Hail damage-resistance roof assembly and method for making same

A hail resistant roof system comprising:

• a roof deck or air sealed substrate;
• a primary waterproofing membrane disposed over at least a substantial portion of said roof deck or air seal substrate;
• an insulation layer loose laid over primary waterproofing membrane;
• an energy absorbing layer supported by said insulation layer, wherein said energy absorbing layer is of a different material than said insulation layer;
• and
• a secondary waterproof membrane loose laid over said energy absorbing layer, such that said waterproof membrane is completely unattached to any portion of the roof system at any area of said secondary waterproof membrane running substantially parallel to a relatively upper surface of said frangible energy absorbing layer, said waterproof membrane only being attached to the roof system at an area of the waterproof membrane running substantially perpendicular to said relatively upper surface of said frangible energy absorbing layer;
• at least one intentional wrinkle in said secondary waterproof membrane, said wrinkle being excess membrane material that is pulled upward from said relatively upper surface of said frangible energy absorbing layer relative to portions of said waterproof membrane on both sides of said wrinkle -disposed over an open area of said relatively upper surface of said frangible energy absorbing layer that is absent any attachment structure, adhesive, or other structure protruding upwardly from said relatively upper surface of said frangible energy absorbing layer relative to a substantial remainder of said relatively upper surface of said frangible energy absorbing layer at any area under said wrinkle, said open area between said secondary waterproof membrane and said relatively upper surface of said frangible energy absorbing layer at said wrinkle allowing said secondary waterproof membrane to be pulled down towards said relatively upper surface of said frangible energy absorbing layer in response to hail impact upon the waterproof membrane without interference from any attaching to said relatively upper surface of said frangible energy absorbing layer or structure between said secondary waterproof membrane and said relatively upper surface of said frangible energy absorbing layer at said wrinkle.

A hail resistant roof system comprising:

• a roof deck;
• a resilient roof insulation layer disposed upon said roof deck, wherein said insulation layer is at least one of expanded polystyrene (EPS) and polyisocyanurate foam (ISO);
• at least 0.5 inches of gypsum board disposed upon said insulation layer, wherein the insulation layer is configured to compress to allow energy absorption when the gypsum is struck by an object;
• and
• a loose laid, non-reinforced waterproofing membrane with fabricated wrinkles disposed upon said gypsum board, such that said waterproof membrane is completely unattached to any portion of the roof system at any area of said waterproof membrane running substantially parallel to a relatively upper surface of said gypsum board, said waterproof membrane only being attached to the roof system at an area of the waterproof membrane running substantially perpendicular to said relatively upper surface of said gypsum board,
• wherein said wrinkles are in said waterproof membrane, said wrinkles being excess membrane material that pulled upward from said relatively upper surface of said gypsum board relative to portions of said waterproof membrane on both sides of said wrinkle -disposed over an open area of said relatively upper surface of said gypsum board that is absent any attachment structure, adhesive, or other structure protruding upwardly from said relatively upper surface of said gypsum board relative to a substantial remainder of said relatively upper surface of said gypsum board at any area under said wrinkle, said open area between said waterproof membrane and said relatively upper surface of said gypsum board at said wrinkle allowing said waterproof membrane to be pulled down towards said relatively upper surface of said gypsum board in response to hail impact upon the waterproof membrane without interference from any attaching to said relatively upper surface of said gypsum board or structure between said waterproof membrane and said relatively upper surface of said gypsum board at said wrinkle.