MOUNTING SYSTEM FOR ROOFS AND THE LIKE
A mounting system for mounting panels to a structure such as a roof comprises a plurality of spaced parallel tracks at least one of which is in the form of a plurality of laterally aligned track segments. Each of the track segments includes a base portion for being mounted to the framework of the structure and the exposed portion for accommodating a fastener. A row of mounting panels is provided for each track. Bach of the mounting panels has a surface indentation such as a slot into which a fastener would be disposed with each fastener having a hook portion mounted over the exposed portion of the track segment.
This application is based upon provisional application Ser. No. 60/737,501, filed Nov. 17, 2005.
BACKGROUND OF THE INVENTIONMy U.S. Pat. Nos. 5,577,360 and 5,617,690 disclose various techniques for attaching panels to a support surface. More particularly, the techniques are useful in applying shingles or mounting panels such as natural or artificial slate to a roof. In general, the techniques involved providing a plurality of tracks which would be secured to a support surface such as a deck. The tracks generally include an offset or exposed portion functioning as a fastener accommodating structure. The mounting panels generally have slots or other surface indentations which are engaged by a spring clip. The clip is also secured to the fastener accommodating structure of the tracks to thereby permit the mounting panels to cover the roof.
It would be desirable if variations of the above systems could be provided to facilitate the mounting of panels to a structure such as a roof.
SUMMARY OF THE INVENTIONAn object of this invention is to provide variations of the above techniques.
A further object of this invention is to provide such variations wherein the panels could be mounted in a quick and efficient manner white minimizing costs.
In accordance with one embodiment of this invention, each spaced parallel track is in the form of spaced track segments or pedestals thereby avoiding the need to have one continuous track which would include track material in areas not actually used for the mounting technique. The track segments could be in the form of a simple small plate with one plate being provided for each mounting panel. Alternatively, the track segments could be of elongated form so that each segment, in turn, supports a plurality of panels. The track segments could include structure to facilitate the mounting of the segments to the framework of the structure, such as the roof or sides of a building. Other structure could be provided on the track segments to cooperate with the fasteners and thereby assure a firm mounting of the fasteners to the track segments.
The invention particularly lends itself to being used where the framework has exposed battens and the track segments are mounted directly to the battens. The invention, however, may also be used by mounting the track segments to a deck.
THE DRAWINGS
The present invention is directed to a mounting system for mounting panels to the framework of a structure. A particular utility of the invention is with regard to mounting shingles, such as natural or artificial slate to a roof. Such panels could thus be made of natural slate, metal, wood, plastic, glass or fibers or any other suitable roofing material. It is to be understood, however, that the invention may be practiced for other types of structures such as the mounting of panels or shingles to a side wall. The general principles of the invention are based upon the type of systems shown in my U.S. Pat. Nos. 5,577,360 and 5,617,690, all of the details of which are incorporated herein by reference thereto. In general, the systems of my prior patents involve utilizing a plurality of spaced parallel tracks. Each track would, for example, extend across the framework of a structure, such as a roof. In a practice of those patents the base portion of each track would be mounted to a deck on the roof. One type of track which is described in those patents is a Z-shaped track so that one portion of the Z comprises the base and the opposite portion of the Z is an off-set exposed portion which functions as fastener accommodating structure. In that regard, a spring-type clip fastener would be inserted in a slot or otherwise secured to a surface indentation of a mounting panel and then hooked over the exposed portion of the track.
In one practice of the present invention, instead of using tracks which extend completely across the structure, a plurality of track segments is used. In that sense the track segments may be considered pedestals. This results in smaller size tracks being used which reduces cost and is easier to handle. It is to be understood, however, that various aspects of this invention may also be practiced where the track is a single continuous track. A further feature of this invention is the recognition that the tracks or track segments could be applied directly to a batten without the need for securing the tracks to a solid deck. It is again to be understood, however, that various aspects of this invention may be utilized where the tracks or track segments are mounted to a deck.
Each track segment may simply be a planar plate having a base portion 22 which would be disposed directly against the batten 4.
In the embodiment illustrated in
Although only a single fastening element 20 for each track segment 12 is illustrated in
The track segment may include various countersinks or risers to accommodate the fasteners so that the fasteners do not interfere with the placement of the panels.
