior of an exposed pipe to attract moisture, known insulation systems have been quickly compromised as a result of the moisture buildup intermixing with the insulation and freezing the same over the pipe. SUMMARY OF THE INVENTION

[0005] The present invention discloses a plurality of heat welded and continuous PVC membrane sheets which are configured for applying over such as an exterior rooftop, with additional subassemblies configured for applying about running lengths of ductwork as well as configured for application over piping, such as which penetrates a hole in the roof surface and which is formed into a series of interlocking sections to create an impermeable vapor barrier system in which a break in a given section does not otherwise compromise the integrity of the remaining sections.

[0006] In piping applications, the pipe is first primed, following which a layer of insulation is applied with a succeeding layer of a thermoplastic olefin (TPO) or polyvinyl chloride (PVC) of wrapping added. A seamless bonded material is then overlapped over an end section of the wrapping in the form of a pre-manufactured boot (such as dimensioned to the outer diameter of the insulation and wrapping) and which is constructed of a heat welded polymer and insulation and which is formed over around a given running length of the pipe. The boot is provided at the location in which the pipe projects from the roof and is bonded together to the overall wrap circumference.

[0007] A nipple portion of the boot placed over a volume of putty and bonded with a surrounding fastener directly to the pipe. The outer membrane (TPO or PVC) of each subsequent section of pipe is heat bonded in a further overlapping fashion to the outer diameter extending edges of the outermost TPO or PVC pipe wrap proximate to its reduced diameter nipple connection. The outer wrapping is broken at periodic sections to provide a thermal break and absolute vapor barrier for each section.

[0008] A similar application is provided for covering any three dimensional ductwork supported in extending fashion above the roof surface, such as upon vertical supports, and again includes overlaying insulation and flexible outer PVC membranes in combination with heat sealing flex corners and custom boots. A separation washer is incorporated underneath the ductwork and insulation.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Reference will now be made to the attached drawings, when read in combination with the following detailed description, wherein like reference numerals refer to like parts throughout the several views, and in which: [0010] Fig. 1 is an environmental view of the continuous heat welded flexible PVC membrane with interlocked vapor barrier system applied to each of a roof, mechanical piping and HVAC ductwork according to one non-limiting embodiment of the invention;

[0011] Fig. 2 is a sectional perspective of a sub-application of the flexible membrane applied in partially overlapping and succeeding sections to a running length of pipe;

[0012] Fig. 3 is an illustration similar to Fig. 2 and further showing the application of a manual incision for purposes of inspection, repair or other purpose, where a break is made in the thermal wrapping at a periodic section, but the absolute vapor barrier for any adjoining section is maintained.;

[0013] Fig. 4 is a sectional cutaway of a pipe at a penetrating location through a roof aperture and further illustrating the features of a sealing subassembly including insulation, outer wrapping and a pre-manufactured boot applied in succession around the pipe;

[0014] Fig. 5 is a plan cutaway view similar to that shown in Fig. 2 and illustrating from another vantage point the overlapping relationship established between a pair of succeeding and interlocking sections of piping overwrap, as well as illustrating one variant of a pressure sensor applied within the exterior skin of the sealed membrane for reflecting any changes in pressure resulting from compromise of the underlying piping or ductwork;

[0015] Fig. 6 is a sectional perspective of a similar sub-application to that shown in Fig. 2 applied to a length of ductwork;

[0016] Fig. 7 is a side profile view of an underside of the ductwork shown in Fig. 6 and further illustrating the feature of an underside positioned and seamlessly incorporated separation washer;

[0017] Fig. 8 is an illustration of the aligning and overlapping edges associated with a plurality of individual sheets of rooftop applied membrane which are heat bonded to one another to cover an exposed roof surface and which are further capable of being easily sectioned or trimmed in order to cooperate with penetrating pipe and HVAC locations as well as other rooftop located obstacles;

[0018] Fig. 9 is a sectional perspective illustration of an open boot, such as shown in cutaway plan view in Fig. 4, and which is again associated with a generally rounded cross sectional pipe; and

[0019] Fig. 10 is a succeeding sectional perspective illustration of a further variant of open boot associated with a roof projecting location of a square shaped ductwork. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] The present invention discloses a continuous heat welded flexible PVC membrane incorporated into an interlocked vapor barrier system. The present invention includes other variants not necessarily limited to roof top applications, which can include such interior or underground application such as associated with, but not limited to, the oil and gas pharmaceutical industries.

