EP4493774A1

EP4493774A1 - A precursor flashing composite and methods of using the same

Info

Publication number: EP4493774A1
Application number: EP23715401.8A
Authority: EP
Inventors: Rodrigo MURILLO MAESE
Original assignee: Holcim Technology Ltd
Current assignee: Holcim Technology Ltd
Priority date: 2022-03-15
Filing date: 2023-03-15
Publication date: 2025-01-22
Also published as: MX2024011100A; US20250230662A1; WO2023178190A1; CA3253407A1

Abstract

A precursor flashing composite comprising (i) a fabric component having a first planar surface and a second planar surface; (ii) a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape; (iii) a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and (iv) wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.

Description

A PRECURSOR FLASHING COMPOSITE AND METHODS OF USING THE SAME

[0001] This application claims the benefit of U.S. Provisional Application No.63 /319,819 filed on March 15, 2022, which is incorporated herein by reference.

FIELD OF THE INVENTION

[0002] Embodiments of the present invention are directed toward precursor flashing composites prepared by employing liquid flashing compositions and fabric components, as well as methods for installing precursor flashing composites using liquid flashing compositions.

BACKGROUND OF THE INVENTION

[0003] In the roofing art, it is common to use membranes to provide a waterproof seal to a roof surface of a flat or low-sloped roof. Typical membrane systems include asphaltbased systems, such as those that employ modified asphalt membranes, as well as polymeric systems that employ EPDM or thermoplastic olefin (TPO) membranes.

[0004] In constructing membrane-based roofing systems, the membranes can be secured to the roof surface by employing ballasting, mechanical fastening, or adhesives. In addition to securing the membrane to the roof surface, adjacent membranes are bonded to each other to form a water-tight seal between membranes. Flashing systems or assemblies are employed to create a water-tight seal between the membrane system and any vertical structural elements on the roof including, but not limited to, parapet walls, gutter edges, and various protrusions such as pipes that penetrate the roof surface.

[0005] In the construction of modified asphalt membrane systems, it is common to employ liquid flashing compositions to create a seal with vertical surfaces. These liquid flashing compositions often include asphaltic-based compositions that include polyurethane or polymethyl methacrylate (PMMA) modification or reinforcement. The liquids can be used in conjunction with a fabric reinforcement, which can be mated to the vertical surface in conjunction with the liquid composition to ultimately form, upon drying or curing or the liquid composition, a flashing assembly. [0006] On the other hand, when polymeric membranes are employed to construct a roof system, the flashing assemblies are typically prepared using flashing membranes, which may also be referred to as membrane flashings. For example, in the case of plastic membranes, plastic flashings can be welded or adhered to the membrane system while being adhesively secured to the non-membrane vertical surfaces. Where rubber membranes are employed, it is common to employ flashing membranes that include uncured rubber, which can be adhesively mated to the rubber membrane and adhesively mated to the vertical nonmembrane surfaces.

SUMMARY OF THE INVENTION

[0007] Embodiments of the present invention provide a precursor flashing composite comprising (i) a fabric component having a first planar surface and a second planar surface; (ii) a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape; (hi) a second precured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and (iv) wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.

[0008] Other embodiments of the present invention provide a method for creating a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface to which the roofing membrane is secured, the method comprising (i) providing a precursor flashing composite including a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body; (ii) positioning the precursor flashing composite on a surface of a vertical structure and a surface of the roofing membrane; and (hi) applying a liquid flashing composition to the precursor flashing composite, the surface of a vertical structure, and the surface of the roofing membrane to thereby form a water-proof seal between the roofing membrane and the vertical structure.

[0009] Yet other embodiments of the present invention provide a method of forming a precursor flashing composite, the method comprising (i) providing a fabric component with a first major planar surface and a second major planar surface; [ii] disposing a first liquid coating layer on the first major planar surface of the fabric component; [iii] disposing a second liquid coating layer on the first major planar surface of the fabric component; and (i v J curing the first liquid coating layer and the second liquid coating layer to thereby form a first body and a second body, respectively, wherein the first body has a first geometric shape, and wherein the second body has a second geometric shape.

[0010] Still other embodiments of the present invention provide a roofing system comprising (i) a roof deck; (ii) optionally, one or more roofing boards; [iii] a roofing membrane; [iv] a vertical structure extending from a roof surface to which the roofing membrane is secured; and (v) a flashing forming a water-proof seal between the roofing membrane and the vertical structure; wherein the flashing includes a composite flashing structure adhered into place with a flashing composition, where the composite flashing structure includes a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second precured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.

[0011] Other embodiments of the present invention provide the use of a precursor flashing composite to create a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface, where including a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is a top-elevational view of a precursor flashing composite according to one or more embodiments of the present invention.

[0013] FIG. 2 is a cross-sectional side-view of a precursor flashing composite according to one or more embodiments of the present invention.

[0014] FIG. 3 is a top-elevational view of a precursor flashing composite according to one or more embodiments of the present invention.

[0015] FIG. 4 is a top-elevational of a precursor flashing composite according to one or more embodiments of the present invention.

