Note: Descriptions are shown in the official language in which they were submitted.
CA 02443143 2003-09-26
KVAS MILLER EVERITT CANADA
File No. 273-FAB 12
TITLE: RO~FING UNDERLAYMENT
APPLICANT: FABRENE INC
CA 02443143 2003-09-26
TITLE: Roofing Underlayment
FIELD OF THE INVENTION
This invention relates generally to the field of roofing materials, and in
particular to a
new and improved roofing underlayment.
BACKGROUND OF THE INVENTION
In the construction of a pitched roof, it is highly desirable from both an
aesthetic and a
functional stand point to ensure that roofing materials are applied in a
manner so that
they are "square" with the ridge of the roof, and so that they are arranged in
a generally
parallel or "straight" configuration. For example, where asphalt shingles are
to be
applied to a roof, alignment of the shingles in equally spaced rows that are
generally
horizontal and parallel to the ridge of the roof ensures an aesthetically
pleasing
appearance and allows the shingles to function in the manner in which they
were
designed; namely, to shed water and prevent leakage. ~i~Iisalignment of
shingles creates
both an unattractive finished product and presents the potential for water to
penetrate
through the roof and into the building. Whether the exterior roofing material
is
comprised of asphalt shingles, tiles, galvanized or other metallic sheeting,
wooden
shakes, slate or any one of a wide variety of other commonly used roofing
materials,
there exists a need to apply the roofing material in an aligned and "square"
fashion.
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To ensure the alignment of roofing materials when applied to a roof substrate,
installation personnel typically resort to one of a variety of common
construction
methods that enable subsequent rows of roofing materials to be aligned with
previously
applied rows. For example, carpenters and roofers will often mark parallel
lines across
the roofing substrate (which in wooden construction is typically plywood,
exterior
wooden sheeting, or roofing boards) through the 'use of a pencil, marker or
chalk line.
In other instances the installer may use a tape measure to physically measure
the
distance between respective rows of roofing materials as each row is laid
down. While
both of these methods may be effective, they are also labour intensive and
introduce the
potential for error as there is a constant requirement for individuals to take
measurements and mark the position for subsequent rows of roofing materials.
Failure
to measure or mark accurately can result in an alignment problem.
The alignment of roofi~ig materials can be further complicated by the fact
that a liner or
underlayment is commonly applied to the roof substrate prior to the
application of
shingles, shakes, tiles or other roofing materials. Such underlayments may be
comprised
of a wide variety of products including roofing paper (generally comprised of
a
petroleum coated cellulose product and often referred to as tar paper),
roofing felt
(comprised generally of asphalt saturated organic felt which may be coated or
uncoated),
rubber or rubberized membranes, and an equally wide variety of synthetic
underlayments
(both woven and extruded). Regardless of the particular form of underlayment
that is
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utilized, its function is essentially the same; to provide a secondary barrier
to water and
moisture beneath the shingles, tiles or other roofing materials and next to
the roof
substrate. Commonly the underlayment is applied to the roof substrate in a
series of
horizontal rows and is secured to the roof through th.e use of nails, staples
or an
adhesive. Once applied, the underlayment obscure s the roof substrate from
view making
it even more difficult for a roofer to properly align the overlying roofing
materials.
SUMMARY OF TILF INVhJNTION
The invention therefore; provides a product and a method that allows for the
installation
of shingles and other roofing materials in an aligned pattern that is "square"
with the roof
structure, that is cost effective, and that minimizes the potential for human
error and the
misalignment of roofing materials.
Accordingly, in one embodiment of the invention there is provided a roofing
underlayment for placement over a roof substrate prior to the application of
shingles,
tiles or other roofing materials, the underlayment comprising a sheeting
material having
an upper surface and a lower surface, said underlayment containing a grid that
is visually
identifiable from above said underlayment when said underlayment is received
over said
roof substrate with said lower surface of said underlayment adjacent to said
roof
substrate, said grid assisting in the aligmnent of said underlayment with said
roofing
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substrate during application of said underlayment to said substrate and
further assisting
in the alignment of roofing materials applied over said underlayment.
In a further aspect the invention provides a roofing underlayment for
placement over a
roof substrate prior to the application of shingles, tiles or other roofing
materials, the
underlayment comprising a sheeting material having an upper surface and a
lower
surface, said underlayment containing a grid that is visually identifiable
from above said
underlayment when said underlayment is received over said roof substrate with
said
lower surface of said underlayment adjacent to said roof substrate, said grid
comprised
of a series of equally spaced apart lines that are parallel to the
longitudinal axis of said
underlayment and a series of equally spaced apart lines that are perpendicular
to the
longitudinal axis of said underlayment, said grid assisting in the alignment
of said
underlayment with said roofing substrate during application of said
underlayment to said
substrate and further assisting in the alignment of roofing materials applied
over said
underlayment.
In yet a further aspect the invention provides a roofing underlayment for
placement over
a roof substrate prior to the application of shingles, tiles or other roofing
materials, the
underlayment comprising a sheeting material having an upper surface and a
lower
surface, said underlayment containing a grid that is visually identifiable
from above said
underlayment when said underlayment is received over said roof substrate with
said
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lower surface of said underlayment adjacent to said roof substrate, said grid
comprised
of a series of spaced apart and parallel lines extending over at least a
portion of said
upper surface of said underlayment, said grid assisting in the alignment of
said
underlayment with said roofing substrate during application of said
underlayment to said
substrate and further assisting in the alignment of roofing materials applied
over said
underlayment.
The invention also provides a roofing underlayment for placement over a roof
substrate
prior to the application of shingles, tiles or other roofing materials, the
underlayment
comprising a sheeting material having an upper surface and a lower surface,
said
underlayment containing a grid that is visually identifiable when said
underlayment is
received over said roofing substrate with said lower surface of said
underlayment
adjacent to said substrate, said grid comprised of a series of spaced apart
longitudinal
lines that are parallel to the longitudinal axis of said underlayment and a
series of spaced
apart perpendicular lines that are perpendicular to the longitudinal axis of
said
underlayment, said longitudinal and said perpendicular lines coloured to
distinguish said
lines from said sheeting material.
In a further aspect the invention concerns a roofing underlayment for
placement over a
roof substrate prior to the application of shingles, tiles or other roofing
materials, the
underlayment comprising a sheeting material having an upper surface and a
lower
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surface, said underlayment containing a grid that is visually identifiable
when said
underlayment is received over said roofing substrate with said lower surface
of said
underlayment adjacent to said substrate, said grid comprised of a series of
spaced apart
longitudinal lines that axe parallel to the longitudinal axis of said
underlayment and a
series of spaced apart perpendicular lines that are perpendicular to the
longitudinal axis
of said underlayment, said longitudinal lines being of at least a first colaur
contrasting
to the colour of said underlayment, said perpendicular lines being of at least
a second
colour contrasting to the colour of said underlayment.
Further aspects and advantages of the invention will become apparent from the
following description taken together with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention, and to show more clearly
how it may
be carried into effect, reference will now be made, by way of example, to the
accompanying drawings which show the preferred embodiments of the present
invention
in which:
ZO Figure 1 is a side sectional view through a portion of a typical pitched
roof showing one
embodiment of the present invention;
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Figure 2 is an upper side perspective view of a pitched roof having a series
of horizontal
rows of a roof underlayment applied thereto;
Figure 3 is an upper perspective view of a roll of roofing underlayment
according to one
embodiment of the present invention;
Figure 4 is an upper perspective view of a roll of roofing underlayment
according to a
second embodiment of the present invention;
Figures SA, SB and SC are upper perspective views of rolls of roofing
underlayment
according to a third, forth and fifth embodiment of the present invention;
Figure 6 is a front view of a portion of a pitched roof showing the
application of a
roofing underlayment in accordance with a preferred embodiment of the present
invention and as used in association with asphalt shingles;
Figure 7 is a magnified detail view of a portion of a roofang underlayment
according to
an embodiment of the present invention where the underlayment is formed from a
woven scrim;
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Figure 8 is a magnified detail side sectional view of a portion of a roofing
underlayment
according to an embodiment of the present invention Where the upper surface of
the
underlayment has a grid pattern embossed thereon;
Figure 9 is a magnified detail side sectional view of a portion of a roofing
underlayment
according to an embodiment of the present invention where the upper surface of
the
underlayment includes a grid pattern formed from .a series of tapes, yarns or
filaments.
DESCRIPTION OF 'CHE PREFERRED EMBODIMENT
The present invention may be embodied in a number of different forms. However,
the
specification and drawings that follow describe and disclose only some of the
specific
forms of the invention and are not intended to limit the scope of the
invention as defined
in the claims that follow herein.
The typical structure of a standard pitched roof (as constructed in wood
framed
buildings) is shown in cross section in Figure 1. In general such roofs are
comprised of
a wooden substrate 1 fastened to a series of trusses or rafters 2. A roofing
underlayment
3 is commonly laid over substrate 1. Thereafter roofing materials 4 are
applied to form
the finished roof. In most instances substrate 1 would be comprised of
plywood,
exterior sheeting, or a series of wooden boards. However, it will be
appreciated that the
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CA 02443143 2003-09-26
scope and application of the present invention will not be limited to a
particular form
of substrate. Similarly, while roofang materials 4 may be comprised of asphalt
shingles
as shown in Figure l, the roofing material may equally be any one of a wide
variety of
exterior roofing products, including clay or cement tiles, wooden shakes,
metal roofing
materials, slate, etc. As in the case of substrate 1, the scope of the present
invention is
not limited to any particular roofing material.
It is expected that in most cases underlayment 3 will be comprised of a
relatively thin
and flexible material formed into rolls (see Figures 3, 4 and 5) that may be
cut to length
as necessary. While underlayment 3 may be manufactured to practically any
desired
dimension, for handling; and transportation purposes rolls of a width of
between 30 and
80 inches are most desirable. Where rolls of this size range are utilized a
series of
horizontally oriented rows of underlayment will be applied to the roof in
order to fully
cover substrate 1. Preferably the rows of underlayment material are applied
beginning
along the lower edge of the roof working toward the top such that each
subsequent row
that is higher up on the roof overlaps the adjacent lower row to allow any
moisture that
may come into contact with the underlayment to be shed as it flows downwardly
along
the pitch of the roof. In o~thaer embodiments of the invention substantially
larger rolls of
material could be manufactured such that a single sheet of underlayment is
capable of
covering the entire exterior surface of substrate 1. Alternatively, the
substrate could be
formed into a rigid or semi-rigid sheeting material that is applied to the
roof in a manner
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similar to the application of the substrate material.
The composition and structure of underlayment 3 may vary substantially
depending
upon the particular application in question. The underlayment may range from a
common tar paper or roofing felt structure, to a plastic or rubberized or PVC
ice and
water shield, to a single ply thermoplastic (for example polyolefin) membrane,
to a high
strength woven product comprised of a series of woven tapes, yarns and/or
filaments
(identified generally as 12 in Figure 7). The underlayment may also be coated
on one
or both sides to enhance abrasion resistence, to increase strength and water
resistance,
and/or to present a slip resistant surface. Depending upon the environment
within which
the roof structure is located, the type of roofing material to be applied over
the
underlayment, the required useful Iife of the roof, and considering
differences in costs,
it may be desirable to use one particular composition and structure of
underlayment
over and above the others. It will be appreciated from a complete
understanding of the
present invention that the preferred embodiment of the invention is not
limited to one
form of underlayment or a particular method of manufacture.
In accordance with a preferred embodiment of the invention underlayment 3 is
comprised of a sheeting or sheet-like material having an upper surface 5 and a
lower
surface 6 that is received over roof substrate 1. Typically underlayment 3 is
secL~red to
substrate 1 through the use of nails, staples or an adhesive. Of particular
importance to
CA 02443143 2003-09-26
the invention is the fact that at least the upper surface 6 of underlayment 3
contains a
visually identifiable grid 7. Grid 7 assists in both the alignment of the
underlayment
with the roof substrate (and with subsequent rows of underlayment) during
application
of the underlayment to the roof, and also assists in 'the subsequent alignment
of roofing
materials that are applied over the underlayment. It will be understood that
there are a
variety of manners in which grid 7 may be applied or adhered to underlayment
3,
including printing or embossing the grid upon upper surface 6 of the
underlayment.
Where grid 7 is embossed on the surface of underlayrnent 3 the effect may be
the
formation of small linear indentations 11 across the suri:ace of the
underlayment (see
Figure 8). Grid 7 may also be printed, embossed or otherwise applied to both
upper
surface 5 and lower surface 6 allowing either of the outer surfaces of the
underlayment
to be placed adjacent to roof substrate 1. Where grid 7 is embossed on
underlayment
3 the embossed surface will also tend to exhibit anti-skid characteristics
further
enhancing the characteristics of the product.
In alternate embodiments of the invention, grid 7 may be comprised of a series
of yarns,
tapes and/or filaments 10 that are woven into the underlayment where the
underlayment
is a woven scrim (See generally Figure 7). The yarns, tapes and/or filaments
10 are
preferably coloured a contrasting colour to the scrim and may be superimposed
or
adjacent to the yarns, tapes and/or filaments 12 of the scrim. Alternatively
yarns, tapes
and/or filaments 10 may be otherwise adhered to either the upper and/or the
lower
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surface of the underlayment (for example see Figure 9) through the use of an
adhesive,
or during a coating process where the underlayment is a coated product.
In one of the preferred embodiments of the invention grid 7 is comprised of a
series of
equally spaced apart lines 8 that are parallel to the longitudinal axis of the
sheeting
material from which the underlayment is made (see Figure 3). Alternately, grid
7 may
be comprised of a series of equally spaced apart lines 9 that are
perpendicular to the
longitudinal axis of the sheeting material (see Figure 4). In yet a third
embodiment grid
7 may be comprised of both a series of equally spaced apart lines 8 that are
parallel to
the longitudinal axis of the sheeting material, and a series of equally spaced
apart lines
9 that are perpendicular to the longitudinal axis of the sheeting material
(see Figures SA,
SB and SC).
Regardless of the particular grid structure that is used, the lines that
comprise grid 7
must be visually identifiable, and to that extent they are preferably of a
colour other than
that of the sheeting material from which the underlayment is constructed (or
other than
the coating material where the underlayment is a coated product). For example,
where
the sheeting material of underlayment 3 is white or a light colour, grid 7 may
be black,
green, red or some other contrasting colour making the lines of the grid
clearly
identifiable upon the surface of the product. In addition, the lines
comprising grid 7 may
in some fashion alternate in colour between a first colour and a second colour
to present
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a further visual identification and distinction between adjacent or groups of
lines. In
these regards, one variation of grid 7 that could be utilized comprises a one
inch spacing
between lines that are parallel to the longitudinal axis of tlae underlayment
with the lines
alternating in colour between green and black. In another variation, grid 7
may be
comprised of lines that are parallel to the longitudinal axis of the
underlayment and that
are spaced apart by one inch increments, and lines that are perpendicular to
the
longitudinal axis of the underlayment and also spaced apart in one inch
increments: The
longitudinally oriented lines may be black with the perpendicular lines green,
presenting
a visual distinction between the rows of lines that will effectively be
oriented vertically
and horizontally when underlayment 3 is placed in a generally horizontal
configuration
across roof substrate 1. The alternating colours of the lines forming in grid
7 helps to
present a visual distinction between adjacent lines and assists in the
alignment of
underlayment 3 and roofing materials 4.
Further possible variations of grid 7 are shown in Figures SA and SB. In the
embodiment shown in Figure SA grid 7 is comprised of lines that are parallel
to the
longitudinal axis of the underlayment with adjacent parallel lines alternating
in colour.
The grid is further comprised of lines that are perpendicular to the
longitudinal axis of
the underlayment with adjacent perpendicular lines alternating in colour.
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In Figure 5B, an embodiment is shown wherein grid 7 is comprised of a series
of lines
parallel to the longitudinal axis of the underlayment and equally spaced apart
in one inch
increments. The longitudinally oriented lines alternate in colour in six inch
blocks
creating groups of lines of like colours that alternate ever<I six inches. The
grid further
comprises a series of lines perpendicular to the longitudinal axis of the
underlayment
and also spaced apart in one inch increments. As in the case of the
longitudinally
oriented lines, the perpendicular lines alternate in colour in six inch
blocks. The
grouping of the perpendicular and parallel lines in six inch blocks, and the
further
subdividing of those six inch blocks into one inch segments, has been found to
provide
the roofing installer with a visually identifiable grid that allows for the
measurement of
larger distances through counting six inch blocks, while at the same time
providing for
relatively precise measurement and alignment through reference to individual
lines
spaced apart in one inch increments.
It will of course be appreciated that while the embodiment depicted in Figure
5B
contemplates a line spacing of one inch with six inch groupings in both the
longitudinal
and perpendicular directions, the individual line spacing, andlor the grouping
of lines
of a common colour, could vary depending upon the particular end use of the
product.
For example, when applying particular types of roofing materials it may be
desirable to
use an alternate line spacing and/or an alternate grouping of lines of
different colours to
more closely conform to the physical dimensions of the particular roofing
materials in
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question. In some cases the line spacing may be as low as 1/8 inch while in
other cases
a spacing as high as 24 inches may be desirable. Further, where both vertical
and
horizontal lines are utilized, the spacing of the horizontal lines may be
different than that
of the vertical lines. For example, it may be advantageous far the horizontal
lines to
have an incremental spacing of one inch whereas the vertically oriented lines
may be
spaced apart at intervals of 12 inches. It should also be noted that grid 7
may be
comprised of lines that are solid, broken or patterned (for example small
dots, squares,
etc.).
Through the utilization of a roofing underiayment as described herein, it will
be
appreciated that a roofer is provided with a means by which the underlayment
itself can
be easily aligned with the roof substrate, and in particular the ridge of the
roof. Where
the underlayment is applied in a series of horizontal rows, the roofing
installer is able
to quickly and easily align adjacent rows with one another so that they
maintain their
horizontal attitude and to ensure that each subsequent row positioned higher
up on the
roof is both parallel to the lower adjacent row and over laps the lower row by
sufficient
degree. Once the underlayment has been applied to the roof the grid pattern
that is
visually identifiable thereon presents the roofer with an ability to quickly
and accurately
align shingles or other roofing materials with both .one another and with the
roof. An
example showing how underlayment 3 may be used to assist in the alignment of
shingles
is shown in Figure 6.
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It will thus be appreciated that utilization of underlayment 3 will remove the
necessity
for roofers to use chalk lines, straight edges, measuring tapes and other
implements to
ensure alignment of roofing materials as they are applied. The invention also
removes
the need for measuring, and the associated potential for error in either
failing to measure
properly or failing to mark a measurement properly upon the roof. The roofer
need only
align the shingles or the roofing materials with the grid pattern upon
underlayment 3 to
ensure that the roofing materials are installed in a horizontal and parallel
configuration
with adequate overlap. Where the underlayment exhibits anti-skid
characteristics its
application over a roof substrate will also present an inherently safer work
surface for
roofing installers.
It is to be understood that what has been described are the preferred
embodiments of the
invention and that it may be possible to make variations to these embodiments
while
staying within the broad scope of the invention. Some of these variations have
been
I S discussed while others will be readily apparent to those skilled in the
art. For example,
while the grid patterns discussed and shown in the attached Figures represent
what are
believed to be some of the most likely practical embodiments of the invention,
a variety
of other grid patterns could equally be utilized, including grid patterns that
are
comprised of non-uniformly spaced apart lines.
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