U.S. patent application number 14/445998 was filed with the patent office on 2014-11-27 for roof mount assembly.
The applicant listed for this patent is VERMONT SLATE & COPPER SERVICES, INC.. Invention is credited to Brian Cecil Stearns.
Application Number | 20140345213 14/445998 |
Document ID | / |
Family ID | 46827334 |
Filed Date | 2014-11-27 |
United States Patent
Application |
20140345213 |
Kind Code |
A1 |
Stearns; Brian Cecil |
November 27, 2014 |
ROOF MOUNT ASSEMBLY
Abstract
A solar panel mounting assembly for mounting a solar panel to a
roof surface includes a bracket having a slot with a generally
t-shaped cross section that extends along at least a portion of a
length of the bracket, a first fastener having a head end
positioned in the slot and a shaft. The first fastener slides along
the slot in a direction substantially parallel to the roof surface.
The assembly further includes a membrane positioned between the
roof surface and the bracket. The bracket is connected to the roof
surface by at least one of a group consisting of the membrane and a
second fastener, and the generally t-shaped cross section includes
a first wide portion sized to receive the head end of the fastener
and a second narrow portion sized to receive the shaft of the
fastener.
Inventors: |
Stearns; Brian Cecil;
(Stowe, VT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VERMONT SLATE & COPPER SERVICES, INC. |
Morrisville |
VT |
US |
|
|
Family ID: |
46827334 |
Appl. No.: |
14/445998 |
Filed: |
July 29, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13272005 |
Oct 12, 2011 |
8826618 |
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14445998 |
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61452983 |
Mar 15, 2011 |
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61485693 |
May 13, 2011 |
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Current U.S.
Class: |
52/173.3 |
Current CPC
Class: |
F24S 25/40 20180501;
G09F 2007/186 20130101; Y02B 10/20 20130101; G09F 7/18 20130101;
H01Q 1/1221 20130101; E04D 13/00 20130101; E04D 13/1407 20130101;
E04D 13/10 20130101; E04G 21/328 20130101; F24S 25/61 20180501;
F24S 2025/601 20180501; Y02E 10/47 20130101 |
Class at
Publication: |
52/173.3 |
International
Class: |
F24J 2/52 20060101
F24J002/52; E04D 13/00 20060101 E04D013/00 |
Claims
1. A solar panel mounting assembly for mounting a solar panel to a
roof surface, the mounting assembly comprising: a bracket having a
slot formed therein, wherein the slot has a generally t-shaped
cross section extending along at least a portion of a length of the
bracket; a first fastener having a head end positioned in the slot
and a shaft, wherein the first fastener is configured to slide
along the slot in a direction substantially parallel to the roof
surface; and a membrane positioned between the roof surface and the
bracket; wherein the bracket is connected to the roof surface by at
least one of a group consisting of the membrane and a second
fastener, and wherein the generally t-shaped cross section includes
a first wide portion sized to receive the head end of the fastener
and a second narrow portion sized to receive the shaft of the
fastener.
2. The mounting assembly of claim 1, wherein the narrow portion of
the t-shaped slot is sized to inhibit rotation of the head end of
the fastener relative to the bracket when the head end of the
fastener is positioned within the slot.
3. The mounting assembly of claim 1, further comprising a nut sized
to engage the fastener shaft, wherein the narrow portion of the
generally t-shaped slot inhibits rotation of the fastener head such
that a user can tighten the nut onto the fastener after the
fastener is inserted into the generally t-shaped slot.
4. The mounting assembly of claim 1, wherein the slot extends along
the entire length of the bracket.
5. The mounting assembly of claim 1, wherein the roof is a membrane
roof and wherein the bracket is connected to the roof surface by
bonding the membrane to the roof surface.
6. The mounting assembly of claim 1, wherein the second fastener
extends through an aperture in the bracket and through the membrane
to connect the bracket to the membrane.
7. The mounting assembly of claim 1, wherein the generally t-shaped
slot is sized to permit a user to install the bracket and the
membrane on the roof prior to inserting the fastener into the
generally t-shaped slot.
8. The mounting assembly of claim 1, wherein the generally t-shaped
slot permits a user to move the fastener between a first mounting
position on the bracket and a second mounting position laterally
spaced along the length of the bracket from the first mounting
position.
9. The mounting assembly of claim 1, further comprising a plate
positioned between the membrane and the roof surface, wherein the
second fastener extends through the plate and into the roof
surface.
10. The mounting assembly of claim 9, wherein an upper surface of
the membrane is bonded to the bracket and a lower surface of the
membrane is bonded to the plate and to the roof surface to connect
the bracket to the roof surface.
11. The mounting assembly of claim 9, wherein the plate includes a
lower portion positioned substantially adjacent the roof surface, a
raised portion spaced from the roof surface and a transition
portion between the lower portion and the raised portion.
12. The mounting assembly of claim 9, wherein the membrane is
elastomeric and wherein the membrane forms a seal around an
aperture in the roof surface through which the second fastener
extends to substantially inhibit fluid from flowing into the
aperture in the roof surface.
13. A solar panel mounting assembly for mounting a solar panel to a
roof surface, the mounting assembly comprising: a bracket having a
slot formed therein, wherein the slot extends along at least a
portion of a length of the bracket; a first fastener having a head
end positioned in the slot and a shaft, wherein the fastener is
configured to slide along the slot in a direction substantially
parallel to the roof surface; and a membrane positioned between the
roof surface and the bracket; wherein the bracket is connected to
the roof surface by at least one of a group consisting of the
membrane and a second fastener, wherein the slot includes a first
wide portion sized to receive the head end of the fastener and a
second narrow portion sized to receive the shaft of the fastener,
wherein the head end of the fastener is positioned closer to the
roof surface than the shaft.
14. The mounting assembly of claim 13, wherein the narrow portion
of the slot is sized to inhibit rotation of the head of the
fastener relative to the bracket when the head of the fastener is
positioned within the slot.
15. The mounting assembly of claim 13, further comprising a nut
sized to engage the fastener shaft, wherein the narrow portion of
the slot inhibits rotation of the fastener head relative to the
bracket such that a user can tighten the nut onto the fastener
after the fastener is inserted into the slot.
16. The mounting assembly of claim 13, wherein the slot extends
along the entire length of the bracket and wherein the slot is
sized to permit the user to move the fastener between a first
mounting position on the bracket and a second mounting position
laterally spaced along the length of the bracket from the first
mounting position.
17. The mounting assembly of claim 13, wherein the roof is a
membrane roof and wherein the bracket is connected to the roof
surface by bonding the membrane to the roof surface and wherein the
second fastener extends through an aperture in the bracket and
through the membrane to connect the bracket to the membrane.
18. The mounting assembly of claim 13, further comprising a plate
positioned between the membrane and the roof surface, wherein the
second fastener extends through the plate and into the roof
surface.
19. The mounting assembly of claim 18, wherein an upper surface of
the membrane is bonded to the bracket and a lower surface of the
membrane is bonded to the plate and to the roof surface to connect
the bracket to the roof surface.
20. The mounting assembly of claim 18, wherein the plate includes a
lower portion positioned substantially adjacent the roof surface, a
raised portion spaced from the roof surface and a transition
portion between the lower portion and the raised portion.
21. The mounting assembly of claim 18, wherein the membrane is
elastomeric and wherein the membrane forms a seal around an
aperture in the roof surface through which the second fastener
extends to substantially inhibit fluid from flowing into the
aperture in the roof surface.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 13/272,005 filed Oct. 12, 2011 which claims the benefit of
and priority to U.S. Provisional Patent Application No. 61/452,983,
filed Mar. 15, 2011, and to U.S. Provisional Patent Application No.
61/485,693, filed May 13, 2011, the entire contents of all of which
are hereby incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to roof mounting structures
and methods of installing and using the same.
SUMMARY
[0003] In one embodiment, the invention provides a roof attachment
assembly for mounting to a roof substrate. The roof attachment
assembly comprises a plate having a substantially frustoconical
protrusion defining an aperture extending therethrough, the plate
defining a first surface and a second surface, the first surface
facing the roof substrate and the second surface spaced from the
roof substrate. The roof attachment assembly also comprises a
membrane positioned adjacent one of the first surface and the
second surface of the plate, and a bracket positioned proximate the
second surface of the plate, the bracket operable to support one or
more roof mounted fixtures. The roof attachment assembly further
comprises a fastener extending through the bracket, the membrane
and the plate, the fastener operable to couple the bracket, the
membrane and the plate together, wherein the roof substrate is
contiguous adjacent to an end of the fastener.
[0004] In another embodiment, the invention provides a roof
attachment assembly for mounting a structure to a membrane roof.
The roof attachment assembly comprises a pair of opposed
compression plates, a first one of the pair of compression plates
defining a recess, a second one of the pair of compression plates
having an outwardly extending frustoconical protrusion matingly
engageable in the recess defined in the first one of the pair of
compression plates. The roof attachment assembly also comprises a
skirt compressed between the pair of opposed compression plates and
substantially shrouding one of the first and second pair of
compression plates, and a standoff positioned proximate the pair of
opposed compression plates, the standoff operable to support the
structure and to space the structure away from the membrane roof.
The roof attachment assembly further comprises a fastener extending
through the standoff, the skirt and the pair of compression plates,
the fastener securing the standoff to the pair of compression
plates and compressing the skirt between the pair of opposed
compression plates to seal the attachment assembly, and a bond
formed between the skirt and a roof membrane secured to the
membrane roof.
[0005] In another embodiment, the invention provides a roof
attachment assembly for mounting a structure to a membrane roof.
The roof attachment assembly comprises a clamp having pair of
opposing clamp halves, a first one of the clamp halves defining a
recess, a second one of the clamp halves having an outwardly
extending frustoconical protrusion matingly engageable in the
recess defined in the first one of the clamp halves. The roof
attachment assembly also comprises a skirt compressed between the
pair of opposed clamp halves, and a standoff positioned proximate
the pair of opposed clamp halves, the standoff operable to support
the structure and to space the structure away from the membrane
roof. The roof attachment assembly further comprises a fastener
extending through the standoff, the skirt and the pair of clamp
halves, the fastener securing the standoff to the pair of clamp
halves and compressing the skirt between the pair of opposed clamp
halves to seal the attachment assembly, and an elastic pad
positioned between the pair of clamp halves and the membrane
roof.
[0006] In another embodiment, the invention provides a roof
attachment assembly for mounting a structure to a roof having a
roof membrane. The roof attachment assembly comprises a bracket
secured to the roof and operable to support the structure and space
the structure away from the roof, and a seal positioned between the
bracket and the roof to prevent leakage around the bracket through
the roof. The seal includes a clamp having a pair of opposed
compression plates and a fastener extending through the bracket and
the compression plates, the fastener having a blunt end supported
away from the roof membrane. The seal further includes a skirt
compressed between the pair of opposed compression plates and
substantially shrouding one of the first and second pair of
compression plates, a bond formed between the skirt and the roof
membrane to substantially enclose one of the first or second pair
of compression plates, and an elastic pad positioned between the
clamp and the membrane roof to shield the roof membrane from
contact with the clamp.
[0007] In another embodiment, the invention provides a roof
attachment assembly to be mounted on a roof substrate. The roof
attachment assembly comprises a base member positioned adjacent to
the roof substrate, the base member having a substantially
frustoconical protrusion extending away from the roof substrate and
defining an aperture, the base member defining a first surface and
a second surface, the first surface facing the roof substrate and
the second surface spaced from the roof substrate. The roof
attachment assembly also comprises a first membrane positioned
adjacent the second surface of the base member, the membrane
defining a second aperture substantially aligned with the first
aperture, a second membrane positioned adjacent the first membrane,
the second membrane defining a third aperture substantially aligned
with the first aperture and the second aperture, and a fastener
extending through the base member and the first membrane. The
fastener is operable to engage a supporting element extending
through the third aperture.
[0008] In another embodiment, the invention provides a roof
attachment assembly to be mounted on a roof substrate. The roof
attachment assembly comprises a first membrane supportable on the
roof substrate, and a base member that defines a first surface
positioned substantially adjacent the first membrane and a second
surface spaced from the roof substrate and the first membrane. The
base member defines a surface area and includes a frustoconical
protrusion extending away from the roof substrate along an axis,
the first surface forms a frustoconical recess and the second
surface forms the frustoconical protrusion. The base member defines
a first aperture extending along the axis from the first surface to
the second surface, the first aperture substantially centrally
positioned in the frustoconical protrusion. The roof attachment
assembly also comprises a second membrane coupled to the first
membrane and coupled to the base member, and a fastener oriented
along the axis, the fastener extending through the first aperture
and the second aperture to couple the base member to the second
membrane. The second membrane is positioned substantially adjacent
the base member second surface, and the second membrane defines a
surface area, wherein the second membrane surface area is greater
than the surface area of the base member. The second membrane is
deformable to substantially conform to the frustoconical protrusion
of the base member. The second membrane defines a second aperture
extending therethrough, the second aperture being substantially
aligned with the first aperture, such that the second aperture
extends along the axis.
[0009] In another embodiment, the invention provides a roof
attachment assembly to be mounted on a roof substrate. The roof
attachment assembly comprises a base member supportable on the roof
substrate. The base member defines a first surface positioned
substantially adjacent the roof substrate, a second surface spaced
from the roof substrate, and a surface area. The base member
includes a frustoconical protrusion extending away from the roof
substrate along an axis, where the first surface forms a
frustoconical recess and the second surface forms the frustoconical
protrusion. The base member defines a first aperture extending
along the axis from the first surface to the second surface, the
first aperture substantially centrally positioned in the
frustoconical protrusion. The roof attachment assembly also
comprises a membrane positioned substantially adjacent the base
member second surface. The membrane defines a surface area, wherein
the membrane surface area is greater than the surface area of the
base member. The membrane is deformable to substantially conform to
the frustoconical protrusion of the base member, the membrane
defining a second aperture extending therethrough, the second
aperture being substantially aligned with the first aperture, such
that the second aperture extends along the axis. The roof
attachment assembly also comprises a fastener oriented along the
axis, the fastener extending through the first aperture and the
second aperture to couple the base member to the membrane.
[0010] In another embodiment, the invention provides a roof
attachment assembly to be mounted on a roof substrate. The roof
attachment assembly comprises a first membrane supportable on the
roof substrate, and a base member that defines a first surface
positioned substantially adjacent the first membrane and a second
surface spaced from the roof substrate and the first membrane. The
base member defining a surface area and including a frustoconical
protrusion extending away from the roof substrate along an axis,
the first surface forms a frustoconical recess and the second
surface forms the frustoconical protrusion. The base member defines
a first aperture extending along the axis from the first surface to
the second surface, the first aperture substantially centrally
positioned in the frustoconical protrusion. The roof attachment
assembly also comprises a second membrane coupled to the first
membrane and coupled to the base member. The second membrane is
positioned substantially adjacent the base member second surface.
The second membrane defining a surface area, wherein the second
membrane surface area is greater than the surface area of the base
member. The second membrane being deformable to substantially
conform to the frustoconical protrusion of the base member, the
second membrane defining a second aperture extending therethrough,
the second aperture being substantially aligned with the first
aperture, such that the second aperture extends along the axis. The
roof attachment assembly further comprises a bracket coupled to the
second membrane, the bracket defining a first surface spaced from
the second membrane and a second surface positioned substantially
adjacent the second membrane. The bracket defines an aperture
extending from the first surface to the second surface. The bracket
is operable to support a roof-mounted assembly, the bracket
aperture being substantially aligned with the first aperture and
the second aperture, such that the bracket aperture extends along
the axis. The roof attachment assembly further comprises a fastener
oriented along the axis, the fastener extending through the first
aperture, the second aperture and the bracket aperture to couple
the base member to the second membrane and to the bracket.
[0011] In another embodiment, the invention provides a roof
attachment assembly to be mounted on a membrane roof. The roof
attachment assembly comprises a plate defining an aperture, a first
surface and a second surface, the first surface facing the membrane
roof and the second surface spaced from the membrane roof. The roof
attachment assembly also comprises a first membrane positioned
adjacent to the first surface of the first plate, a second membrane
positioned adjacent to the second surface of the plate and
substantially shrouding the plate, a bracket positioned proximate
to the second membrane, the bracket defining a recess aligned with
an aperture of the plate, the bracket operable to support one or
more roof mounted fixtures. The roof attachment assembly further
comprises a fastener that substantially mates with the recess of
the bracket.
[0012] Other aspects of the invention will become apparent by
consideration of the detailed description and accompanying
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an exploded view of a roofing system with a roof
attachment assembly according to an embodiment of the present
invention.
[0014] FIG. 1A is an exploded view of an alternative embodiment of
the roof attachment assembly according of FIG. 1.
[0015] FIG. 2 is a cross-sectional view of the roofing system and
the roof attachment assembly of FIG. 1.
[0016] FIG. 2A is a cross-sectional view of the roofing system and
the roof attachment assembly of FIG. 1A.
[0017] FIG. 3 is an exploded view of an alternative embodiment of a
roof attachment assembly according to an embodiment of the present
invention.
[0018] FIGS. 4 and 5 illustrate compression plates usable with the
roofing system and the roof attachment assembly of FIGS. 1-3.
[0019] FIG. 6 is an exploded view of a roofing system with a roof
attachment assembly according to another embodiment of the present
invention.
[0020] FIG. 7 is an exploded view of an alternative embodiment of
the roofing system with the roof attachment assembly of FIG. 6.
[0021] FIG. 8 is a cross-sectional view of the roofing system and
the roof attachment assembly of FIG. 7.
[0022] FIG. 9 is an exploded view of a roofing system with a roof
attachment assembly according to another embodiment of the present
invention.
[0023] FIG. 10 is an assembled view of the roofing system with the
roof attachment assembly of FIG. 9.
[0024] FIG. 11 is a cross-sectional view of the roofing system and
the roof attachment assembly of FIG. 9.
[0025] FIGS. 12-14 illustrate various brackets usable with the
roofing system and the roof attachment assembly.
[0026] FIG. 15 illustrates an extension usable with the roofing
system and the roof attachment assembly.
[0027] FIGS. 16-18 illustrate an alternative embodiment of a
roofing system and a roof attachment assembly according to an
embodiment of the present invention.
[0028] FIGS. 19 and 20 illustrates a further alternative embodiment
of a roofing system and a roof attachment assembly according to an
embodiment of the present invention.
[0029] FIG. 21 illustrates a plate usable with the roofing system
and the roof attachment assembly of FIGS. 16-20.
[0030] FIG. 22 illustrates a spacer usable with the roofing system
and the roof attachment assembly of FIGS. 16-20.
DETAILED DESCRIPTION
[0031] Before any independent embodiments of the invention are
explained in detail, it is to be understood that the invention is
not limited in its application to the details of construction and
the arrangement of components set forth in the following
description or illustrated in the following drawings. The invention
is capable of other embodiments and of being practiced or of being
carried out in various ways. Also, it is to be understood that the
phraseology and terminology used herein is for the purpose of
description and should not be regarded as limiting. The use of
"including," "comprising," or "having" and variations thereof
herein is meant to encompass the items listed thereafter and
equivalents thereof as well as additional items.
[0032] Unless specified or limited otherwise, the terms "mounted,"
"connected," "supported," and "coupled" and variations thereof are
used broadly and encompass both direct and indirect mountings,
connections, supports, and couplings. Further, "connected" and
"coupled" are not restricted to physical or mechanical connections
or couplings.
[0033] Also, it is to be understood that phraseology and
terminology used herein with reference to device or element
orientation (such as, for example, terms like "central," "upper,"
"lower," "front," "rear," etc.) are only used to simplify
description of embodiments of the present invention and do not
alone indicate or imply that the device or element referred to must
have a particular orientation. In addition, terms such as "first"
and "second" are used herein for purposes of description and are
not intended to indicate or imply relative importance or
significance.
[0034] FIGS. 1 and 2 illustrate a roofing system 10 including a
metal roof deck 12, a roof substrate 14 (e.g., insulation,
tarpaper, plywood or other decking material, and the like)
supported on the roof deck 12, a membrane 16 extending across and
supported on the substrate 14 (i.e., placed immediately adjacent an
upper surface of the substrate 14 or supported on one or more
intermediate layers of roofing or sealing material, which in turn
are placed on the substrate 14). The roofing system 10 can be
utilized on any of a variety of roof types, such as slate roofs,
membrane roofs, aluminum roofs, standing seam roofs, tile roofs,
shingle roofs, and the like.
[0035] The roofing system 10 is operable to support any of a
variety of roof-mounted fixtures, such as, for example, snow
fences, solar panels, conduit for solar panels, cables for lighting
rods, an antenna, signs, billboards, or any of a number of other
roof-mountable assemblies. Depending on one or more of the
geographic location, anticipated quantity and type of
precipitation, and anticipated roof and wind loading, the roofing
system 10 can include any of a variety of flashing, seal and
bracket arrangements, as will be discussed below.
[0036] A roof attachment assembly 18 can be coupled to the roofing
system 10 with few or no fasteners extending through the membrane
16. One such roof attachment assembly 18 is illustrated in FIGS. 1
and 2 and includes a first membrane pad 20, a plate 22 having a
substantially frustoconical protrusion 24, a second membrane pad
26, a compression plate 28, a washer 30, a nut 32 and a bolt 34.
The bolt 34 extends through the first membrane pad 20, the
frustoconical protrusion 24 of the plate 22, the second membrane
pad 26, the compression plate 28, the washer 30 and the nut 32. In
other embodiments, the washer 30 and the nut 32 can be omitted and
the bolt 34 can be connected to a bracket 43 that is operable to
act as a standoff and to support one or more roof mounted fixtures.
For example, the body of the bolt 34 can substantially mate with a
recess defined by the bracket to secure the bracket to the roof
attachment assembly 18.
[0037] Although the illustrated roof attachment assembly 18 is
substantially circular, other shapes are possible. For example, the
roof attachment assembly 18 can be square, ovular, round,
rectangular, triangular, pentagonal or other regular or non-regular
shape.
[0038] In some embodiments, the plate 22 can include one or more
stiffening ribs or flanges to increase rigidity. The plate 22 has a
top surface 22A facing the second membrane pad 26 and a bottom
surface 22B facing the first membrane pad 20. In other words, the
bottom surface 22B of the plate faces the roof substrate and the
top surface 22A is spaced from the roof substrate. In some
embodiments, the top surface 22A and/or the bottom surface 22B is
coated with a material similar to the roof material, such as a
membranous material. Embodiments in which both the top surface 22A
and the bottom surface 22B are coated can omit one or more of the
first membrane pad 20 and the second membrane pad 26.
[0039] The illustrated plate 22 is substantially circular, but the
plate can be other regular or non-regular shapes. The illustrated
plate 22 is metallic, but is other embodiments the plate is
polymeric.
[0040] The plate 22 extends substantially along a plane. The
frustoconical protrusion 24 of the plate 22 extends away from the
roof substrate 14 and defines an aperture 25 extending along an
axis 27. The aperture 25 is circular, but in other embodiments, can
have other regular or irregular shapes. The illustrated aperture 25
is substantially centered on the upwardly extending protrusion 24,
but other, non-centered embodiments are possible. The frustoconical
protrusion 24 has a diameter in the plane, and the aperture 25 has
diameter in a second plane that is substantially parallel to but
spaced from the plane. The diameter of the aperture 25 is less than
the diameter of the protrusion 24, to form a truncated cone or
frustoconical shape. In other embodiments, the protrusion 24 can
have other shapes and configurations, corresponding to the shape of
an underside of an associated bracket 43 (shown in FIG. 1A).
[0041] As best illustrated in FIG. 2, the protrusion 24 defines a
concave interior side 37 and an exterior side 38. As used herein,
frustoconical includes cones with rounded, flat, non-flat or nearly
flat upper portions and truncated cones with rounded, flat,
non-flat or nearly flat upper portions. The illustrated upwardly
extending protrusion 24 is circular, but in other embodiments, can
be square, D-shaped, triangular, pentagonal, hexagonal, ovular, or
other regular or irregular shapes. Similarly, in some embodiments,
the concave interior side 37 of the protrusion 24 may have a number
of different shapes and configurations, including but not limited
to configurations in which the arch provided by the interior side
37 does not include a uniform radius.
[0042] In some embodiments, the plate 22 and the bolt 34 are
connected to inhibit rotation of the bolt with respect to the plate
22. The plate 22 and the bolt 34 can be connected by spot welding,
heat welding, forging, indenting the threads with pins or other
projections, double-sided tape or other adhesive, or other
permanent or semi-permanent connection. The connected plate 22 and
bolt 34 can be sold as a single component. In other embodiments,
the plate 22 and the bolt 34 can be sold as separate
components.
[0043] The first membrane 20 and the second membrane 26 have
substantially circular shapes, but other shapes of these membranes
are possible. In one embodiment, the first membrane 20, the second
membrane 26, and the roof membrane 16 are constructed from the same
material (e.g., polymeric material). In other embodiments, these
membranes can be constructed from different materials. In the
illustrated embodiment, the diameter of the second membrane 26 is
larger than the diameter of the first membrane 20, but in other
embodiments the membranes 20 and 26 can have different diameters.
The second membrane 26 extends outwardly beyond the outer perimeter
of the plates 22 and 28. The second membrane 26 is secured to the
plate 22 and forms a skirt at least partially enclosing the plate
22. The first membrane 20 is positioned adjacent to the bottom
surface 22B of the plate 22, and the second membrane 26 is
positioned adjacent to the top surface 22A of the plate 22. The
first membrane 20 and the second membrane 26 include corresponding
apertures 29A and 29B. The apertures 29A and 29B of the membranes
20 and 26 are substantially aligned with the aperture 25 of the
plate 22, such that the apertures 29A and 29B extend along the axis
27.
[0044] The compression plate 28 can include a substantially
frustoconical recess 36 that matingly receives the frustoconical
protrusion 24 at least partially therein. The second membrane 26 is
compressed between the compression plate 28 and the plate 22 at an
approximate center or aperture 29A. Thus, the compression plate 28
and the plate 22 act like a clamp on the second membrane 26. The
clamp created by the compression plate 28 and the plate 22 deforms
the second membrane 26 to define a circuitous path between the
plates 22 and 28.
[0045] The bolt 34 applies an adjustable compression force to the
second membrane 26 between the compression plate 28 and the plate
22. The outwardly extending base of the bolt 34 is countered to
matingly engage a recess defined in concave interior side 37 of the
frustoconical protrusion 24. The base of the bolt 34 is positioned
adjacent to the roof membrane 16 and the body of the bolt 34 is
received within the frustoconical recess 36 of the plate 28. The
compression plate 28 illustrated in FIGS. 1-4. is circular, but a
square compression plate 29 having a frustoconical recess 36 is
illustrated in FIG. 5. Any suitable size and shape compression
plate can be utilized. In some embodiments, the compression plate
28, 29 can be omitted.
[0046] The frustoconical protrusion 24 of the plate 22 can
substantially match a head shape of the bolt 34. In some
embodiments, the plate 22 and the bolt 34 are formed as a single
unitary piece. In some embodiments, the first membrane pad 20 is
connected to the bolt 34 (for example by heat welding). In such
embodiments, the first membrane pad 20 is connected to the bolt 34
either prior to or while connecting the roof attachment assembly 18
to the roofing system 10. The illustrated plate 22 is substantially
circular, but other can be other regular or non-regular shapes.
[0047] In some embodiments, other washers and nuts, or other
fastening apparatuses and methods are utilized in place of washer
30 and nut 32. In some embodiments, projections or fasteners, other
than bolt 34 are utilized. These projections and fasteners may or
may not be threaded. The nut 32 can be omitted in embodiments that
utilize a bracket having a threaded aperture. In such embodiments,
pins or other protrusions can be used to fix the bracket to the
fastener or projection. Further, in the embodiments that use a
bracket to support a structure on the roof, the roof attachment
assembly 18 can act as a seal positioned between the bracket and
the roof to prevent leakage around the bracket through the
roof.
[0048] In some embodiments, in place of the washer 30 and the nut
32, the roof attachment assembly 18 includes a single piece bracket
43. In other embodiments, the bracket 43 replaces the plate 22 and
the bolt 34. In some embodiments, the bracket 43 includes at least
one horizontal component 43A and an upwardly-facing projection 43B,
such as any of the brackets illustrated in FIGS. 12-14. Further,
any of the brackets illustrated in published application US
2010/0307074, the entire contents of which are herein incorporated
by reference, can be utilized with the present invention. In
embodiments that utilize the brackets from US 2010/0307074, the
fastener can be inverted, such that the fastener does not penetrate
the roof, but rather extends upward through the bracket. In
embodiments that utilize the brackets from FIGS. 12-14 or from US
2010/0307074, the brackets are coupled to the roof by any
non-penetrating fastening method, such as welding, adhering,
gluing, bonding, and the like. The brackets can include one or more
stiffening ribs or flanges to increase rigidity. Further, the
brackets can each include a coating on either or both of a top
surface and a bottom surface of the bracket.
[0049] In some embodiments (see FIG. 1A), the bracket 43 is
configured to be coupled to the compression plate 28 or to the
second membrane 26 and is operable to support one or more roof
mounted fixtures. The bracket 43 illustrated in FIG. 1A. is
substantially rectangular, but a square, a circle, or other shaped
and sized bracket can be utilized. The bracket 43 includes a first
recess 44, a second recess 45 and an aperture 46 extending between
the first recess 44 and the second recess 45. The illustrated first
recess 44 of the bracket 43 is substantially frustoconical and,
when the assembly omits the second plate 28, the recess 44
condmatingly receives the frustoconical protrusion 24 at least
partially therein. The frustoconical protrusion 24 can
substantially match the shape of the first recess 44. In one
embodiment, the bolt 34 can extend into the first recess 44 and
engage the bracket 43. In other embodiments, the second recess 45
of the bracket 43 is sized to engage the head of a second bolt 34A
to inhibit rotation of the second bolt 34A within the second recess
45.
[0050] The bracket aperture 46 is substantially circular, but other
shapes, such as ovular, square, rectangular, hexagonal, and the
like are possible. In one embodiment, the bracket aperture 46 is
sized to receive the bolt 34 or any fastener, protrusion, or the
like therethrough. The circular shape of the aperture 46 permits
flexibility and slight relative movement between the bracket 43 and
the bolt 34, fastener, projection or the like, when installed. The
bracket aperture 46 is substantially aligned with the plate
aperture 25 and the apertures 29A and 29B of the membranes 20 and
26, such that the bracket apertures 32 also extends along the axis
27.
[0051] At least one extension, such as the extension 42 shown in
FIG. 15, can be utilized in combination with any of the embodiments
described herein. The extension 42 is substantially rectangular,
but in other embodiments, the extension 42 can have different
shapes. The extension 42 includes a top recess 42A and a bottom
recess 42B. In some embodiments, the bottom recess 42B is
constructed to accept the frustoconical protrusion 24. The
extensions 42 can be threaded onto the bolt 34 (e.g., through the
bottom recess 42B) or connected to another fastener in placed of
the nut 32. The extension 42 provides adjustability and flexibility
to various design and roof arrangements. Other suitable
height-adjustment arrangements, such as the bracket illustrated in
FIGS. 12-14, or any of the height-adjustable brackets in co-pending
patent application Ser. No. 12/727,726, filed Oct. 28, 2010, the
entire contents of which are herein incorporated by reference, can
be utilized in combination with the present invention.
[0052] The roof attachment assembly 18 can be coupled to the
roofing system 10 with any suitable non-penetrating fastening
method, such as welding, adhering, gluing, bonding, and the like.
The roof attachment assembly 18 can be coupled directly to the roof
membrane 16 (as shown in FIGS. 1 and 2) or can be coupled to a
target patch T positioned on the roof membrane 16 of the roof
substrate 14 (as shown in FIG. 3). As illustrated in FIG. 3, the
roof attachment assembly 18 can be coupled to the roofing system
above the target patch T (also known as a membrane or a flashing)
and a plate P that is secured by a roof-penetrating fastener F.
[0053] The plate P is substantially circular, but the plate P can
be other regular or non-regular shapes. The plate P defines a
counterbore or recess 40 that is configured to accept the fastener
F. Further, the plate P defines a top surface 41 spaced from the
roof membrane 16 and the roof substrate 14. One of the sides of the
target patch T is adjacent to the top surface 41 of the plate P,
and the other side of the target patch T is adjacent to the first
membrane 20. The illustrated embodiment includes a RhinoBond.RTM.
plate P and fastener F, but other plates, fasteners and other roof
mounting structures can be utilized. In the embodiment shown in
FIG. 3, the diameter of the target patch T is substantially larger
than the diameter of the plate P. However, in other embodiments,
the target patch T and the plate P can have different diameters.
The fastener F can be a bolt, a screw, or any other suitable
fastener that allows that plate P to be securely coupled to the
roof substrate 14. The target patch T seals any penetrations caused
by the fastener F.
[0054] The roof attachment assembly 18 is operable to support any
of a variety of roof-mounted fixtures, such as snow guards, snow
fences, solar panels, conduit for solar panels, cables for lighting
rods, an antenna, signs, billboards, or any other assembly
mountable to a roof. Some roof-mounted fixtures are described in
detail in commonly-assigned U.S. Pat. No. 5,609,326, filed Jun. 16,
1995, and U.S. Pat. No. 6,526,701, filed Dec. 6, 2000, the contents
of both of which are herein incorporated by reference.
[0055] In some embodiments of the roof attachment assembly 18 that
omit the first membrane pad 20, the second membrane pad 26 is
welded, glued or otherwise adhered to the membrane 16 only around a
perimeter of the first membrane pad 20. Thus, a secured bond is
formed between the second membrane pad 26 and the roof membrane 16.
In some embodiments, this bond non-removably secures the roof
attachment assembly 18 to the roof. It is to be understood that
non-removable attachment requires damage to the roof membrane 16 in
order to remove the roof attachment assembly 18 from the roof 10.
In other embodiments that omit the first membrane pad 20, the plate
22 is coated on the top surface 22A and/or the bottom surface 22B
with a membranous material, an adhesive. In some embodiments, an
adhesive, such as double-sided tape or a double-sided
RhinoBond.RTM. plate is connected to the bottom surface 22B, to
adhere the plate 22 directly to the membrane 16.
[0056] In some embodiments, the first membrane pad 20 is coupled to
the roof membrane 16 by any suitable non-penetrating method, and
then in a subsequent step, the plate 22 or one of the brackets is
coupled to the first membrane pad 20. In other embodiments, the
plate 22 or one of the brackets is coupled to the first membrane
pad 20 to form a single unit, and the single unit is coupled to the
roof membrane 16 by any suitable non-penetrating method. In these
embodiments, the second membrane pad 26 can be omitted.
[0057] In some embodiments, the plate 22 or one of the brackets is
coupled to the roof membrane 16 by any suitable non-penetrating
method, and then the second membrane pad 26 is coupled to the plate
22 or one of the brackets. In other embodiments, the plate 22 or
one of the brackets is coupled to the second membrane pad 26 to
form a single unit, and the single unit is coupled to the roof
membrane 16 by any suitable non-penetrating method. In these
embodiments, the first membrane pad 20 can be omitted.
[0058] In some embodiments, the first membrane pad 20 is coupled to
the roof membrane 16 by any suitable non-penetrating method, then
the plate 22 or one of the brackets is coupled to the first
membrane pad 20, and then the second membrane pad 26 is coupled to
the plate 22 or one of the brackets, is coupled to the first
membrane pad 20, and is coupled to the roof membrane 16. In other
embodiments, the plate 22 or one of the brackets is coupled to the
first membrane pad 20 and the second membrane pad 26 to form a
single unit, and the single unit is coupled to the roof membrane 16
by any suitable non-penetrating method.
[0059] One suitable non-penetrating fastening method includes
providing an adhesive on any of the roof membrane 16, the first
membrane 20, the plate 22 and the second membrane 26. In some
embodiments, one or more of the membranes 16, 20, 26 comprises a
meltable material that can be construed as an adhesive. In other
embodiments, a separate adhesive is applied to the top 22A and/or
the bottom 22B of the plate 22. The roof attachment assembly 18 is
positioned on the roof membrane 16, and is then heated by a heat
source, such as by an induction coil. The adhesive at least
partially melts in response to the heat source. Once solidified,
the adhesive can couple the roof attachment assembly 18 to the roof
membrane 16. In some embodiments, one or more weights are
positioned on the roof attachment assembly 18 during or subsequent
to heating, to deform the molten adhesive, and thereby encourage
adhesion of the roof attachment assembly 18 to the roof membrane
16. Other suitable methods are possible, such as welding, gluing,
adhering, bonding and the like, and the present method is given by
way of example only.
[0060] In some embodiments, the first membrane 20 is adhered to the
roof membrane 16 to couple the roof attachment assembly 18 to the
roofing system 10. In other embodiments, the second membrane 26 is
adhered to the roof membrane 16 to couple the roof attachment
assembly 18 to the roofing system 10. In some embodiments, the
plate 22 is adhered to the roof membrane 16 to couple the roof
attachment assembly 18 to the roofing system 10. In other
embodiments, the second membrane 26 is adhered to the plate 22, and
the plate 22 is adhered to the roof membrane 16 to couple the roof
attachment assembly 18 to the roofing system 10. In some
embodiments, the second membrane 26 is adhered to the plate 22, the
plate 22 is adhered to the first membrane 20 and the first membrane
20 is adhered to the roof membrane 16 to couple the roof attachment
assembly 18 to the roofing system 10. In other embodiments, two or
more of the first membrane 20, the plate 22 and the second membrane
26 are adhered to the roof membrane 16 to couple the roof
attachment assembly 18 to the roofing system 10.
[0061] FIGS. 6-8 illustrate another construction of a roof
attachment assembly 50. The roof attachment assembly 50 can be
coupled to a roofing system 10, which is similar to the previously
described roofing system 10 of FIGS. 1-3. Specifically, the roof
attachment assembly 50 can be attached to a roof substrate 14
having a roof membrane 16. The roof attachment assembly 50 includes
a first membrane pad 52 supported on the roof substrate 14, a plate
or a base member 54 having a substantially frustoconical protrusion
56, a second membrane pad 58, a bracket 60, and a fastener 62
(e.g., a bolt). The fastener 62 extends through the plate 54, the
second membrane 58, and the bracket 60 to couple the plate 54, the
second membrane 58 and the bracket 60. In other embodiments, the
fastener 62 can also extend through the roof substrate 14.
[0062] In the illustrated embodiment, the first membrane 52 is
supported on the roof substrate 14. In one embodiment, the first
membrane 52 defines a perimeter that is larger than the perimeter
defined by the plate 54 and the second membrane 58. The first
membrane 52 and the roof substrate 14 can be connected by spot
welding, heat welding, forging, indenting the threads with pins or
other projections, double-sided tape or other adhesive, by
fasteners, or other permanent or semi-permanent connection. In one
embodiment, the length of the first membrane is approximately
sixteen inches, but the length can be larger or smaller.
[0063] The illustrated plate 54 of the roof attachment assembly 50
is substantially circular, but the plate can be other regular or
non-regular shapes. The 54 is metallic, but is other embodiments
the plate is polymeric. The plate 54 defines a first surface 54A
positioned substantially adjacent the first membrane 52, and a
second surface 54B spaced from the roof substrate and the first
membrane. The frustoconical protrusion 56 of the plate 54 extends
away from the roof substrate 14 along an axis 64. Further, the
first surface 54A of the plate 54 forms a frustoconical recess 65
and the second surface 54B forms the frustoconical protrusion 56.
The frustoconical protrusion 56 of the plate 54 defines an aperture
66 extending along the axis 64 from the first surface 54A to the
second surface 54B. The first aperture 66 is substantially
centrally positioned in the frustoconical protrusion 56.
[0064] In one embodiment, the plate 54 includes a plurality of
openings 67 extending from the first surface 54A through the second
surface 54B. The openings 67 are configured to accept fasteners 68
(e.g., bolts, screws, etc.) that couple the plate 54 to the first
membrane 52 and to the roof substrate 14 of the roofing system 10.
In other embodiments, the plate 54 does not use fasteners 68, but
is coupled to the roof substrate 14 via other suitable
non-penetrating methods or mechanisms (e.g., via adhesive, heat
welding, forging, etc.).
[0065] The second membrane 58 is positioned substantially adjacent
the second surface 54B of the plate 54 and is coupled to the first
membrane 52. The second membrane 58 defines a surface area or a
perimeter that is greater than the surface area of the plate 54.
The second membrane 58 is deformable to substantially conform to
the frustoconical protrusion 56 of the plate 54 when the second
membrane 58 attaches to the plate 54. Further, the second membrane
58 defines an aperture 70 extending through the second membrane 58,
where the aperture 70 is substantially aligned with the aperture 66
of the plate 54, such that the aperture 70 extends along the axis
64.
[0066] In one embodiment, the bracket 60 of the roof attachment
assembly 50 is coupled to the second membrane 58 via the fastener
62. The bracket 60 is operable to support at least one roof-mounted
assembly. The bracket 60 defines a first surface 60A spaced from
the second membrane 58 and a second surface 60B positioned
substantially adjacent the second membrane 58. The bracket 60
further defines an aperture 72 extending from the first surface 60A
to the second surface 60B. The frustoconical protrusion 56 extends
at least partially into the bracket aperture 72. Because the second
membrane 58 is deformed by the frustoconical protrusion 56, the
second membrane 58 also extends into the bracket aperture 72. The
bracket aperture 72 is substantially aligned with the aperture 66
of the plate 54 and the aperture 70 of the second membrane 58 such
the bracket aperture 72 extends along the axis 64.
[0067] The fastener 62 of the roof attachment assembly 50 is
oriented along the axis 64 and extends through the aperture 66 of
the plate 54, the aperture 70 of the second membrane 58, and the
bracket aperture 72 to couple the plate 54 to the second membrane
58 and to the bracket 60. In one embodiment, the diameter defined
by the plate 54 is greater than the diameter defined by the
aperture 66 of the plate 54 and the diameter defined by the
aperture 70 of the second membrane 58.
[0068] In some embodiments, the roof attachment assembly 50 is
constructed without the bracket 60 or the first membrane 52 (see
FIG. 6). In these embodiments, the plate 54 is directly positioned
on the roof substrate 14 or the roof membrane 16 of the roofing
system 10. The plate 54 can be heat welded, or otherwise coupled,
to the second membrane 58. Further, the plate 54 can be attached to
the roof substrate 14 via the fasteners 68 or by any other
reasonable means. The fastener 62 extends through the aperture 66
of the plate 54 and the aperture 70 of the second membrane 58 to
couple the plate to the second membrane 58.
[0069] In other embodiments, the fastener 62 of the roof attachment
assembly 50 is configured to accept a compression fitting 69 (see
FIG. 8). The fastener 62 further defines an attachment point 76
exposed for mechanical fastening.
[0070] FIGS. 9-11 illustrate another construction of a roof
attachment assembly 80. The roof attachment assembly 80 can be
attached to a roofing system 10, which is similar to the previously
described roofing system 10. The roof attachment assembly 80
includes a first membrane pad 82 supported on the roof substrate 14
or the roof membrane 16, a plate 84 defining a center aperture 85,
a second membrane pad 86, a bracket 88, and a fastener 90 (e.g., a
bolt). The fastener 90 extends upwardly through a recess of the
bracket 88 and is operable to support one or more roof mounted
fixtures.
[0071] The roof attachment assembly 80 can be coupled to the
roofing system 10 with any suitable non-penetrating fastening
method, such as welding, adhering, gluing, bonding, and the like.
The roof attachment assembly 80 can be coupled directly to the roof
membrane 16 or can be coupled to a plate 92 positioned on the roof
membrane 16 of the roof substrate 14. As illustrated in FIGS. 9-11,
the plate 92 is secured by a roof-penetrating fastener F. The roof
attachment assembly 80 is operable to support any of a variety of
roof-mounted fixtures, such as snow guards, snow fences, solar
panels, conduit for solar panels, cables for lighting rods, an
antenna, signs, billboards, or any other assembly mountable to a
roof.
[0072] The plate 84 has a top surface 84A facing the second
membrane pad 86 and a bottom surface 84B facing the first membrane
pad 82 and the membrane roof. In some embodiments, the top surface
84A and/or the bottom surface 84B is coated with a material similar
to the roof material, such as a membranous material. Embodiments in
which both the top surface 84A and the bottom surface 84B are
coated can omit one or more of the first membrane pad 82 and the
second membrane pad 86. In other embodiments, a fastener (not
shown) can extend through the aperture 85 of the plate 84 to couple
the plate 84 and the first membrane 82 to the roof. In these
embodiments, the roof attachment assembly 80 may omit the second
membrane 86 and/or the bracket 88. The fastener extending through
the plate 84 and the first membrane 82 can be configured to attach
to a bracket that supports a roof mounting fixture. Further, in
these embodiments, the plate 84 and the first membrane 82 can be
single monolithic component.
[0073] The illustrated plate 84 is substantially circular, but the
plate can be other regular or non-regular shapes. The illustrated
plate 84 is metallic, but is other embodiments the plate is
polymeric. The aperture 85 defined by the plate 84 is circular, but
in other embodiments, can have other regular or irregular shapes.
The illustrated aperture 85 is positioned substantially centered on
the plate 84, but other, non-centered embodiments are possible.
[0074] The first membrane 82 and the second membrane 86 have
substantially circular shapes, but other shapes of these membranes
are possible. In one embodiment, the first membrane 82 and the
second membrane 86 are constructed from the same material (e.g.,
polymeric material). In the illustrated embodiment, the diameter of
the second membrane 86 is smaller than the diameter of the first
membrane 82, but in other embodiments the membranes 82 and 86 can
have different diameters. The second membrane 86 extends outwardly
beyond the outer perimeter of the plate 84 and shrouds the plate
84. The second membrane 86 is configured to substantially conform
to the shape of the plate 84, when the plate 84 is compressed
between the first membrane 82 and the second membrane 86.
[0075] The first membrane 82 is positioned adjacent to the bottom
surface 84B of the plate 84, and the second membrane 86 is
positioned adjacent to the top surface 84A of the plate 84. In some
embodiments, the first membrane 82 and the second membrane 86
include corresponding apertures 82A (not shown) and 86B. The
apertures 82A and 86B of the membranes 82 and 86 are substantially
aligned with the aperture 85 of the plate 84. In other embodiments,
the first membrane does not include an aperture.
[0076] The bracket 88 is configured to be coupled to the second
membrane 86 and is operable to support one or more roof mounted
fixtures. The bracket 88 illustrated in FIGS. 9-11. is
substantially circular, but a square, a rectangular, or other
shaped and sized bracket can be utilized. The bracket defines a
first recess 91 positioned on the upper portion of the bracket 88,
and a second recess or an aperture 94 positioned near the second
membrane 86. The bracket aperture 94 is substantially circular, but
other shapes, such as ovular, square, rectangular, hexagonal, and
the like are possible. In one embodiment, the assembly 80 can
include a fastener (not shown) extending through the apertures 82A,
85, and 86B and engaging the second recess 94 of the bracket 88.
The circular shape of the aperture 94 permits flexibility and
slight relative movement between the bracket 88 and the fastener,
projection or the like, when installed. In the illustrated
embodiment, the first recess 91 of the bracket 88 is sized to
engage the head of the fastener 90 to inhibit rotation of the
fastener 90 within the first recess 91.
[0077] The roof attachment assembly 80 can include other types of
plates that differ from the plate 84. Further, the roof attachment
assembly 80 can include any of the previously described
brackets.
[0078] A possible non-penetrating fastening method for attaching
the roof attachment assembly 80 includes providing an adhesive on
any of the roof membrane 16, the plate 84, the first membrane 82
and the second membrane 86. In some embodiments, one or more of the
roof membrane 16, the plate 84, the first membrane 82 and the
second membrane 86 comprises a meltable material that can be
construed as an adhesive. In other embodiments, a separate adhesive
is applied to the top and/or the bottom 84A/84B of the plate 84.
The roof attachment assembly 80 is positioned on the roof membrane
16, and is then heated by a heat source, such as by an induction
coil. The adhesive at least partially melts in response to the heat
source. Once solidified, the adhesive can couple the roof
attachment assembly 80 to the roof membrane 16. Other suitable
attachment methods are possible, such as welding, gluing, adhering,
bonding and the like, and the present method is given by way of
example only.
[0079] In some embodiments, the first membrane 82 is adhered to the
roof membrane 16 to couple the roof attachment assembly 80 to the
roof 10. In other embodiments, the first membrane 82 and the second
membrane 86 are adhered to the plate 84 and these elements are
adhered to the plate 92 and to the roof membrane 16 to couple the
roof attachment assembly 80 to the roof 10. In other embodiments,
the bracket 88 is adhered to the second membrane 86, the first
membrane 82 is adhered to the plate 84, and the first membrane 82
is adhered to the plate 92 and to the roof membrane 16 to couple
the roof attachment assembly 80 to the roof 10. In yet other
embodiments, both the plate 92 and the first membrane 82 are
adhered to the roof membrane 16 to couple the roof attachment
assembly 80 to the roof 10. In the last embodiment, the plate 92
may not include fasteners.
[0080] FIGS. 16-22 illustrate another construction of a roofing
system 110 including a metal roof deck 112, a roof substrate 114
(e.g., insulation, tarpaper, plywood or other decking material, and
the like) supported on the roof deck 112, a membrane 116 extending
across the substrate 114 (i.e., placed immediately adjacent an
upper surface of the substrate 114 or supported on one or more
intermediate layers of roofing or sealing material, which in turn
are placed on the substrate 114). The roofing system 110 can be
utilized on any of a variety of roof types, such as slate roofs,
membrane roofs, aluminum roofs, standing seam roofs, tile roofs,
shingle roofs, and the like. The roofing system 110 possesses all
characteristics of the previously described roofing systems 10.
[0081] The roofing system 110 is operable to support any of a
variety of roof-mounted fixtures, such as, for example, snow
fences, solar panels, conduit for solar panels, cables for lighting
rods, an antenna, signs, billboards, or any of a number of other
roof-mountable assemblies. Depending on one or more of the
geographic location, anticipated quantity and type of
precipitation, and anticipated roof and wind loading, the roofing
system 110 can include any of a variety of flashing, seal and plate
arrangements, as will be discussed below.
[0082] A roof attachment assembly 118 can be coupled to the roofing
system 110 with few or no fasteners extending through the membrane
116. One such roof attachment assembly 118 is illustrated in FIGS.
12-14. The illustrated roof attachment assembly 118 includes a
plate (also called a base member) 120 having an upwardly extending
fastener 122, a membrane pad 124, a compression washer 126 having a
substantially frustoconical aperture or a pocket 128, a spacer 130,
a flashing 132 and a hose clamp 134.
[0083] The roof attachment assembly 118 can be coupled to the
roofing system 110 with any suitable non-penetrating fastening
method, such as welding, adhering, gluing, bonding, and the like.
The roof attachment assembly 118 is operable to support any of a
variety of roof-mounted fixtures, such as described above for the
roof attachment assembly 18. Although the illustrated roof
attachment assembly 118 is substantially square, other shapes are
possible. For example, the roof attachment assembly 118 can be
round, ovular, rectangular, triangular, pentagonal or other regular
or non-regular shape.
[0084] FIGS. 16-18 illustrate an embodiment of the roof attachment
assembly 118 in which the plate 120 is connected to the roofing
system 110 by a non-penetrating fastening method. Alternatively,
FIGS. 19 and 20 illustrate an embodiment of the roof attachment
assembly 118 in which the plate 120 is connected to the roofing
system 110 by fasteners 135 that penetrate the roofing system 110.
The membrane 124 acts as a target patch over the fasteners 135. The
roof attachment assembly 118 is considered to not penetrate the
roofing system 110, because the membrane pad 124 (or target patch)
is connected to the roofing system 110 by welding, adhesive or by
some other non-penetrating manor to suitably inhibit or prevent any
leakage through the penetrations caused by the fasteners 135.
[0085] FIG. 21 illustrates the plate 120 and the fastener 122 in a
greater detail. The plate 120 of the roof attachment assembly 118
can include a substantially frustoconical protrusion 136 defining
an aperture 137. In some embodiments, the plate 120 can include one
or more stiffening ribs or flanges to increase rigidity. Other type
of plates can be utilized in place of plate 120 and the roof
attachment assembly 118 can include more than one plate 120. The
plate 120 has a top surface 120A facing the membrane pad 124 and a
bottom surface 120B facing the roof membrane 116. In some
embodiments, the top surface 120A and/or the bottom surface 120B is
coated with a material similar to the roof material, such as a
membranous material. Embodiments in which both the top surface 120A
and the bottom surface 120B are coated can omit the membrane pad
124. In one embodiment, the plate 120 is coupled to the roof by any
non-penetrating fastening method, such as welding, adhering,
gluing, bonding, and the like. In other embodiments, the plate 120
can be coupled to the roof by using fasteners 135.
[0086] The plate 120 includes a plurality of openings 147 extending
from the top surface 120A through the bottom surface 120B. The
openings 147 are configured to accept the fasteners 135 (e.g.,
bolts, screws, etc.) that couple the plate 120 to the roof
substrate 114 of the roofing system 110. In other embodiments, the
plate 120 does not use fasteners 135, but is coupled to the roof
substrate 116 via other suitable non-penetrating methods or
mechanisms (e.g., via adhesive, heat welding, forging, etc.).
[0087] As shown in FIGS. 16-20, the fastener 122 extends through
the frustoconical protrusion 136 and the aperture 137 of the plate
120. The frustoconical protrusion 136 extends at least partially
into the frustoconical aperture 128 of the washer 126. The washer
126 can be circular, square, ovular, pentagonal or any other
suitable size and shape. In some embodiments, the washer 126 can be
omitted. In the illustrated embodiment, the plate 120 and the
upwardly extending fastener 122 are formed as a single unitary
piece. In some embodiments, the plate 120 and the upwardly
extending fastener 122 are formed as separate pieces and joined
during installation.
[0088] As discussed above, any of the plates discussed herein and
described above can be utilized in place of the plate 120. The
plates are coupled to the roof by any non-penetrating fastening
method, such as welding, adhering, gluing, bonding, and the like.
Further, the plates can each include a coating on either or both of
a top surface and a bottom surface of the plate.
[0089] In some embodiments, the plate 120 is coupled to the roof
membrane 116 by any suitable non-penetrating method, and then the
membrane pad 124 is coupled to the plate 120. In other embodiments,
the plate 120 is coupled to the membrane pad 124 to form a single
unit, and the single unit is coupled to the roof membrane 116 by
any suitable non-penetrating method.
[0090] The membrane 124 has a substantially rectangular form, but
other shapes of the membrane 124 are also possible. The membrane
124 is positioned adjacent to the top surface 120A of the plate
120, and defines an aperture 125 that substantially aligns with the
aperture 137 of the plate 120 and the frustoconical aperture 128 of
the washer 126. The membrane 124 defines a top surface 124A and a
bottom surface 124B. In other embodiments, the membrane 124 may be
constructed without the aperture 125.
[0091] The flashing 132 is positioned adjacent to the top surface
124A of the membrane 124. The illustrated flashing 132 comprises
metal, but in other embodiments, other material(s) can also be used
to construct the flashing 132. The flashing 132 can include a
coating on top surface 132A and/or a bottom surface 132B. In
embodiments that include a coating on the bottom surface 132B, the
coating can be adhered or otherwise coupled to the membrane 116,
and the membrane 124 can be omitted. In embodiments that omit the
membrane pad 124, the flashing 132 is directly connected to the
membrane 116. In some such embodiments, the flashing 132 can
include an adhesive, such as double-sided tape, on the bottom
surface 132B.
[0092] The flashing 132 defines a projection area 133 that is
configured to accept at least a portion of the frustoconical
protrusion 136 and the washer 126. The flashing 132 further defines
a flashing aperture 138 that substantially aligns with the aperture
125 of the membrane 124, the aperture 137 of the plate 120, and the
frustoconical aperture 128 of the washer 126. The flashing aperture
138 has a diameter that is larger than the diameter of apertures
125, 137, and 125, such that it allows the spacer 130 to pass
through the aperture 138.
[0093] In the illustrated embodiment, the perimeters of the
membrane 124 and the pipe flashing 132 are substantially equal, and
both perimeters are larger than the perimeter of the plate 120. In
other embodiment, these elements of the roof attachment assembly
118 can have different perimeters. The fastener 122 extends through
the aperture 137 of the frustoconical protrusion 136, the
frustoconical aperture 128 of the washer 126, and engages the
spacer 130. As shown in FIG. 22, the spacer 130 includes a top
aperture 130A and a bottom aperture 130B that are configured to
accept a fastener (e.g., fastener 122). The spacer 130 extends
through the aperture 138 of the flashing 132. In other embodiments,
other fastening apparatuses and methods, or combinations of
fastening apparatuses are utilized in place of washer 126, spacer
130, flashing 132 and hose clamp 134.
[0094] One suitable non-penetrating fastening method includes
providing an adhesive on any of the roof membrane 116, the plate
120, the membrane 124 and the flashing 132. In some embodiments,
one or more of the roof membrane 116, the plate 120, the membrane
124 and the flashing 132 comprises a meltable material that can be
construed as an adhesive. In other embodiments, a separate adhesive
is applied to the top 120A and/or the bottom 120B of the plate 120.
The roof attachment assembly 118 is positioned on the roof membrane
116, and is then heated by a heat source, such as by an induction
coil. The adhesive at least partially melts in response to the heat
source. Once solidified, the adhesive can couple the roof
attachment assembly 118 to the roof membrane 116. Other suitable
attachment methods are possible, such as welding, gluing, adhering,
bonding and the like, and the present method is given by way of
example only.
[0095] In some embodiments, the membrane 124 is adhered to the roof
membrane 116 to couple the roof attachment assembly 118 to the roof
110. In other embodiments, the plate 120 is adhered to the roof
membrane 116 to couple the roof attachment assembly 118 to the roof
110. In some embodiments, the membrane 124 is adhered to the plate
120 and the plate 120 is adhered to the roof membrane 116 to couple
the roof attachment assembly 118 to the roof 110. In other
embodiments, the membrane 124 is adhered to the plate 120, and the
membrane 124 is adhered to the roof membrane 116 to couple the roof
attachment assembly 118 to the roof 110. In yet other embodiments,
both the plate 120 and the membrane 124 are adhered to the roof
membrane 116 to couple the roof attachment assembly 118 to the roof
110.
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