[0021] As will be further described, the present invention incorporates a number of variants of sealed membrane including application to both planar areas (such as rooftops) and/or applications to conduit (defined as piping and/or ductwork). The present invention includes other variants not necessarily limited to rooftop applications, and which can include such as interior or underground applications, such as associated but not limited to the oil and gas industries.

[0022] In reference to the illustrated embodiments set forth, subset applications are described below and include, in one variant, the provision of a boot formed about a pipe with insulation overwrap and which bonds about the pipe at a penetrating location through a roof. Succeeding overwrap sections are provided and engaged in end to end and partially overlapping fashion. Similar overwrapping applications are incorporated into roof projecting lengths of ductwork and include over layers of duct insulation, flexible membrane vapor seals and flex corners, and the provision of underside washers incorporating into ductwork supports.

[0023] Referring first to Fig. 1, an environmental view is generally shown at 10 of the continuous heat welded flexible PVC membrane with interlocked vapor barrier system applied to collectively to each of a roof, mechanical piping and HVAC ductwork according to one non- limiting embodiment of the invention. A first roof top supported subassembly is depicted by a single flat membrane illustrated at 12 however, and as further shown in Fig. 8, can be understood as provided by a plurality of individual sheets 14, 16, 18, et seq. which are arranged in aligning and edge overlapping fashion, and which are further heat bonded to one another along the overlapping locations indicated at 20, 22, and 24 established between the three sheets 14, 16 and 18 in the example shown. The membranes can further exhibit any desired thickness, such as ranging from a few mils up to 1/4" or greater.

[0024] The membrane sheets or rolls are constructed of a polyvinyl chloride (PVC) or thermoplastic polyolefin (TPO) or other suitable material and can exhibit any desired sheet width, length and thickness. It is further understood and envisioned that the membrane construction can further include any type of waterproof film or layer which may be heat sealed to such as an adjoining edge of a consecutive and overlapping membrane. Although not shown, it is further envisioned that the membrane sheets can also be provided in roll form and which are further capable of being easily sectioned or trimmed in order to cooperate with penetrating pipe and HVAC locations as well as other rooftop located obstacles both within and about a defined installation perimeter.

[0025] Referring again to Fig. 1 in combination with Figs. 2, 3 and 5, a description is provided of individual sections of interlocking membrane provided about a pipe, in combination with a further membrane (Fig. 4) interlocking membrane section constructed with a custom boot for sealing a location of the pipe where it penetrates an aperture in an underlying roof. As shown in the example of Fig. 1, a series of three pipes are generally shown at 26, 28 and 30 extending respectively through apertures in the roof to a piece of rooftop located equipment 31. Each of the pipes (hidden from view in Fig. 1) are covered by a series of interconnected and overlapping membrane covered sections, these including first bottom most sections incorporating a custom boot and shown at 32, 34 and 36, succeeding intermediate and custom flex corner section 38, 40 and 42 and further overlapping and interconnecting sections 44-46, 48-50 and 52-54 leading respectively to the rooftop located equipment 31.

[0026] Referring now to Fig. 2, a sectional perspective is shown of a sub-application of the flexible membrane applied in partially overlapping and succeeding sections, such as corresponding to sections 44 and 46 shown in Fig. 1, of a running length of pipe identified at 48. In application, the pipe 48 is first primed, following which a layer of an insulating material 50 (as best shown in Fig. 4) is applied according to a desired material construction and thickness in generally rolled fashion about the pipe 48.

[0027] A boot, see as best shown in Figs. 2 and 5, exhibits a generally modified funnel shape with a generally flattened central disc exhibiting a radial extending profile 52 and terminating both at an outer diameter in a first angled lip edge 54 covering an associated edge of the insulating material 50, as well as at an opposite directed and inner (narrowest diameter) lip edge 56 directly contacting the pipe 48. Although not shown, it is understood that the boot exhibits an incised extending edge which permits the boot to be fashioned about any type of conduit (pipe or ductwork), such edge being initially heat staked or welded and prior to successive heat staking of the angled edges of the boot to the interfacing membrane sections of the roof and conduit. A mechanical fastener 58 (such as a band or clamp) is fastened about the inner diameter lip edge 56 (also termed a reduced diameter nipple connection). [0028] Also illustrated in Fig. 5 at 59 is one potential variant of a pressure sensor applied within the illustrated section 46 exterior skin of the sealed membrane and, in operation, is provided to reflect any changes in pressure resulting from compromise of the underlying piping or ductwork 48. Given the fluid tight sealing nature of the individual vapor sections 44, 46, et seq., it is envisioned that the provision of a suitable sensor 59 in embedded fashion within each membrane section (this including mounting the sensor in the manner illustrated in which a base component of the sensor 59 is exposed on the outside of the skin/membrane 46, as well as reconfiguring to mount entirely underneath the membrane with either wires or a wireless transmitting portion projecting through sealed locations) will assist in quickly identifying and localizing any breach occurring within the piping/ductwork. Additional or alternative to detecting pressure variations, it is envisioned that each of the sensors 59 can be reconfigured to detect other parameters such as moisture.

[0029] As further shown in both Figs. 2 and 5, a succeeding section of insulation material 60 is positioned over a further extending portion of the pipe and is further notched or otherwise deflected internally at 62 (Fig. 5) so as to seat over the inner lip (nipple) edge 56 and in generally abutting contact with the radial profile 52 of the configured boot. An outer membrane layer associated with the wrap section 46 is then applied over the insulation later and in generally overlapping fashion with a circumferential edge band associated with the preceding membrane section 44.

[0030] As further shown in Fig. 2, a heat knife 64 is then provided for heat weld sealing the membrane layers directly to one another in a seamless fashion. A box cutter or other suitable knife edge (see at 66 in Fig. 3) is provided for creating a manual incision (further shown at 67 in reference to membrane 44) for providing a break in the thermal wrapping at periodic sections and in order to maintain and absolute vapor barrier for each section. The incision 67 depicted is understood as being located within a dedicated section of membrane and while maintaining a vapor barrier integrity of an adjoining section.

[0031] Figure 4 illustrates a sectional cutaway of pipe 48 at a further location, such as generally corresponding to outer membrane wrapped section 32 shown in Fig. 1 at which the pipe penetrates at a location through a roof aperture. This is further represented by roof substrate layers 68 and 70 and underlying structural deck 72. Successive sections of insulation are shown at 74 and 76, wrapped around the pipe 48 at the general location in which it projections above the uppermost roof substrate 68. [0032] In sealing the projecting location through the roof, a lower associated outer membrane wrapping 78 is configured over the lower insulation section 74 and terminates in an end surface 80 narrowing to an inner diameter (nipple) portion 82 which contacts the pipe 48. The nipple portion is usually placed over a volume of putty and prior to be affixed with a surrounding fastener directly to the pipe. A non-curing and low expanding foam sealant 84 is then applied between the outer diameter of the membrane wrapping 78 and the inner rim aperture of the roof substrates and structural decking.

[0033] Further components include a further horizontally applied layer of membrane 86 (see also Fig. 1) applied over the roof membrane 12 and exposed sealant 84 and lower membrane end surface 80, the membrane 86 exhibiting an inner diameter nipple portion 88, in this instance which overlaps the nipple portion 82 previously described and prior to the application of the mechanical band or fastening clamp 90. At this point, a seamless bonding material in the form of a further version of pre-manufactured or pre-configured boot is provided, see with first 92 and second 94 interconnected and angled sides encircling and overlaying both the level membrane 12 and upwardly extending membrane wrap 32, the boot 92 exhibiting a similar thermo-formable material and being heat welded directly to the adjoining membrane layers 12 and 32. Other post- application steps include applying a silicon based caulking along an exterior of the vapor barrier, as well as between the structural decking and pipe wrap.

[0034] As previously described, the outer membrane (TPO or PVC) of each subsequent section of pipe is heat bonded in a further overlapping fashion to the outer diameter extending edges of the outermost TPO or PVC pipe wrap proximate to its reduced diameter nipple connection. The outer wrapping is again broken at periodic sections to provide a thermal break and absolute vapor barrier for each section. The pre-manufactured boots, including such as depicted at 52 disposed between succeeding and overlapping sections of pipe membrane, as well as at 86/92 in sealing application over a roof aperture through which the pipe extends, can be individually sized at varying diameters (such as without limitation according to any incrementing dimensions ranging from 1" to 30") and other dimensions, this in order to be quickly and repetitively installed during a roof sealing application, this further based upon the sizing of the pipe and overlapping insulation.