Although
In the embodiment shown in
The various track segments shown various embodiments could be mounted either to a batten or to a solid deck.
The various track segments described with respect to
It is to be understood that although the invention may be practiced where the resiliency or springiness is achieved through the use of a resilient clip or fastener. The invention may also be practiced with a rigid clip or fastener and the resiliency may be achieved by having a springy or resilient engaging member on the track. Thus, for example, fastener 14E including its projection 65 could be rigid or non-resilient and could interact with track segment 12E through use of the retainer finger 63 being resilient.
The track segment 12F shown in
The track segment 12G shown in
The track segments shown in
The track section 12I shown in
The various track segments described in
The tracks or track segments could be formed in various manners.
As shown in
An alternative to what is shown in
The variation shown in
The track 12U shown in
The invention could be practiced where the carrier is rigid and even where the carrier is a batten itself.
The carrier could be a horizontal strip for rows of pedestals or could be a vertical strip for columns of pedestals.
This aspect of the invention could be practiced with other forms of rocking enhancing surfaces such as bent, pointed or stepped surfaces or from a dog leg structure or from springs. The provision of rocking enhancing surfaces could be in the longitudinal or transverse directions.
The feature of the invention wherein the tracks are actually segments or pedestals provides a number of distinct advantages. For example, such pedestals improve or maximize the dispersion of loads to a greater extent than a continuous track which supports the panel or slate over its entire width. This is a benefit which results whether the panel is flat or humped.
The use of segments or pedestals is particularly advantageous for slate panels. In that regard, slate panels tend to break and have irregularities whereby their surfaces are not completely flat whereby there is not likely to be a total surface to surface contact where an elongated or continuous track is used. By using track segments or pedestals having a width smaller than the width of the slate, the slate is free to rock and less likely to break because the segment is located at only a portion of the slate. A further advantage with segments or pedestals is that air circulation is enhanced in that the segments or pedestals occupy only small width dimensions spaced from each other as compared to a continuous track extending the width of a plurality of panels and even of the entire roof.
Clip 14 of
The inclusion of limited panel contacting surfaces on the clip, such as shown in
The clip 14 in its various forms illustrated in
Although the invention is preferably practiced with resilient or springy clips, other types of fasteners could be used including rigid fasteners. Reference is made to my U.S. Pat. Nos. 5,577,360 and 5,617,690 which show various fasteners and tracks that could be usable in this invention. All of the details of those patents are incorporated herein by reference thereto.
Although
The concept of providing spacers to create an open area or air layer between vertically adjacent panels could be accomplished by the use of separate spacer members which could be of any suitable size, shape and material and could be mounted to the panels in any suitable manner. What is important is that the spacers would be located between vertically adjacent panels so as to cause each panel to be spaced away from and out of contact with its vertically adjacent panel and thereby permit the creation of the air layer. The use of separate spacers could be done in addition to utilizing fasteners or clips 14 which create a spacing or could be done as an alternative to the fasteners or clips 14 such as when the fasteners or clips 14 are mounted in recesses in the panels and otherwise do not extend upwardly away from the panel a sufficient distance to create the intended spacing.
In this practice of the invention it is not necessary that either the spacers or the clips must be in recesses. Any form of fastener/mounting structure could be used.
It should be appreciated that the final roof assembly results in a column of support of each panel which comprises track/head of slate/overlying slate/clip for that slate/next overlying slate. See
Given the suggestions herein the invention could be practiced with many variations. For example, the individual segments or pedestals can extend from a common base where a spacing is created from the upper surface downwardly so that the spaced pedestals or segments comprise the portions of a continuous track which are located against the panels. Preferably where pedestals or segments are used, each panel is provided with its own pedestal where the head of the panel would be at or near the centerline of the pedestal and wherein the pedestal is of a lesser width than the width of the panel to enhance rocking and to create under panel ventilation as well as reducing costs.
The invention could be practiced with various forms of tracks including a simple I-beam construction rather than the various forms of Z-shaped tracks shown herein.
The invention could also be practiced where the pedestal-like effect can be achieved by, for example, providing spaced projections on the rafters or on a deck which would be located where the previously described track segments are located. In such broad practice of the invention the rows of panels would be mounted on a roof structure and fastened to the roof structure in any suitable manner without being dependent on any special form or even requiring the types of tracks or fasteners described herein. In such practice of the invention the projections or bumps on the roof structure would serve to space vertically overlapping panels from each other to create an air layer.
Another variation of the invention would be to use a continuous track and to mount a spacer such as a C-clip or any other form of clip at the locations where the pedestals or track segments were previously described as being. Such spacer would lift the head of its panel.
Another variation of the invention is to displace the location of the bearing surface of the panel. In the various illustrated embodiments the bearing surface is at the end of the track, such as shown in
It is to be understood that the invention could be practiced where a fastener or clip is made of sufficient width so that the same clip could be inserted into two kerfs or slots of adjacent panels whereby the same fastener would thus be used for simultaneously mounting two panels.
The invention is practiced in its various embodiment by the utilization of compliancy or resiliency. Characteristic of compliancy can be achieved by having portions of the various components compliant with other portions rigid. Thus, a compliant fastener or clip could be used with a rigid track or with a track also having compliant features. A compliant clip could also be used where the batten itself functions as the track. Similarly, a compliant clip or fastener could be used with a rigid solid deck with or without any other track segments where the deck is modified to function as a track.
The invention may be practiced where the tracks are mounted on a roof deck which are corrugated or of non-planar shape. In such practices the track segments would preferably have a conforming shape to fit snugly against the deck.
Although the fasteners are preferably spring clips which are disposed in slots in the panels the fastener engaging structure of the panels could take other forms. For example, an artificial panel could be made of steel cloth or screen material could be provided on the panel to accommodate the fasteners. The term “surface” indentation is thus intended to include any type of fastener accommodating structure on the mounting panels which would cooperate with the fasteners for permitting the mounting panels to be mounted against the track segments.
Any suitable material could be used for making the components of the invention. For example, the track segments could be made of metal, wood or plastic and could extend the full length so that a single track is used for a row of mounting panels or elongated track segments could be used wherein each segment would mount a plurality of panels in a row or where smaller size track segments could be used for accommodating only a single panel. The fasteners may also be made of any material such as metal or plastic having the necessary characteristics for the particular type of fastener such as springiness. Similarly, any suitable dimensions may be used. The track segments should be made of a material or should be thick enough to effectively function for its mounting purposes. Portions of the track segments could be made sufficiently thin to provide springiness where desired.
As previously described the tracks or panel supports may be continuous track, i.e. wider than a panel. The invention could also be practiced using track segments or pedestals, i.e. narrower than a panel. Pedestals confer certain benefits.
Pedestals Provide a Better Fit:
Slate panels and roof support surfaces can possess certain irregularities. Such irregularities as twist or protrusions can prevent the panel from lying flat. It is desirable for panels to lie as flat as possible. A panel that lies flat is maximally supported by preceding panel courses, reducing the likelihood of breakage. It also presents the least opportunity for wind and weather to penetrate into the roof structure by reducing the apertures that tilted panels might produce. It also presents the smallest purchase on to which wind may seize, thus offering reduced susceptibility to wind damage.
A panel that does not lie flat, in addition to suffering the conditions described above, also can present a raised corner which invites breakage when loaded by, for example, foot traffic or snow.
Pedestals ease these problems by supporting the panel near its midline. This has two benefits: It diminishes the effect of the irregularities and it facilitates movement of the panel (especially if the panel is flexibly attached).
Pedestals Conserve Material:
Another advantage of pedestals over continuous tracks is that they conserve materials, reducing cost and weight. Pedestals maximize air and water flow:
Another advantage of pedestals is that they maximize air flow beneath the panels. Air flow is a desirable characteristic that can prolong the service life of the panels and the structures they cover. Pedestals are as close as is practicable to allowing the panels to “float” above the support structure, offering a minimally obstructed layer of air beneath the panels.
This minimal obstruction is also useful for water management.
A further advantage of pedestals is that they facilitate the drainage of water. Panel coverings such as roofs are prone in certain weather conditions, such as driving rain, to admit water. Such roofs, sometimes described as consisting of discontinuous elements, are designed to shed water; they are not impermeable; they are not continuous as are certain membrane applications. Thus, it is optimal for a panel roof to have provision for the discharge of any “secondary” incursion of water beneath its panels. Frequently underlayments and other surfaces beneath the panels can temporarily prevent water from entering the structure itself, but such materials are not primary, weather resistant defenses. Water must be shed quickly or the materials will decay. In cold weather, water that is not shed quickly can freeze, accumulate and cause severe damage. (Ice damming is one form of problem that is well known.)
Pedestals present a clear, maximally open path beneath panels for the discharge of water.
It is to be understood that various features described with respect to individual tracks or track segments (pedestals), clips or panels in particular embodiments may be used with other embodiments within the spirit of this invention.
Thus as used herein, unless otherwise stated a track segment or pedestal is intended to mean something of small width preferably, although not necessarily, a width less than the width of a panel it supports. The term track, however, could be an elongated continuous track supporting multiple laterally disposed panels or could be a track segment/pedestal.
Claims
1. A mounting system for mounting a plurality of mounting panels to a structure having a framework, comprising a plurality of spaced parallel tracks, at least one of said tracks comprising a plurality of laterally aligned track segments, each of said track segments having a base portion for being mounted to the framework, each of said track segments having an exposed portion to function as fastener accommodating structure, a row of mounting panels for each of said tracks, each of said mounting panels having a head portion and an end portion and opposite side edges, an inwardly directed surface indentation in each of said side edges of said panel, a fastener engaged at each of said surface indentations, and said fastener having a track engaging portion mounted against said exposed portion of said track segment to mount said mounting panel to said track segment and thereby mount said mounting panel to said framework.
2. The system of claim 1 wherein said surface indentations comprise slots, each of said fasteners comprising a spring clip mounted in said slot, said spring clip terminating at one end in a leg disposed against the outer surface of said panel, and said spring clip having as said track engaging portion a hook portion remote from said leg hooked over said exposed portion of said track segment.
3. The system of claim 1 wherein said exposed portion of said track segment includes an outwardly extending stop member, said fastener being a spring clip having as said track engaging portion a hook portion disposed over said exposed portion of said track member, and said hook portion having a bent portion disposed toward said stop member.
4. The system of claim 1 including at least one raised rib at said base portion of said track segment.
5. The system of claim 1 wherein said base portion of said track segment includes at least one integral tab extending generally perpendicular to said base portion in a direction away from said mounting panel.
6. The system of claim 5 wherein said integral tab comprises a positioning member adapted to be disposed against the framework.
7. The system of claim 5 wherein said integral tab terminates in a pointed end whereby said integral tab is capable of being a fastening element which penetrates said framework.
8. The system of claim 1 wherein said base portion includes a recessed section for accommodating a fastening element extending through said base portion for mounting said base portion to the framework.
9. The system of claim 1 wherein said base portion includes locator structure for providing a reference mark for location at the longitudinal center of the mounting panel.
10. The system of claim 1 including a cushioning element mounted to said base portion and extending outwardly toward the mounting panel.
11. The system of claim 10 wherein said base portion includes at least one resilient integral tab which comprises said cushioning element, said base portion including a recessed wall for accommodating a fastener element, and said base portion terminating in side walls.
12. The system of claim 1 wherein said track segment is in the form of a bracket terminating in a pair of outwardly extending flanges with a U-shaped intermediate portion between said flanges, said flanges comprising said base portion, and said intermediate portion comprising said exposed portion.
13. The system of claim 1 wherein said base portion includes a planar portion for being disposed against the framework, and said base portion including an outwardly bent springy tab for fitting over the framework.
14. The system of claim 1 wherein said track segment has a plurality of mounting panels mounted thereto.
15. The system of claim 14 wherein said track segment is made of extruded metal, said exposed portion terminating in a flange extending away from said mounting panels, said base portion terminating in a flange extending toward said mounting panels, said base portion including a recessed wall for accommodating a fastening element, an intermediate flange located between said exposed portion flange and said base portion flange, and said intermediate flange extending away from said mounting panels for being disposed against the framework.
16. The system of claim 14 wherein said track segment is made of extruded material, and said exposed portion terminating in a flange extending away from said mounting panels.
17. The system of claim 14 wherein said track segment is made of stamped material, said exposed portion terminating in a flange extending away from said mounting panels, and said track segment having at least one push out tab for being disposed against the framework.
18. The system of claim 1 wherein said track segment is cut to size from a roll.
19. The system of claim 1 wherein said track segment includes a slot, said track engaging portion of said fastener extending through said slot, and said track engaging portion being disposed on a side of said slot remote from said panel.
20. The system of claim 19 wherein said slot includes an edge to comprise said fastener accommodating structure, and said track engaging portion of said fastener being a projection disposed against said edge.
21. The system of claim 1 wherein said fastener accommodating structure includes a loop terminating in a bent edge, and said track engaging portion of said fastener being a projection disposed against said bent edge.
22. The system of claim 1 wherein said track engaging portion of said fastener is a projection mounted on the end of an arm portion of said fastener.
23. The system of claim 1 wherein said fastener is a resilient clip having a leg disposed against the outer surface of said panel and an arm disposed generally perpendicularly to said leg, said arm terminating in a bent portion which comprises said track engaging portion, and a second resilient member disposed between said leg and said bent end with said panel being sandwiched between said leg and said member.
24. The system of claim 1 wherein a plurality of said tracks are comprised of said aligned track segments laterally spaced from each other with a common continuous base portion.
25. The system of claim 1 in combination with a framework having a plurality of rafters interconnected by a plurality of spaced horizontal battens, a plurality of spaced tracks mounted to said battens, at least one of said tracks comprising a plurality of said track segments being laterally aligned and mounted to one of said battens, each of said track segment base portions being disposed against and mounted to said batten, each of said track segments having an exposed portion extending above said batten to comprise said fastener accommodating structure, and each of said surface indentations being an inwardly directed slot in each of said side edges.
26. The system of claim 25 wherein each of said track segments has only a single mounting panel mounted to said track segment and is of lesser width than the width of said mounting panel.
27. The system of claim 25 wherein a plurality of mounting panels is mounted to each of said track segments.
28. The system of claim 25 wherein said track segment includes at least one integral pointed end, and said pointed end being mounted into said batten.
29. The structure of claim 25 wherein said track segment has a loop portion terminating in a bent edge which comprises said fastener accommodating structure, and said fastener having an outwardly extending arm with a projection disposed against said bent edger and said projection comprising said track engaging portion.
30. A roof structure including a framework having a plurality of rafters interconnected by a plurality of spaced horizontal battens, each of said battens having an inner side and an outer side interconnected by a top edge and a bottom edge, a row of mounting panels for each of said battens, each of said mounting panels having opposite side edges, an inwardly directing slot at each of said side edges, a fastener in the form of a spring clip mounted in each of said slots, each of said fasteners including a leg mounted against said mounting panel on a side of said mounting panel remote from said outer side of said batten, and each of said fasteners extending at least partially around and being mounted to said batten.
31. The roof structure of claim 30 wherein said top edge of said batten is notched to create an upper portion of reduced thickness, and said spring clip being hooked over and disposed against said upper portion of reduced thickness.
32. The structure of claim 30 wherein said top edge of said batten includes a longitudinal recess a spline mounted in said recess and extending outwardly above said top edge of said batten and said spring clip being mounted around and in contact with said spline.
33. A mounting system for mounting a plurality of mounting panels to a structure having a framework comprising a plurality of spaced parallel tracks, each of said tracks having a base portion for being mounted to the framework and an exposed portion spaced from said base portion to function as fastener accommodating structure and with an intermediate connecting portion joining said base portion to said exposed portion, said exposed portion having a downwardly extending projection extending toward said base portion, each of said mounting panels having a head portion and an end portion and opposite side edges, an inwardly directed surface indentation in each of said side edges of said panel, a fastener engaged at each of said surface indentations, said fastener being in the form of a generally R-shaped resilient clip having a free leg merging into an intermediate head which merges into an inward portion which merges into a bend which terminates in a free end, said free leg being disposed against a respective one of said panels with said one of said panels and a vertically adjacent panel being disposed between said free leg and said fastener accommodating portion of said track, and said intermediate head being disposed against said projection of said track.
34. The system of claim 33 wherein said track includes weep holes.
35. The system of claim 33 wherein said track is a pedestal having a width less than the width of said panel.
36. The system of claim 35 wherein each of said pedestals is mounted to a carrier with said pedestals being spaced apart from each other.
37. The system of claim 36 wherein said carrier has an adhesive coated surface, and a protective liner detachably covering said adhesive coated surface.
38. The system of claim 33 wherein said track includes an enlarged portion which functions as a batten for the framework.
39. The system of claim 33 wherein said fastener accommodating structure has an outer surface disposed in contact with one of said panels, and said outer surface having a rocking enhancing shape.
40. The system of claim 33 wherein said intermediate connecting portion includes a series of projections for selective engagement against said clip.
41. The system of claim 33 wherein each of said clips has a panel engaging surface with rounded corners.
42. The system of claim 33 wherein each of said free legs of said clips has a limited panel engaging surface contacting said panel.
43. The system of claim 33 wherein said free end of said clip is a curved ramp.
44. The system of claim 33 wherein said fastener accommodating surface has a nose for engaging and preventing dislodgement of said clip.
45. The system of claim 33 wherein said track has a panel bearing surface located at said intermediate connecting portion.
46. The system of claim 33 wherein said track includes a guide ledge extending below said base portion.
47. A mounting system for mounting a plurality of panels to a roof structure, said mounting system comprising a plurality of rows of panels, each of said panels having a head portion and an end portion and opposite side edges, said rows of panels being arranged in overlapping fashion whereby an end portion of one panel is located vertically above a head portion of a vertically lower panel, mounting structure for mounting said rows of panels to said roof structure, and spacers between said rows of panels to maintain said vertically adjacent panels out of contact with each other to create an open area for an air layer between said vertically adjacent panels.
48. The system of claim 47 including a track for each of said rows of panels, and said mounting structure being fasteners.
49. The system of claim 48 wherein said fasteners are clips which also comprise said spacers.
50. The system of claim 48 wherein said spacers include spacing members separate and distinct from said fasteners.
51. The system of claim 48 wherein said spacers are discrete members mounted to said track at spaced locations.
52. A mounting system for mounting a plurality of panels to a roof structure comprising said roof structure, a plurality of rows of panels, each of said panels having a head portion and an end portion and opposite side edges, said rows of panels being arranged in overlapping fashion whereby an end portion of one panel is located vertically above a head portion of a vertically lower panel, a plurality of outward projections mounted to said roof structure at spaced locations corresponding to one of said projections being disposed at each of said panels, each of said projections having a width less than the width of its said panel, and fastening structure mounting said panels to said roof structure.
53. The system of claim 52 wherein said roof structure includes a solid deck, and said projections being on said solid deck.
54. The system of claim 52 wherein rows of tracks are mounted to said roof structure, and said projections being on said rows of tracks.
55. The system of claim 52 wherein each of said panels is disposed against said projection in the manner capable of rocking.
56. The system of claim 52 wherein each of said projections is mounted at the centerline of its panel.
57. A mounting fastener for mounting a panel to a roof structure, said mounting fastener comprising a generally R-shaped resilient clip having a free leg merging into an intermediate head which merges into an inward portion which merges into a bend which terminates in a free end, stiffening structure at said intermediate head, and said free end being a curved ramp.
58. The clip of claim 57 wherein said free leg includes surface irregularities for preventing a complete surface to surface contact of said free end with the panel.
59. A method of mounting roofing panels to a roof comprising the steps of preassembling fasteners to panels to create a plurality of panels/fastener sub-assemblies, providing a plurality of sets of spaced tracks on the roof, locating the preassembled panels/fasteners on the tracks without engagement of the fasteners to the tracks, and engaging the subassemblies to the tracks by engaging the fasteners with the tracks.
60. The method of claim 59 wherein the tracks are individual pedestals, mounting the pedestals on an adhesive coated carrier sheet with the pedestals spaced apart a distance corresponding to their installed distance on the roof, engaging the fasteners with the panels while the panels remain on the carrier sheet, and placing the carrier sheet on the roof to mount the pedestals at their intended location.
Type: Application
Filed: Nov 16, 2006
Publication Date: May 31, 2007
Inventor: Alden Gibbs (Wilmington, DE)
Application Number: 11/560,409
International Classification: E04B 1/38 (20060101);