[0016] FIG. 5 is a top-elevational of a precursor flashing composite according to one or more embodiments of the present invention.

[0017] FIG. 6 is a cross-sectional side-view of a precursor flashing composite according to one or more embodiments of the present invention.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0018] Embodiments of the present invention are based, at least in part, on the discovery of a precursor flashing composite wherein a fabric component includes at least a first precured portion and a second pre-cured portion, each of which may include the cured residue of a liquid flashing composition. The precursor flashing composites of the present invention advantageously provide ease of installation by reducing the amount of liquid flashing composition necessary to form a water-proof seal during field application. As a result, less uncured material is necessary during installation, which also provides environmental benefits. The precursor flashing composites are therefore advantageously useful in preparing water-proof seals along vertical structures adjacent to a roofing membrane.

PRECURSOR FLASHING COMPOSITE

[0019] As indicated above, the precursor flashing composite includes a fabric and first and second pre-cured portions, which may also be referred to as pre-cured bodies, or simply bodies, disposed on the fabric. In one or more embodiments, at least two or more bodies are disposed on the fabric component such that a hinge, which may also be referred to as a hinge region, a gap, or a flexible joint, is formed between the edges of at least two or more of the bodies. According to embodiments of the invention, the hinges are regions of the fabric component between the at least two or more bodies that allow for flexing, folding, articulation, and other manipulation of the composite along the hinge.

[0020] Aspects of the present invention can be understood with reference to FIG. 1, which shows a precursor flashing composite 100 including a fabric component 101, a first body 111 (i.e. pre-cured body 111], and a second body 112 (i.e. pre-cured body 112]. Further, the placement of body 111 and body 112 on fabric component 101 forms a hinge region 121 along the gap between the two bodies in the portion of fabric component 101 between first body 111 and second body 121.

[0021] Body 111 and body 112 are the cured residue of a liquid flashing composition applied to on fabric component 101. In one or more embodiments, firstbody 111 and second body 112 are bonded or secured to fabric component 101 by virtue of being applied to the fabric as a liquid that is subsequently cured.

[0022] In one or more embodiments, fabric component 101 extends beyond first body 111 and second body 112. In one or more embodiments, bodies 111, 112 may be formed such that none of the fabric component 101 is exposed along the outside perimeter of fabric 101 (i.e. outside relative to bodies 111, 112]. The skilled person will appreciate that the amount of fabric component 101 extending beyond body 111 and body 112 may be selected according to the type of installation for which precursor flashing composite 100 is adapted. [0023] As also shown in FIG. 1, first body 111 includes a hinge edge 211, longitudinal edges 221, 231, and a lateral edge 241. Second body 112 includes a hinge edge 212, longitudinal edges 222, 232, and a lateral edge 242. In some embodiments, longitudinal edges 221, 231 and 222, 232 are adjacent to lateral edges 241 and 242, respectively. The distance between hinge edges 211 and 212 represents hinge region 121, which allows for the precursor flashing composite to be folded to match a desired configuration during installation (i.e. angle between the vertical structure and the roofing membrane].

[0024] As shown in FIG. 2, fabric component 101 has thickness 272, bodies 111, 112 have thickness 271, and precursor flashing composite has overall thickness 273. Hinge region 121 is shown as fabric component 101 between bodies 111, 112. [0025] The skilled person appreciates that hinge region 121 is adapted to allow for folding of fabric component 101 during installation to accommodate any number of installation geometries encountered in roofing environments. In one or more embodiments, hinge region 121 is adapted to be folded to generally form at a least a 90-degree angle.

[0026] Another embodiment of the present invention can be described with reference to FIG. 3, which shows pre-cured bodies 311, 312, 313, and 314 disposed on fabric component 101. A first hinge region 321 is formed between body 311 and 312. And, a second hinge region 322 is formed between body 311 and 313. A third hinge region 323 is formed between body 313 and 314. Additionally, perforation 331 may be formed in fabric component 101, which allows fabric component 101 to be separated along perforation 331, thereby allowing for hinge regions 321, 322, 323 to all be independently foldable.

[0027] In one or more embodiments, perforation 331 may include an actual perforation formed during manufacturing of precursor flashing composite. Perforation 331 may also be a marked line indicating to an installer where to cut fabric component 101. Perforation 331 may be formed through machine manipulation such that an installer can tear fabric component 101 along perforation 331. Perforation 331 may also be a pre-cut portion of fabric component 101.

[0028] The skilled person understands that selection of the shape, placement, and size of additional bodies may be made according to the demands of the installation location on a roofing surface. Common installation configurations include parapet walls, interior corners, exterior corners, round structures. Embodiments of the present invention are adapted to be used during installation for these configurations.