[0035] Referring now to Fig. 6, a sectional perspective is generally shown at 96 of a similar sub-application to that shown in Fig. 2, and in this instance applied to a length of ductwork 98, and which is shown extending in projecting and angled fashion from the rooftop over which the membrane 12 is applied. As shown, the ductwork 98 exhibits upward, angled corner and horizontal interconnected sections and is further supported upon the rooftop by any number of vertical supports 100.

[0036] Similar to the piping applications previously described, a four sided layer of duct insulation 102 is folded or otherwise fitted over the exposed surface of the ductwork 98. Following this, a series of sections of flexible membrane (again including PVC, TPO or the like) are inter-fitted and mechanically heat sealed together. These membrane sections include a boot section 104 applied over the upward (roof projection duct section), a corner section 106 applied over the angled intermediate location succeeding the upward projecting section, and a further membrane section 108 applied over the ductwork and insulation in a further partially overlapping and transitioning location from the angled corner section 104. As further previously described, the membrane sections 104-108 exhibit a similar material constructed as utilized with the piping and rooftop membrane sections.

[0037] Referring further to Fig. 7, a side profile view is shown of an underside of the ductwork 98 shown in Fig. 6 and further illustrating the feature of an underside positioned and seamlessly incorporated separation washer 110 arranged about a proximate extending location of the associated support 100 and between an underside location of associated outer membrane wrap section 108. During installation, the separation washer 110 is dimensioned to provide underside support to the membrane section 108 and insulation 102 and to further prevent sagging or tearing.

[0038] Referring again to Fig. 1, the provision of customized boot sections is again envisioned in a ductwork sub-application of the vapor barrier membrane, see at 112, and which can be used cooperatively with any given running membrane section 114 in order to seal a given ductwork location extending from the rooftop surface to such as a further given item of HVAC equipment 116. Related applications envision mechanically inter-engaging the membrane sections using either again a hot knife (at 64 in Fig. 2) or heated air in order to inter-weld the overlapping sections of membrane.

[0039] Figure 9 is a sectional perspective illustration of open boot, such as shown in cutaway plan view in Fig. 4 see with first 92 and second 94 interconnected and angled sides and which is again associated with a generally rounded cross sectional pipe. Figure 10 is a succeeding sectional perspective illustration of a further variant of open boot associated with a roof projecting location of a square shaped ductwork and which likewise includes first 118 and a second 120 interconnected and angled sides. In each instance, exposed and opposing wraparound edges are provided for each boot along its entire extending length established by the interconnecting sides and to permit the boot to be fashioned around a suitably dimensioned pipe or ductwork, with the flap edges (see at 122 & 124 in Fig. 9 and at 126 & 128 in Fig 10) subsequently being heat sealed together.

[0040] In further variants, the covering membrane can further be provided as multiple sheets supported upon a skid or pallet or, alternatively, in a roll form in order to facilitate fast application and installation, such as in further combination with strategically located and pre-dimensioned boot sections for fitting with each of the rooftop, piping and ductwork in a single seamless and vapor barrier enabling application. In application, the flexible membranes are laid over the application specific insulation and are interlocked/heat sealed to the membrane boots and related mechanical components. Non-straight runs or irregular surfaces are typically addressed by the installer during fabrication, this again in combination with pre-sized boot components pre-manufactured for specific installation to a pipe or HVAC duct.

[0041] In use, the seamless vapor barrier system improves the energy efficiency of the associated thermo (by example refrigeration) system, and accomplishes this by providing a complete vapor barrier resulting from the inter-welding of the overlapping thermo edges of the membranes along all joints, seams, laps and the like established between each of the rooftop, piping and ductwork components. This entails in non-limiting fashion the provision of a vapor barrier to the fluid conveying pipes as well as sanitation provided by the air conveying ductwork. The sectionalized manner in which the membrane sections are inter-fitted further prevents a break or rupture at one location from compromising the overall effectiveness of the system.

[0042] An additional benefit of the present design is the ability to utilize separate vapor barrier sections in a number of applications, not limited to roofing, such as where hazardous materials are transported within the conduit (pipes or ducts). In this fashion, access is facilitated to any given section(s) without compromising the vapor barrier established within individual adjoining sections. This further enables an operator or isolate and repair a breach in any given section(s) without contaminating the balance of the piping or ductwork.

[0043] Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims.

[0044] I claim: