[0001] This disclosure relates to roofing assemblies, and more particularly, to a roofing assembly for efficiently attaching and distributing weight of an object to a roof structure, while maintaining an effective fluid seal with the roofing membrane.

[0002] Many fastening systems and components exist for securing a membrane to a roof structure. Most notably, seam plates are disposed at predetermined positions over a fluid sealing roof membrane and attached to the underlying roofing substructure via driving a securing member or heat sealing. Additional systems exist for attaching objects over the roof/membrane structure, such as the system disclosed in U.S. Patent Application Publication No. 2013/0009025. However, known attachment systems are often unsuitable for attachment of heavy objects such as large scale solar panels because the assembly or roof substructure is unable to support the mass of the panels when concentrated over a relatively small area or would require too numerous points of attachment to be feasible in practice. There is a need for a roof attachment system which is usable with common roofing components and effective at dissipating force on a roof over a large area with improved integrity of attachment, while maintaining an effective and failsafe seal with a roofing membrane.

SUMMARY

[0003] A roof attachment and weight distribution system has a base member with top and bottom surfaces. The base member is positioned on a substantially flat substrate disposed on a roofing substructure, and defines a plurality of attachment openings and is attached to the roofing substructure. A solid membrane is disposed over the top surface of the base member and is sealed to a portion of the base member. The system includes an attachment member with a bottom plate defining a central opening. A stud with a shank extends from a head through the central opening. A secondary membrane is disposed intermediate the bottom plate and a lock nut and has an outer periphery that extends past the peripheral edge of the bottom plate. The secondary membrane outer periphery is attached to the primary membrane in a fluid tight seal. The base member bottom surface has an area A and the base member is sized and shaped to distribute force from a mass of a fixture mounted on the attachment member on the substrate substantially evenly over the area A.

[0004] Another embodiment of the roof attachment and weight distribution system has a base member with an upper surface and lower surface defining a plurality of attachment openings. A primary membrane is attachable to the base member without puncturing and is disposed over the entire upper surface of the base member. An attachment member comprises a bottom plate that defines a central opening. A stud with a shank extends from a head through the central opening. A secondary membrane is disposed intermediate the bottom plate and a lock nut with an outer periphery that extends past the peripheral edge of the bottom plate. The attachment member is fixable to the primary membrane via a fluid tight seal of the outer periphery of the secondary membrane to the primary membrane.

[0005] Additionally, a roof attachment installation comprises a roofing substructure and a plurality of base members attached thereto in a spaced configuration. A solid primary membrane is disposed over the top surface of the base members and secured to a portion of each base member without puncturing the primary membrane. An attachment member is secured to each base member in a fluid tight seal with the secured primary membrane. Each attachment member includes a portion that extends away from the base member and roofing substructure that is configured for mounting of a fixture having a mass. The base members are each sized and shaped to distribute force from the mass of a mounted fixture in the direction of the of the roofing substructure substantially evenly over the area of the respective base members.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is an exploded section view of an embodiment of the disclosed attachment system;

[0007] Figure 2 is a section view of the system of Figure 1 installed on a roofing structure; [0008] Figures 3 is a perspective view showing sliding installation of the lower plate into the base of the disclosed system; and

[0009] Figure 4 is a perspective view showing the lower plate installed into the base.

DETAILED DESCRIPTION

[0010] With reference to the drawings wherein the following numerals represent like parts throughout the several figures, an attachment system for weight distribution and failsafe sealing on a roofing structure is generally designated by reference numeral 10.

[0011] As shown, the disclosed system has an expansive base member 12 that is attachable to a roofing substructure 32. A typical installation of the disclosed system 10 begins with placement of a base 12 on a roofing substrate 34 (typically and insulation material) and attachment to a roofing substructure (in this case, a corrugated roofing deck 32) via driving of fasteners F (i.e., screws, nails, etc.) through the respective attachment openings, 28 and 30, of the base 12 and the substrate 34, and into the roofing structure 32. Preferably, in a corrugated roofing substructure, like that depicted, the fasteners F are driven into the crest portions 33 in roofing structure. Indeed, preferred embodiments include attachment openings, 28 and 30, that are spaced from each other a predetermined distance such that when one opening (for example, center opening 30) is aligned with a crest portion, other opening(s) (i.e. outer openings 28) necessarily align with other crest portion(s).

[0012] In the depicted embodiment, the base 12 defines a central open slot 36 configured for slideable receipt and vertical retention of a lower plate 14. When the lower plate 14 is slidably received by the slot 36, an upper lip 38 of the base cooperatively engages an outer flange 26 on the lower plate 14 to vertically retain the plate 14 within the slot 36, as shown most clearly in Figure 4. A head portion of a central securing member F _c may also engage with a bottom key opening in the lower plate (not depicted) to aid secure attachment between the base and the lower plate. Additional methods for aiding attachment of the lower plate and base may be employed, such as for example, adhesive, clips or additional fasteners. Further, the slideable engagement depicted in the representative figures is not a limiting characteristic. Other suitable engagement techniques may be employed, such as for example, snapping, bayonet engagement, threaded engagement and the like.

[0013] Usually, a plurality of base member 12 and lower plate 14 units are engaged in a spaced configuration on the roofing substrate 34 and attached as described above. A single, solid primary membrane 16 may be laid over the roof substrate 34, and respective bases 12 and lower plates 14. Typically the primary membrane 16 is secured via welding to the respective lower plates, which may be metallic (note: primary membrane 16 omitted from Figure 3 depiction to improve viewing of the other system elements). An upper attachment unit 17 comprising a pull through plate 14, secondary membrane 20, stud 24 and lock nut 22 are secured via welding around the outer edge 21 of the secondary membrane 20 to the primary membrane 16. In this manner, the entire upper attachment unit 17 may be secured to the primary membrane 16 without puncturing the primary membrane with a fastener or similar attachment member. The upper attachment structure may be similar to the embodiments described and depicted in U.S. Patent Application Publication No. 2013/0009025 which has a common inventor with the system disclosed herein and is incorporated herein by reference.

[0014] As shown best in Figure 2, the base 12 includes attachment openings 28 and 30 spaced at predetermined optimal distances to substantially align with the crest portions 33 of standard corrugated decking substructures. In this manner, when the central attachment opening of the base is aligned with a crest portion of a corrugated roofing structure, the opposite outer attachment openings will be aligned with other crest portions. This system and the method by which it is attached serendipitously distribute uplift force (from blowing wind or the like) over numerous crests in the roofing substructure, compared to systems that are secured via a single point of attachment. The outer attachment openings in the base 12 are spaced and positioned to correspond closely to the standard spaced locations of crest portions 33 in standard corrugated roof. The bases 12 may be specifically configured as necessary for different types of roofing substructures, corrugated or otherwise. Once installed, the configuration of the nut 22 with stud 24 in the attachment unit 17 allows adjustment of height of the attached structure simply by rotating the nut 22 on the threading.

[0015] The base 12 is typically manufactured from a material such as plastic to reduce manufacturing cost, though other relatively light-weight, rigid and durable materials may be substituted. The slot 36 and upper lip 38 are sized and shaped to correspond with and reliably retain roofing plates known in the field that typically would be installed directly on the roofing substrate. Several attachment systems 10 are typically installed for supporting large items such as high powered solar panels at numerous points of support and attachment on a roofing structure. When installed on the attachment system the force from the large mass of the solar panels is distributed over the entire area of the respective expanded bases, rather than concentrated centrally near the stud as would be the case if the plate were installed directly on the roofing substrate or on an attachment member with a single attachment point and/or more concentrated footprint.

[0016] This significant advancement protects the integrity and effectiveness of the roofing substrate (insulation) when large, heavy fixtures are installed, which may be compromised if compressed. Altogether the disclosed system 10 increases the number of attachment points to the roofing substructure per point of attachment of a fixture, and thus the holding power of the unit to the roofing substructure. The system 10 also substantially increases the footprint on the roofing substrate 34 to distribute force of the mass of the fixture in the direction of the roofing substrate 34 substantially evenly over the entire area of the bottom surface of the bases 12. The depicted embodiment of the base member has a frustoconical shape to aid in even distribution of weight. For example, an installation of four 3 foot by 5.5 foot solar panels connected to each other via hinged attachment on adjacent edges in an "accordion style" can be attached and maintained in a pitched configuration on a roof using nine spaced attachment systems like those disclosed herein, the preferred diameter of a base being approximately 10-18 inches, and more preferably approximately 14 inches.

[0017] Another key advancement over known roofing attachment systems is that the disclosed system 10 may be installed without puncturing of the primary membrane 16. Once attached via welding along the circumferential edge of the secondary membrane 20 to the primary membrane 16, if the object attached were to be lifted upward from the roofing deck (by high winds or the like) causing a substantial upward lifting force, the seal between the primary membrane 16 and secondary membrane 20 would initially fail, leaving the primary membrane 16, which is free of apertures, completely intact over the roofing substrate. This especially effective and failsafe seal provides an additional safeguard to the fluid seal over the roofing substrate 34, and thus substantially improves the integrity and longevity of the roof. The components of the system are configured such that any failure (by tearing from upward forces, for example) compromises the secondary membrane while leaving the primary membrane undamaged. The system may be repaired accordingly without water damage to the building structure. A particularly preferred welding technique includes induction heating; however the inventive spirit of the disclosure is not limited as such.

[0018] While the disclosed system 10 is especially suitable for use with corrugated roofing substructures with an insulation substrate, it may be utilized with a variety or roofing types, such as for example, slate roofs, membrane roofs, aluminum roofs, standing roofs, tile roofs and shingle roofs. Additionally, while fixture of accordion style solar panels is contemplated herein, the system is suitable for attaching and supporting a variety of fixtures, including without limitation, snow fences, lightning rod cables, lighting fixtures, antennae, signs and billboards. The depicted preferred base member 12 has a substantially circular footprint; however this particular configuration is nonlimiting. Base members exist that have ovular, square or other polygonal footprints.

[0019] While a preferred embodiment has been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit of the invention and scope of the claimed coverage.