[0029] Further, the skilled person understand that the present invention may encompass many variations of foldable precursor flashing composites. For example, perforations may be formed in the fabric component such that the fabric component may be separated from itself, or portions of the fabric component may be removed according to a pattern of perforations. An object of the present invention is to create a water-proof seal between a vertical structure adjacent to a roofing surface. As such, the precursor flashing composite is advantageously adapted to lay flat against both the vertical structure and the roofing surface when installed. Accordingly, variations of foldable precursor flashing composites may be required to achieve this objective. For example, a vertical structure adjacent to a roofing surface, such as a parapet wall, may employ a precursor flashing composite including a single hinge region, which allows for an approximately 90-degree fold during installation of the precursor flashing composite. The bodies may be shaped as rectangular, and the fabric component may be shaped as rectangular. During installation, the hinge region may be formed into a pointed corner or have degree of curvature to accommodate the needs of the vertical structure.

[0030] In other examples, such as where it is desired to install the composite at the corner of a roof where two parapet walls intersect, a different precursor flashing composite is required to allow for easy installation into the corner of the parapets. An example of a suitable precursor flashing composite for this use is shown in FIG. 4, where pre-cured bodies 411, 412, 413, 414 are disposed on fabric component 101. A perforation 431 is formed such that a portion 401 of fabric component 101 is removable from precursor flashing composite 400. These features allow for precursor flashing composite 400 to be advantageously installed at a corner formed by the intersection of two parapet walls.

[0031] In yet other examples, vertical structures such as circular vents, which may be found on a roofing structure, may demand another type of precursor flashing composite. These precursor flashing composites may have perforations such that when wrapped around the circular, vertical structure during installation, the perforations are broken allowing for the precursor flashing composite to lay flat against the roofing surface and the vertical structure. An example of a suitable precursor flashing composite for this use is shown in FIG. 5, where composite 500 includes a plurality of pre-cured bodies 511, each of which are disposed on fabric component 501. A plurality of perforations 531 are formed in fabric component 501 such that fabric component 501 can be separated along each of perforations 531 during installation. These features allow for precursor flashing composite 500 to be advantageously installed at a rounded vertical surface rising from a roofing surface. [0032] The skilled person further understands that precursor flashing composites according to the present invention may be cut to size or in order to create overlap regions between a flashing composite and any other flashing components, including another precursor flashing composite. These modifications may be required according to roofing needs and may be made without impacting the integrity of the waterproof seal formed by using the precursor flashing composite. [0033] Some embodiments can be described with respect to the percentage of the surface area of fabric component that the pre-cured body covers. For example, the pre-cured body may cover greater than 80%, in other embodiments greater than 85%, and in other embodiments greater than 90% of the surface area of the fabric. In one or more embodiments, the cured body covers from about 80 to about 99% of the fabric of the body. A greater percentage of the surface area of the fabric covered advantageously requires less liquid flashing composition during installation of the precursor flashing composite.

[0034] Some embodiments can be described with reference to the dimensions of the hinge region. For example, the hinge region may have a width, which is measured from precured body to pre-cured body, of from about 0.1 to about 2 inches, in other embodiments from about 0.2 to about 0.7 inches, or in other embodiments from about 0.25 to about 0.5 inches.

PRE-CURED BODY

[0035] As suggested above, the pre-cured portions (i.e. bodies) are the cured residue of a liquid flashing composition applied to a surface of a fabric. These bodies are generally three-dimensional bodies that may have a substantially uniform thickness, although a non- uniform thickness may offer advantages in certain situations. While certain shapes may be advantageous for certain installations (as suggested above), the shape of the body may be regular or irregular polygonal shapes, curved shapes, and other two-dimensional shapes. Relative to plurality of bodies that may exist in a composite, the composites of one or more embodiments may have a substantially uniform thickness relative to each other.

[0036] In one or more embodiments, the one or more pre-cured bodies of a given composite may have a thickness of greater than 0.2 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm. In these or other embodiments, the pre-cured bodies may have a thickness of less than 25 mm, in other embodiments less than 20 mm, and in other embodiments less than 15 mm. In one or more embodiments, the precured bodies may have a thickness of from about 0.2 to about 25 mm, in other embodiments from about 0.7 to about 20 mm, and in other embodiments from about 1.0 to about 15 mm. [0037] As suggested above, the composites of this invention may have more than one pre-cured body disposed on the fabric component. In some embodiments, the composite may have at least two or more pre-cured bodies formed on a fabric component, where the at least two or more pre-cured bodies are formed having the same planar shapes. In some embodiments, the at least two or more pre-cured bodies having the same planar shapes may have uniform thicknesses. In some embodiments, the at least two or more pre-cured bodies having the same planar shapes may have non-uniform thicknesses.

[0038] Further, the skilled person will appreciate that the pre-cured bodies may be referenced according to their relative placement during installation of a precursor flashing composite. For example, pre-cured bodies placed upon a roofing surface may be referred to as roof-oriented bodies or roof bodies, and pre-cured bodies placed upon a vertical surface adjacent to a roofing surface may be referred vertical surface-oriented bodies or vertical bodies. It should be appreciated that the label "vertical” does not require vertical structures to be perpendicular to a roofing surface. Instead, vertical structures refer to any structure which extends upward from an adjacent roofing surface.

LIQUID FLASHING COMPOSITION

[0039] As indicated above, the pre-cured bodies may be the cured residue of a liquid flashing composition. Also, as will be described in greater detail below, a liquid flashing composition may be employed in the installation of the flashing composites of this invention. [0040] The liquid flashing compositions employed in the practice of this invention may include liquid flashing compositions that are generally known in the art. The skilled person understands that liquid flashing compositions are generally flowable compositions (at operating conditions) that can be applied to a substrate to form an uncured or partially cured coating that, upon curing, forms a cured residue of the composition. In one or more embodiments, the liquid flashing compositions have an appropriate viscosity to allow useful application methods such as brushing or rolling, while at the same time having sufficiently low viscosity to prevent deleterious sagging or running when applied to a vertical surface.

[0041] The skilled person also appreciates that these compositions may cure by different mechanisms depending on the nature of the compositions itself. In one or more embodiments, the composition can cure by evaporation of a solvent without any chemical reactions taking place with one or more of the constituents of the composition. In other embodiments, the compositions may cure by a reaction taking place wherein one of the ingredients acts a reactant (e.g. one-part curable composition) or where two or more of the ingredients react with each other (e.g. two-part curable composition). For example, a reactive cure may take place where one or more of the ingredients react with moisture (i.e. water in the environment), such as a one-part polyurethane or a moisture-curable alkoxysilane polymer. Other exemplary compositions may include two-part reactive compositions where a first reactant is supplied by a first part of the composition [e.g. an A-side stream) and a second reactant is supplied by a second component (e.g. a B-side stream). Upon mixing or contact, two parts form a reactive mixture that cures to form a cured residue. In one or more embodiments, the constituents of the composition that react and form a cured component of the overall composition may form a continuous (e.g. matrix) or discontinuous phase of the overall cured composition. The skilled person also appreciates that reactive curing may take place in conjunction with removal of any solvent or carrier that may be present within the composition.

[0042] In one or more embodiments, the liquid flashing composition includes a one-part polyurethane composition. As those skilled in the art appreciate, these compositions typically include isocyanate prepolymers that are crosslinked upon exposure to water (e.g. moisture within the air).

[0043] In one or more embodiments, the liquid flashing compositions include two-part polyurethane compositions that are formedby two distinct reactant streams. Namely, useful two-part polyurethane compositions include an A-side stream, which includes an isocyanate or isocyanate prepolymer, and a B-side stream, which includes an isocyanate-reactive component, such as a polyol. As is known in the art, these compositions can include various other additives, which are typically supplied together with the polyol within the B-side stream, such as catalysts, plasticizers, and extenders.

[0044] In one or more embodiments, the liquid flashing compositions include two-part acrylate resin compositions. For example, these compositions may include methyl methacrylate monomer compositions, which are typically supplied in a first stream. These polymers, either alone or in combination with other constituents, may crosslink upon exposure or contact to a catalyst or initiator, which is typically supplied by a second reactant stream. In one or more embodiments, a free radical initiator, such as a peroxide, is supplied to the acrylate polymers.

[0045] In one or more embodiments, the liquid flashing compositions include silicon adhesives, which may also be referred to as polysiloxane adhesives. Useful silicon- containing polymer adhesive systems also include polymer systems that include terminal siloxy or alkylsiloxy groups. As the skilled person appreciates, these polysiloxane adhesives can cure upon exposure to water (e.g. moisture within the air). These compositions may include various complementary constituents such as tackifier resins, moisture scavengers, and silane adhesion promoters. These adhesive systems are generally known in the art as disclosed in WO 2014/145482, WO 2014/095650, U.S. Patent Nos. 7,019,074, 6,183,551, and U.S. Publication No. 2007/0282080.

[0046] In one or more embodiments, the reactive component (e.g. moisture-curable isocyanate-containing constituent) is one component of the composition. For example, flashing compositions may include asphalt or polymeric constituents that do not necessarily react with the reactive component. For example, in one or more embodiments, the liquid flashing composition is an asphalt-based composition that is modified by one or more reactive polymer such as polyisocyanate prepolymers alkoxy-silane terminated prepolymers.

[0047] Useful flashing compositions are commercially available. For example, useful flashing compositions can be obtained under the tradenames Ultraflash one-part liquid flashing, Ultraflash two-part liquid flashing, Multi-purpose MB Flashing Cement, Firestone AC Fast FR, and Multi-Purpose MB Cold Adhesive.

FABRIC COMPONENT

[0048] As suggested above, the precursor flashing composite includes a flashing fabric component. These fabrics may include those fabrics conventionally employed in constructing flashings for asphaltic roof systems as known in the prior art.

[0049] A variety of fabrics may be used as the fabric component. In one or more embodiments, fabric is a synthetic fabric including glass or polymeric fibers or filaments. In one or more embodiments, the fabric is a woven fabric. In other embodiments, the fabric may be non-woven. In yet other embodiments, the fabric may include a non-woven fabric with woven reinforcement. In one or more embodiments, the fabric includes a continuous filament polyester, needle punched, nonwoven fabric. In other embodiments, the fabric is a scrim reinforced nonwoven polyester mat. In yet other embodiments, the fabric is a glass fiber mat. In still other embodiments, the fabric is a polyolefin fabric, including nonwoven polypropylene or polyethylene mats. [0050] The skilled person appreciates that flashing fabric is commonly sold as a rolled product. Each roll includes a width of fabric corresponding with a width of the roll, while the length is the amount of fabric wound into the roll. Accordingly, in one or more embodiments the width of the fabric component may be about 6 inches or greater, in other embodiments about 12 inches or greater, in other embodiments about 18 inches or greater, in other embodiments, about 24 inches or greater, in other embodiments about 30 inches or greater, and in other embodiments about 36 inches or greater.

[0051] The skilled person also appreciates that the length of flashing fabric installed at any one time may be selected by the installer in accordance with how quickly the installer is able to apply the liquid flashing composition during its working window before curing. Advantageously, as a result of the above-described percentage of the surface area of fabric component that the pre-cured body covers, an installer is able to install a precursor flashing composite of greater length during the working window of the liquid flashing composition relative to flashing fabric alone. In one or more embodiments, where the precursor flashing composite is designed for installation along a parapet wall, the length of the fabric component is about 4 feet or greater, in other embodiments 5 feet or greater, in other embodiments 6 feet or greater, in other embodiments 7 feet or greater, in other embodiments 8 feet or greater, other embodiments 9 feet or greater. in other embodiments 10 feet or greater, other embodiments 11 feet or greater, in other embodiments 12 feet or greater, in other embodiments 13 feet or greater. in other embodiments 14 feet or greater, in other embodiments 15 feet or greater, in other embodiments 16 feet or greater, in other embodiments 17 feet or greater, in other embodiments 18 feet or greater, in other embodiments 19 feet or greater, and in other embodiments 20 feet or greater.

[0052] In one or more embodiments, where the fabric is a glass fiber mat, the fabric may be characterized by a basis weight of greater than 50 g/m², in other embodiments greater than 60 g/m², and in other embodiments greater than 70 g/m². In these or other embodiments, the glass fiber mat may be characterized by a basis weight of less than 150 g/m², in other embodiments less than 130 g/m², and in other embodiments less than 100 g/m². In one or more embodiments, the glass fiber mat may be characterized by a basis weight of from about 50 to about 150 g/m², in other embodiments from about 60 to about 130 g/m², and in other embodiments from about 70 to about 110 g/m².

[0053] In one or more embodiments, where the fabric is a glass fiber mat, the glass mat may be characterized by a thickness of greater than 0.5 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm. In these or other embodiments, the glass mat may be characterizedby a thickness of less than 2.0 mm, in other embodiments less than 1.5 mm, and in other embodiments less than 1.2 mm. In one or more embodiments, the glass mat may be characterized by a thickness of from about 0.5 to about 2.0 mm, in other embodiments from about 0.7 to about 1.5 mm, and in other embodiments from about 1.0 to about 1.2 mm.

[0054] In one or more embodiments, where the fabric is a polyester fabric, the fabric may be characterized by a basis weight of greater than 70 g/m², in other embodiments greater than 85 g/m², and in other embodiments greater than 100 g/m². In these or other embodiments, the polyester fabric may be characterized by a basis weight of less than 400 g/m², in other embodiments less than 300 g/m², and in other embodiments less than 280 g/m². In one or more embodiments, the polyester fabric may be characterized by a basis weight of from about 70 to about 400 g/m², in other embodiments from about 85 to about 300 g/m², and in other embodiments from about 100 to about 280 g/m².

[0055] In one or more embodiments, where the fabric is a polyester fabric, the glass mat may be characterized by a thickness of greater than 0.3 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm. In these or other embodiments, the polyester fabric may be characterized by a thickness of less than 4.0 mm, in other embodiments less than 2.0 mm, and in other embodiments less than 1.5 mm. In one or more embodiments, the polyester fabric may be characterized by a thickness of from about 0.3 to about 4.0 mm, in other embodiments from about 0.7 to about 2.0 mm, and in other embodiments from about 1.0 to about 1.5 mm.

[0056] In one or more embodiments, where the fabric is a polyolefin mat, the fabric may be characterized by a basis weight of greater than 35 g/m², in other embodiments greater than 42 g/m², and in other embodiments greater than 50 g/m². In these or other embodiments, the polyolefin mat may be characterized by a basis weight of less than 400 g/m², in other embodiments less than 300 g/m², and in other embodiments less than 280 g/m². In one or more embodiments, the polyolefin mat may be characterized by a basis weight of from about 35 to about 400 g/m², in other embodiments from about 42 to about 300 g/m², and in other embodiments from about 50 to about 280 g/m².

[0057] In one or more embodiments, where the fabric is a polyolefin mat, the glass mat may be characterized by a thickness of greater than 0.3 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm. In these or other embodiments, the polyolefin mat may be characterized by a thickness of less than 4.0 mm, in other embodiments less than 2.0 mm, and in other embodiments less than 1.5 mm. In one or more embodiments, the polyolefin mat may be characterized by a thickness of from about 0.3 to about 4.0 mm, in other embodiments from about 0.7 to about 2.0 mm, and in other embodiments from about 1.0 to about 1.5 mm.

[0058] Commercial products suitable for use in accordance with embodiments of the present invention include UltraFlash™ Fabric, available from ELEVATE.

ROOF SYSTEM

[0059] As indicated above, the composite of the present invention can be used to flash between a membrane on a longitudinal surface and a vertical surface of a roof to form a roof system. Other components of the roof system may be conventional in nature. In this regard, reference can be made to FIG. 6, which shows roof system 660 including roof deck 605, optional construction and/or insulation board layer 604, roofing membrane 603, and vertical structure 606. Additionally, installed precursor flashing composite 600 is shown having fabric component 601, first pre-cured body 611, second pre-cured body 612, and cured liquid flashing composition 602. Installed precursor flashing composite 600 and cured liquid flashing composition 602 advantageously create a water-proof seal between roofing membrane 603 and vertical structure 606.

[0060] Practice of this invention is not limited by the selection of any particular roof deck. Accordingly, the roofing systems of this invention can include a variety of roof decks such as concrete pads, steel decks, wood beams, and foamed concrete decks.

[0061] Practice of this invention is likewise not limited by the selection of any water- protective layer or membrane. In one or more embodiments, the membrane layer is an asphaltic membrane system. Those skilled in the art appreciate that these membrane systems can be formed from modified-bitumen rolled membrane product. These membranes are commonly modified with atactic polypropylene (e.g. APP 160 available from ELEVATE) and styrene-butadiene-styrene block copolymer (e.g. SBS FR Torch available from ELEVATE). These membranes may include a roof substrate contacting adhesive surface and an upper surface that may include a weather resistant film or granule surface.

[0062] In other embodiments, polymeric membranes may be used. Useful polymeric membranes include both thermoplastic and thermoset materials. For example, and as is known in the art, membrane prepared from poly(ethylene-co-propylene-co-diene) terpolymer rubber or poly(ethylene-co-propylene) copolymer rubber can be used. Roofing membranes made from these materials are well known in the art as described in U.S. Patent Nos. 6,632,509, 6,615,892, 5,700,538, 5703,154, 5,804,661, 5,854,327, 5,093,206, and 5,468,550, which are incorporated herein by reference. Other useful polymeric membranes include those made from various thermoplastic polymers or polymer composites. For example, thermoplastic olefin (i.e. TPO), thermoplastic vulcanizate (i.e. TPV), or polyvinylchloride (PVC) materials can be used. The use of these materials for roofing membranes is known in the art as described in U.S. Patent Nos. 6,502,360, 6,743,864, 6,543,199, 5,725,711, 5,516,829, 5,512,118, and 5,486,249, which are incorporated herein by reference. In one or more embodiments, the membranes include those defined by ASTM D4637-03 and/or ASTM D6878-03.

[0063] Other layers or elements of the roofing systems are not excluded by the practice of this invention. For example, and as is known in the art, another layer of material can be applied on top of the protective membrane. Often these materials are applied to protect the protective membranes from exposure to electromagnetic radiation, particularly that radiation in the form of UV light. In certain instances, ballast material is applied over the protective membrane. In many instances, this ballast material simply includes aggregate in the form of rock, stone, or gravel; U.S. Patent No. 6,487,830, is incorporated herein in this regard.

[0064] Practice of this invention is likewise not limited by the selection of any particular insulation board. Moreover, the insulation boards are optional. Several insulation materials can be employed including polyurethane or polyisocyanurate cellular materials. These boards are known as described in U.S. Patent Nos. 6,117,375, 6,044,604, 5,891,563, 5,573,092, U.S. Publication Nos. 2004/0109983, 2003/0082365, 2003/0153656, 2003/0032351, and 2002/0013379, as well as U.S. Serial Nos. 10/640,895, 10/925,654, and 10/632,343, which are incorporated herein by reference.

[0065] In one or more embodiments, cover boards may include high density polyurethane or polyisocyanurate board as disclosed in U.S. Publication Nos. 2006/0127664, 2013/0164524, 2014/0011008, 2013/0036694, and 2012/0167510, which are incorporated herein by reference. In other embodiments, the cover boards may include construction boards such as DensDeck.

[0066] As those skilled in the art appreciate, insulation boards and cover boards may carry a variety of facer materials including, but not limited to, paper facers, fiberglass- reinforced paper facers, fiberglass facers, coated fiberglass facers, metal facers such as aluminum facers, and solid facers such as wood.

[0067] The construction boards of this invention can be secured to a building structure by using various known techniques. For example, in one or more embodiments, the construction boards can be mechanically fastened to the building structure (e.g. the roof deck). In other embodiments, the construction boards can be adhesively secured to the building structure.

[0068] Advantageously, the present invention provides for installed flashings to form waterproof seals that exhibit excellent adhesion strength. In one or more embodiments, the installed flashing composites of the present invention provide an adhesion strength that can be determined according to the methods defined by ASTM D413. In one or more embodiments, the adhesion strength is comparable to that of traditional flashing arrangements.

METHOD OF INSTALLING PRECURSOR FLASHING COMPOSITE

[0069] In one or more embodiments, a roof system advantageously employing the precursor flashing composites of the present invention can be prepared by a method that includes providing a precursor flashing composite as described herein, positioning the precursor flashing composite at a desired location, and then applying a liquid flashing composition to at least partially cover the exposed fabric of the precursor flashing composite. [0070] In one or more embodiments, the step of positioning the precursor flashing composite includes positioning composite to traverse a location at or near where a membrane ends at a vertical structure so that composite contacts both the membrane and the vertical surface. In this regard, reference can be made to FIG. 6. In one or more embodiments, composite 600 is positioned so that first pre-cured body 611 is positioned to contact vertical surface 606, second pre-cured body 612 is positioned to contact membrane 603, and hinge area 609 traverses the corner formed by vertical structure 606 and membrane 603. The step of positioning may include one or more sub-steps. For example, it may be useful to secure the composite into position prior to applying the liquid flashing composite, particularly to the vertical surface. This may be accomplished with mechanical or adhesive fastening (e.g. a base coat of liquid flashing material can be applied to the surfaces upon which the composite is placed or the composite can be temporarily affixed with a mechanical fastener). The step of positioning may include folding or otherwise manipulating the hinge area to facilitate shaping the composite to the corner in which it is installed.

[0071] Once the composite is positioned, the liquid flashing composition is applied. As the skilled person will appreciate, the liquid flashing composition is applied in a manner such that the fabric of the composite is at least partially covered to thereby form a water-tight seal. In one or more embodiments, the liquid flashing composition can be applied to cover a portion of the pre-cured bodies.

[0072] When applying the composition, conventional techniques for applying liquid flashing compositions can be employed. For example, the liquid flashing composition can be applied by using brushing or rolling techniques. In other embodiments, especially where the liquid flashing composition has a higher viscosity, known tools such as knives and trowels can be employed. Also, the liquid flashing composition can be applied as one single layer or as multiple layers. In other embodiments, a first layer of liquid flashing composition can be applied to the vertical surface of the vertical structural element, and then the precursor flashing composite can be applied to the first layer of liquid flashing material, and then another layer of liquid flashing material may be applied to cover the fabric component. In one or more embodiments, the precursor flashing composite can be applied to both the vertical surface and the horizontal (or a portion of the horizontal) surface such that the fabric component traverses the transition or corner between the vertical and horizontal surfaces. In any event, the skilled person will appreciate that the liquid flashing composition is applied to traverse the precursor flashing composite and the vertical surface of the vertical structural element. As shown in FIG. 6, application of the liquid flashing composition can extend from the surface of membrane 603 to a surface of vertical surface 606, or it may only traverse a portion of the precursor flashing composite.

[0073] Advantageously, the bodies formed on the fabric of the precursor flashing may serve as a guide or level during installation. In particular, the thickness of a body provides for a visual indicator of the appropriate thickness of liquid flashing composition to be applied to obtain a waterproof barrier. Further, this feature provides for a way to prevent excess liquid flash composition from being applied in accordance with the desire to reduce the amount of liquid flashing composition required during installation of the flashing composite.

METHOD OF FORMING PRECURSOR FLASHING COMPOSITE

[0074] The precursor flashing composite can be formed through a variety of techniques that generally include applied a liquid flashing composition to a fabric. In other embodiments, the pre-cured bodies can first be formed (e.g. within a mold) and then secured to the fabric.

[0075] In one or more embodiments, the fabric is placed into a contact with a template or form and then the liquid flashing composition is applied to the fabric in a manner that allows the form to dictate the shape of the cured body. In one or more embodiments, the form or template may be formed using masking techniques. In one or more embodiments a mask is placed on a first major surface of the fabric component (or otherwise some means of allowing the liquid flashing to be applied in a pattern).

[0076] Once the liquid flashing composition is applied to the fabric, sufficient time is provided to allow the composition to cure. In one or more embodiments, the pre-cured composite may be heated or placed into an environment to facilitate curing.

[0077] The formed precursor flashing composite may be further processed to optionally attach adhesives with release liners used during installation of the precursor flashing composite. Additionally, the formed precursor flashing composite may be packed as a flat pack or rolled according to storage needs. [0078] Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art. This invention is not to be duly limited to the illustrative embodiments set forth herein.

Claims

CLAIMS What is claimed is:

1. A precursor flashing composite comprising:

(i) a fabric component having a first planar surface and a second planar surface;

(ii) a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape; fiiij a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and

(iv) wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.

2. The precursor flashing composite of claim 1, wherein the first pre-cured body has a hinge edge along the hinge region, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge.

3. The precursor flashing composite of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the first pre-cured body.

4. The precursor flashing composite of any of the preceding claims, wherein the second pre-cured body has a hinge edge, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge.

5. The precursor flashing composite of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the second pre-cured body. The precursor flashing composite of any of the preceding claims, further comprising:

(v) at least one additional pre-cured body disposed on at least one additional portion of the first planar surface of the fabric component, wherein the at least one additional pre-cured body is defined by an at least one additional geometric shape; and

[vi] wherein said at least one additional pre-cured body is positioned relative to said first pre-cured body and said second pre-cured body to provide an at least one additional gap between either of said first pre-cured body and said second pre-cured body and said additional pre-cured body to thereby form an at least one additional hinge region. The precursor flashing composite of claim 6, wherein a number of additional precured bodies positioned on the first major surface of the fabric component is selected based on an installation geometry. The precursor flashing composite of any of claims 1-6, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including one-part polyurethane composition. The precursor flashing composite of any of claims 1-6, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including two-part polyurethane composition. The precursor flashing composite of any of claims 1-6, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable polymethyl methacrylate. The precursor flashing composite of any of claims 1-6, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable silicon-containing polymer. A method for creating a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface to which the roofing membrane is secured, the method comprising:

(i) providing a precursor flashing composite including a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second precured body to provide a hinge region between the first pre-cured body and the second pre-cured body;

(ii) positioning the precursor flashing composite on a surface of a vertical structure and a surface of the roofing membrane; and

(iiij applying a liquid flashing composition to the precursor flashing composite, the surface of a vertical structure, and the surface of the roofing membrane to thereby form a water-proof seal between the roofing membrane and the vertical structure. The method of any of the preceding claims, wherein the step of positioning includes folding the precursor flashing composite at the hinge region. The method of any of the preceding claims, wherein the step of positioning includes tacking the precursor flashing composite to the surface of the vertical structure. The method of claim 14, wherein the step of tacking the precursor flashing composite to the surface of the vertical structure includes applying an adhesive or a liquid flashing composition to the precursor flashing composite or to the surface of the vertical structure. The method of any of the preceding claims, wherein the first pre-cured body has a hinge edge along the hinge region, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge. The method of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the first pre-cured body. The method of any of the preceding claims, wherein the second pre-cured body has a hinge edge, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge. The method of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the second pre-cured body. The method of any of the preceding claims, further comprising:

(ivj at least one additional pre-cured body disposed on at least one additional portion of the first planar surface of the fabric component, wherein the at least one additional pre-cured body is defined by an at least one additional geometric shape; and

(v) wherein said at least one additional pre-cured body is positioned relative to said first pre-cured body and said second pre-cured body to provide an at least one additional gap between either of said first pre-cured body and said second pre-cured body and said additional pre-cured body to thereby form an at least one additional hinge region. The method of claim 20, wherein a number of additional pre-cured bodies positioned on the first major surface of the fabric component is selected based on an installation geometry. The method of any of claims 12-21, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including one-part polyurethane composition. The method of any of claims 12-21, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including two-part polyurethane composition. The method of any of claims 12-21, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable polymethyl methacrylate. The method of any of claims 12-21, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable silicon- containing polymer. A method of forming a precursor flashing composite, the method comprising:

(i) providing a fabric component with a first major planar surface and a second major planar surface;

(ii) disposing a first liquid coating layer on the first major planar surface of the fabric component;

CiiiD disposing a second liquid coating layer on the first major planar surface of the fabric component; and

(iv) curing the first liquid coating layer and the second liquid coating layer to thereby form a first body and a second body, respectively, wherein the first body has a first geometric shape, and wherein the second body has a second geometric shape. A roofing system comprising:

(i) a roof deck;

(ii) optionally, one or more roofing boards; (iii) a roofing membrane;

(ivj a vertical structure extending from a roof surface to which the roofing membrane is secured; and

(v) a flashing forming a water-proof seal between the roofing membrane and the vertical structure; wherein the flashing includes a composite flashing structure adhered into place with a flashing composition, where the composite flashing structure includes a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body. The roof system of claim 27, wherein the first pre-cured body has a hinge edge along the hinge region, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge. The roof system of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the first pre-cured body. The roof system of any of the preceding claims, wherein the second pre-cured body has a hinge edge, longitudinal edges orthogonal to the hinge edge, and a lateral edge parallel to the gap edge. The roof system composite of any of the preceding claims, wherein the fabric component extends beyond the longitudinal edges and the lateral edge of the second pre-cured body. The roof system of any of the preceding claims, further comprising:

[vi] at least one additional pre-cured body disposed on at least one additional portion of the first planar surface of the fabric component, wherein the at least one additional pre-cured body is defined by an at least one additional geometric shape; and

(vii) wherein said at least one additional pre-cured body is positioned relative to said first pre-cured body and said second pre-cured body to provide an at least one additional gap between either of said first pre-cured body and said second pre-cured body and said additional pre-cured body to thereby form an at least one additional hinge region. The roof system of claim 27, wherein a number of additional pre-cured bodies positioned on the first major surface of the fabric component is selected based on an installation geometry. The roof system of any of claims 27-33, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including one-part polyurethane composition. The roof system of any of claims 27-33, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including two-part polyurethane composition. The roof system of any of claims 27-33, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable polymethyl methacrylate. The roof system of any of claims 27-33, wherein the first pre-cured body and the second pre-cured body are the cured residue of a composition including a curable silicon-containing polymer. The use of a precursor flashing composite of any of the preceding claims to create a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface.