Roofing system and method

• US 8,166,713 B2
• Filed: 10/12/2011
• Issued: 05/01/2012
• Est. Priority Date: 03/19/2010
• Status: Active Grant

• Current Assignee: Rillito River Solar LLC (Esdec B.V.)
• Original Assignee: Vermont Slate & Copper Services, Inc.
• Inventors: Stearns, Brian Cecil, Lounsbury, Douglas Timothy
• Primary Examiner(s): Katcheves, Basil
• Assistant Examiner(s): STEPHAN, BETH A
• Application Number:
  US13/271,633
• Publication Number:
  US 20120023848A1
• Time in Patent Office: 202 Days
• Field of Search: 52 24- 26, 52/58, 52/60, 526/98, 523/021, 523/026, 523/027, 521/731, 521/733, 52/97, 524/08, 527/414, 411/439, 411/542, 126/621, 126/623, 136/244, 248/237, 248/500, 248/505, 285/42, 285/43
• US Class Current: 52/58
• CPC Class Codes: E04B 1/66 Sealings damp-proof courses E04B1/644; fire-proof sealings E04B1/948; additions of anti-leak properties to plaster C04B; bituminous sealing masses C08L95/00; sealings for hydraulic engineering work in general E02B3/16; against ground humidity or ground water E02D31/02; coverings against rain or other precipitations of the atmosphere E04D; composition of material or manufacture of sealing foils, see the relevant classes for these foils
• CPC Class Codes: E04D 13/04 Roof drainage; Drainage fittings in flat roofs, balconies or the likegutter tiles E04D1/30; gutter slabs E04D3/40; vessels for collecting rainwater E03B3/03; street gullies E03F5/04
• CPC Class Codes: E04D 13/10 Snow traps ; Removing snow from roofs; Snow melters
• CPC Class Codes: E04D 13/14 Junctions of roof sheathings to chimneys or other parts extending above the roof
• CPC Class Codes: E04D 13/1407 for flat roofs
• CPC Class Codes: E04D 13/147 specially adapted for inclined roofs trays for cavity walls E04B1/70
• CPC Class Codes: F16B 43/001 for sealing or insulation
• CPC Class Codes: F16B 5/0258 using resiliently deformable sleeves, grommets or inserts F16B43/001 takes precedence
• CPC Class Codes: F24S 2025/021 Sealing means between support elements and mounting surface
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A roof mounting system can include a roof substrate and flashing supportable on the substrate and including an outwardly extending projection having a concave interior side and an aperture extending through the projection between top and bottom surfaces of the flashing. A seal can extend through the aperture and contact at least a portion of the top surface and at least a portion of the bottom surface. The seal can be conformable with the concave interior side and can define a seal aperture substantially aligned with the flashing aperture. A mounting bracket can be supportable on the flashing and can define an aperture sized to receive at least a portion of each of the seal and the projection. A fastener can extend through the mounting bracket aperture, seal aperture, and flashing aperture to inhibit fluid flow through the flashing aperture.

Claims

1. A roof mount for securing structures on a roof surface, the roof mount comprising:

flashing defining at least one aperture extending therethrough;

a fastener extending through the aperture to retain the flashing on the roof surface;

a bracket having a top surface and a bottom surface and defining a first height, the bracket defining a first aperture having a first diameter and extending from the top surface to the bottom surface, the first aperture sized to receive the fastener therethrough, the bracket defining a second aperture having a second diameter extending from the bottom surface to a location between the top surface and the bottom surface, wherein the second diameter is greater than the first diameter, the bracket defining a substantially cylindrical pocket, both of the first and second apertures opening into the pocket; and

a washer defining an aperture sized to receive the fastener therethrough, wherein the washer has an outer diameter that is substantially identical to the second diameter, the washer positionable in the pocket and operable to substantially seal a perimeter of the second aperture at the bottom surface of the bracket, wherein when the washer is positioned in the second aperture, the washer aperture is substantially co-linear with the first aperture and the second aperture, wherein the washer forms an interference fit with the bracket to substantially seal a perimeter of the first aperture at the location between the top surface and the bottom surface of the bracket.

2. The roof mount of claim 1, wherein the washer spaces the bracket away from the flashing.

3. The roof mount of claim 1, wherein the flashing includes a frustoconical protrusion adjacent the flashing aperture, and wherein the frustoconical protrusion urges the washer into the pocket.

4. The roof mount of claim 1, wherein the fastener extends through the first and second apertures of the bracket, the washer aperture, the flashing aperture, and the roof surface to retain the bracket, the washer, and the flashing on the roof surface.

5. The roof mount of claim 1, wherein the washer is elastomeric and deformable to substantially fill the second aperture.

6. The roof mount of claim 1, wherein the washer is deformable to substantially fill the pocket.

7. The roof mount of claim 1, wherein the bracket and the fastener are operable to support one or more roof mounted structures above the roof surface.

8. The roof mount of claim 1, wherein the fastener has a first end which extends above the bracket, a second end which extends into the roof surface, and a middle portion between the first end and the second end, and wherein the middle portion extends through the first and second bracket aperture, the washer aperture, and the flashing aperture.

9. The roof mount of claim 1, wherein the fastener is a threaded bolt.

10. A method of forming a seal between a roof mount and a roof, the method comprising:

positioning a flashing on the roof;

positioning a seal on the flashing adjacent a flashing aperture;

inserting a fastener through a seal aperture of a seal and the flashing aperture, and into the roof;

positioning a bracket on the flashing;

aligning a bracket aperture with the seal aperture;

receiving at least a portion of the seal into a bracket recess;

compressing the seal between the flashing and the bracket;

forming an interference fit between the flashing and the bracket in response to compressing the seal between the flashing and the bracket; and

forming a labyrinth seal between the flashing and the bracket, the labyrinth seal having a tortuous path inhibiting flow of fluid between the flashing and the bracket.

11. The method of claim 10, further comprising spacing the bracket from the flashing with the seal.

12. The method of claim 10, further comprising urging the seal into the bracket aperture with a frustoconical protrusion on the flashing.

13. The method of claim 10, further comprising positioning a washer having a washer aperture adjacent the bracket aperture and extending the fastener through the bracket aperture, the washer aperture, and the flashing aperture.

14. The method of claim 13, further comprising retaining the bracket, the washer and the flashing on the roof surface with the fastener.

15. The method of claim 10, further comprising deforming the seal to substantially fill the bracket aperture.

16. The method of claim 10, further comprising supporting one or more roof mounted structures on at least one of the bracket and the fastener.

17. The method of claim 10, wherein compressing the seal between the flashing and the bracket includes tightening the fastener.

18. The method of claim 10, wherein compressing the seal between the flashing and the bracket includes reducing a distance between the fastener and the bracket.