US20070119117A1 - Mounting system for roofs and the like - Google Patents

Mounting system for roofs and the like Download PDF

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Publication number
US20070119117A1
US20070119117A1 US11/560,409 US56040906A US2007119117A1 US 20070119117 A1 US20070119117 A1 US 20070119117A1 US 56040906 A US56040906 A US 56040906A US 2007119117 A1 US2007119117 A1 US 2007119117A1
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Prior art keywords
track
portion
system
panels
mounting
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Abandoned
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US11/560,409
Inventor
Alden Gibbs
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Gibbs Alden T
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Priority to US11/560,409 priority patent/US20070119117A1/en
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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3408Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastener type or material
    • E04D2001/3414Metal strips or sheet metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3408Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastener type or material
    • E04D2001/3438Fasteners comprising several coacting elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3444Fastenings for attaching roof-covering elements to the supporting elements characterised by the roof covering or structure with integral or premounted fastening means
    • E04D2001/345Fastenings for attaching roof-covering elements to the supporting elements characterised by the roof covering or structure with integral or premounted fastening means the fastening means being integral or premounted to the roof structure
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3452Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means
    • E04D2001/3461Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means on the lateral edges of the roof covering elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/3452Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means
    • E04D2001/3467Fastenings for attaching roof-covering elements to the supporting elements characterised by the location of the fastening means through apertures, holes or slots
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/34Fastenings for attaching roof-covering elements to the supporting elements
    • E04D2001/347Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastening pattern
    • E04D2001/3473Fastenings for attaching roof-covering elements to the supporting elements characterised by the fastening pattern fastening single roof elements to the roof structure with or without indirect clamping of neighbouring roof covering elements

Abstract

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.

Description

    CROSS REFERENCE TO RELATED APPLICATION
  • This application is based upon provisional application Ser. No. 60/737,501, filed Nov. 17, 2005.
  • BACKGROUND OF THE INVENTION
  • My 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 INVENTION
  • An 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
  • FIG. 1 is a top plan view of a mounting system for roofs and the like in accordance with this invention;
  • FIG. 2 is a right side elevational view of the system shown in FIG. 1;
  • FIG. 3 is an enlarged view of a portion of the system shown in FIG. 2;
  • FIG. 4 is a view similar to FIG. 3 of a modified form of system in accordance with this invention;
  • FIG. 5 is a top plan view of a modified track segment in accordance with this invention;
  • FIG. 6 is a side elevational view of the track segment shown in FIG. 5;
  • FIG. 7 is a view similar to FIG. 5 of a variation of the track segment;
  • FIG. 8 is a top plan view of yet another form of track segment in accordance with this invention;
  • FIG. 9 is a side elevational view of the track segment shown in FIG. 8;
  • FIG. 10 is a view similar to FIG. 8 of a variation of the track segment in accordance with this invention;
  • FIG. 11 is a side elevational view of the track segment shown in FIG. 10;
  • FIG. 12 is a top plan view of yet another track segment in accordance with this invention;
  • FIG. 13 is a side elevational view partly broken away of the track segment shown in FIG. 12;
  • FIG. 14 is a top plan view of still yet another track segment in accordance with this invention;
  • FIG. 15 is a side elevational view of the track segment shown in FIG. 14;
  • FIG. 16 is a view similar to FIG. 14 of yet another track segment in accordance with this invention;
  • FIG. 17 is a side elevational view of the track segment shown in FIG. 16 and also illustrating a mounting panel;
  • FIGS. 18 and 19 are views similar to FIG. 16 of yet further variations of a track segment in accordance with this invention;
  • FIG. 20 is a side elevational view of the track segment shown in FIG. 19 and also showing the mounting panel and fastener;
  • FIGS. 21-24 are side elevational views of various forms of fasteners which can be used in the practice of this invention;
  • FIG. 25 is a view similar to FIG. 20 showing a modified fastener;
  • FIG. 26 is a view similar to FIG. 20 of yet another modified fastener prior to being secured to the track segment;
  • FIG. 27 is a view similar to FIG. 26 showing the fastener secured to the track segment;
  • FIG. 28 is a top plan view of yet another track segment in accordance with this invention;
  • FIG. 29 is a side elevational view of the track segment shown in FIG. 28;
  • FIG. 30 is a perspective view of still yet another track segment in accordance with this invention;
  • FIG. 31 is a plan view of a track segment in accordance with a further practice of this invention;
  • FIG. 32 is a side elevational view showing a panel mounted to the track segment of FIG. 32;
  • FIG. 33 is a view similar to FIG. 31 of still yet another form of track segment in accordance with this invention;
  • FIG. 34 is a perspective view of a fastener usable with the track segments of FIGS. 31-33;
  • FIG. 35 is a perspective view of a further form of track segment in accordance with this invention;
  • FIG. 36 is a top plan view of the track segment shown in FIG. 35;
  • FIG. 37 is a side elevational view of the track segment shown in FIGS. 35-36 and showing the segment in use;
  • FIG. 38 is a view similar to FIG. 35 of a modified form of track segment in accordance with this invention;
  • FIGS. 39-40 are views similar to FIGS. 36-37 showing the track segment of FIG. 38;
  • FIG. 41 is a perspective view of still yet another track segment in accordance with this invention;
  • FIG. 42 is a view similar to FIGS. 37 and 38 showing the track segment of FIG. 41;
  • FIG. 43 is a perspective view of still yet a further track segment in accordance with this invention;
  • FIG. 44 is a view similar to FIGS. 37, 38 and 42 showing the track segment of FIG. 43;
  • FIG. 45 is a side elevational view showing a track segment mounted to the top of a batten;
  • FIG. 46 is a perspective view showing a modified form of track segment in accordance with this invention;
  • FIG. 47 is an exploded side elevational view showing the mounting of a fastener in the track segment of FIG. 46;
  • FIG. 48 is a perspective view of still yet another track segment in accordance with this invention;
  • FIG. 49 is a top plan view showing the track segment of FIG. 48 in use;
  • FIG. 50 is a side elevational view of the track segment shown in FIG. 49;
  • FIG. 51 is a top plan view showing a modified form of track segment in accordance with this invention;
  • FIG. 52 is a perspective view of the track segment shown in FIG. 51;
  • FIG. 53 is a side elevational view of the track segment shown in FIG. 51;
  • FIGS. 54-55 are top plan views of further track segments in accordance with this invention;
  • FIG. 56 is a side elevational view of the track segment shown in FIG. 55;
  • FIG. 57 is a top plan view of yet another form of track segment in accordance with this invention;
  • FIG. 58 is a side elevational view of the track segment shown in FIG. 57;
  • FIG. 59 is a view similar to FIG. 58 of a variation of the track segment shown therein;
  • FIG. 60 is a top plan view of yet another form of track segment in accordance with this invention;
  • FIG. 61 is a side elevational view showing the track segment of FIG. 60 mounted to a batten;
  • FIG. 62 is a side elevational view of the track segment shown in FIG. 60 mounted to a deck;
  • FIG. 63 is a top plan view of an extruded track segment in accordance with this invention;
  • FIG. 64 is a side elevational view of the track segment shown in FIG. 63;
  • FIG. 65 is a perspective view of a further track segment in roller form in accordance with this invention;
  • FIG. 66 is a top plan view of a stamped track segment in accordance with this invention;
  • FIG. 67 is a side elevational view of the track segment shown in FIG. 66;
  • FIG. 68 is a top plan view of still yet another track segment in accordance with this invention;
  • FIG. 69 is a side elevational view of the track segment shown in FIG. 68;
  • FIG. 70 is a side elevational view showing a panel mounted to the track segment of FIGS. 68-69;
  • FIG. 71 is a perspective view of still yet another view of track segment in accordance with this invention;
  • FIG. 72 is a side elevational view showing the track segment of FIG. 71 mounted in place;
  • FIGS. 73-76 are side elevational views showing still yet other forms of track segments in accordance with this invention;
  • FIGS. 77-79 are side elevational views showing how a batten may be used as a track in accordance with this invention;
  • FIG. 80 is a front elevational view of a further form of track in accordance with this invention;
  • FIG. 81 is a side elevational view of the track shown in FIG. 80;
  • FIG. 82 is a rear elevational view of the track shown in FIGS. 80-81;
  • FIG. 83 is a top plan view of the track shown in FIGS. 80-82;
  • FIG. 84 is a cross sectional view in elevation of yet another form of track in accordance with this invention;
  • FIGS. 85-86 are views similar to FIG. 84 showing variations of the track of FIG. 84;
  • FIG. 87 is a front elevational view of a track segment in accordance with yet another embodiment of this invention;
  • FIGS. 88-89 are right side and rear elevational views of the track segment shown in FIG. 87;
  • FIG. 90 is a top plan view of the track segment of FIGS. 87-89;
  • FIG. 91 is a top plan view of a modified form of track similar to that shown in FIGS. 87-90;
  • FIG. 92 is a top plan view of a track segment or pedestal attached to a batten in accordance with this invention;
  • FIG. 93 is a front elevational view of yet another form of track in accordance with this invention;
  • FIG. 94 is a side elevational view of the track shown in FIG. 93;
  • FIG. 95 is a rear elevational view of the track shown in FIGS. 93-94;
  • FIG. 96 is a top plan view of the track shown in FIGS. 93-95;
  • FIG. 97 is a side elevational view of yet another form of track in accordance with this invention;
  • FIG. 98 is a side elevational view showing a variation of the track shown in FIG. 97;
  • FIG. 99 is a top plan view showing a plurality of track segments or pedestals mounted on a carrying strip in accordance with this invention;
  • FIG. 100 is a front elevational view of the arrangement shown in FIG. 99;
  • FIG. 101 is a front elevational view of yet another form of track in accordance with this invention;
  • FIG. 102 is a side elevational view of a fastener in accordance with this invention;
  • FIG. 103 is a front elevational view of the fastener shown in FIG. 102;
  • FIG. 104 is a top plan view of the fastener shown in FIGS. 102-103;
  • FIG. 105 is a bottom plan view of the fastener shown in FIGS. 102-104;
  • FIG. 106 is a side elevational view of yet another form of fastener in accordance with this invention;
  • FIG. 107 is a side elevational view of a variation of the fastener shown in FIG. 106;
  • FIGS. 108-109 are side elevational views showing the fastener of FIGS. 102-105 mounted in place;
  • FIG. 110 is a side elevational view showing a modified form of fastener in accordance with this invention;
  • FIG. 111 is a schematic side elevational view showing a plurality of panels mounted generally parallel and spaced from to each other to create layers of air between vertically adjacent panels;
  • FIG. 112 is a top plan view showing one stage in the mounting of fasteners to panels in accordance with this invention;
  • FIG. 113 is a top plan view showing another stage in the mounting of the panels to a roof in accordance with this invention;
  • FIG. 114 is a cross-sectional view taken through FIG. 113 along the line 114-114;
  • FIG. 115 is a top plan view showing a further stage in the mounting of panels in accordance with this invention;
  • FIG. 116 is a side elevational view taken through FIG. 115 along the line 116-116;
  • FIG. 117 is a top plan view showing the final stage in the mounting of panels in accordance with this invention; and
  • FIG. 118 is a cross sectional view taken through FIG. 117 along the line 118-118.
  • DETAILED DESCRIPTION
  • 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.
  • FIG. 1 shows one form of structure which includes framework comprising roof joists or rafters 2. The plurality of battens 4 are mounted across the spaced joists 2. In accordance with this invention the plurality of sets of spaced parallel tracks is utilized for mounting the panels 10. As shown in FIG. 1 each set of spaced tracks includes a plurality of laterally aligned track segments or pedestals 12. In the embodiment shown in FIGS. 1-4 each track segment 12 is utilized for mounting a single panel 10. This mounting is accomplished through the use of a fastener 14. The fastener 14 can take any suitable form. Preferably, the fastener is a spring clip which would be engaged in a surface indentation such as a slot or kerf 16 in each side edge 18 of each panel 10. Preferably, the slots 16 are aligned with each other and are located in the head portion of each panel remote from the lower end portion. Although the surface indentations are preferably slots, the indentations could be recesses and the fasteners could have some type of spring bias or clamping mechanism to engage in the recesses. Preferably, however, slots 16 are used since it maximizes the engagement action of the fastener 14 with the panel 10.
  • Each track segment may simply be a planar plate having a base portion 22 which would be disposed directly against the batten 4. FIG. 4, for example, illustrates the plate segment 12 mounted by any suitable fastening element, such as a screw 20 extending through the base portion 22 and into the batten 4. The upper end 24 of the track segment 12 extends above the batten 4 and is thereby exposed to function as fastener accommodating structure.
  • In the embodiment illustrated in FIGS. 1-4, the fastener 14 is a spring clip of generally R-shape having an inward bend 26 which would, because of its springiness, be pressed against the inner surface of track segment 12.
  • FIG. 3 shows a variation where the upper end of track segment 12 terminates in a downward bend 28 to create a stop that would be located at the bend 26 of clip or fastener 14 to prevent dislodgement of the clip 14. The bend or curled edge 28 thus prevents the panel 10 from moving up and helps keep the panel in its desired location. The provision of a curled plate edge, such as edge 28, is advantageous in that it engages the bent end 26 of the clip 14 to prevent any up slope sliding as a result of wind conditions.
  • Although only a single fastening element 20 for each track segment 12 is illustrated in FIG. 1, there could be at least two such fastening elements in the form of screws or nails to minimize the tendency for any rotation of the track segment 12.
  • 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. FIG. 5, for example, illustrates a raised rib 30 extending completely across the base portion of track segment 12. As shown in FIG. 6 the raised rib 30 extends outwardly the same distance as the head of the screw or nail 20. FIG. 7 illustrates a variation wherein a single centrally located rib 32 is provided between two fasteners 20. Other variations could include having a plurality of ribs located at various areas of the base portion of the track segment 12.
  • Although FIG. 1 illustrates the use of track segments for each of the battens, it is to be understood that the invention may be practiced where a single continuous track is mounted on one or more of the battens in combination with the track segments on one or more of the other battens.
  • FIGS. 8-9 illustrate a practice of the invention wherein tabs 34,34 are pressed out of the base portion of the track segment 12. The tabs 34 could be disposed against the upper surface of batten 4 as illustrated in FIG. 9, thus functioning as positioning tabs.
  • FIGS. 10-11 show a variation where the tabs 36 are formed with pointed ends to penetrate the batten 4 and thus act as integral nails for mounting the track segment to the batten. Any number, shape or positioning of such tabs could be utilized.
  • FIGS. 12-13 illustrate a variation where the track segment includes a reference mark 38 which could be in the form of a notch, an indentation or a physically applied manual mark to act as a reference for the center line of the panel to thereby facilitate properly locating the panel with regard to the track segment.
  • FIGS. 14-15 illustrate a track segment wherein the base portion terminates in a raised edge 40 which has sufficient springiness to flex and act as a cushion for the panel. In addition, the raised edge 40 functions as a counter sink for the fastening element 20.
  • FIGS. 16-17 illustrate the inclusion of a cushioning pad 42 secured to the base portion of track element 12 to function in the same manner as raised edge 40. The cushioning pad could be made of any suitable material, such as a rubbery or sponge-type material having springiness characteristics.
  • FIG. 18 shows a variation of the embodiment of FIGS. 16-17. In FIG. 18 a plurality of cushioning pads 44,44 is mounted to the base portion of track segment 12. The pads 42,44 could be separate elements secured to the base portion of the track segment 12 or could be formed by pressing out sections of the base portion. The pads provide a cushioning for the head portion of the panel 10, as well as springiness.
  • In the embodiment shown in FIGS. 19-20 the cushioning effect is achieved by having the raised edge 46 comprise only a portion of the bottom end of track segment 12.
  • FIG. 20 shows the use of a springy biasing member such as raised edge 46 when the components are mounted in place. The same functions of raised edge 46 could also be achieved by the cushioning members 42,44 or raised edge 40. As shown in FIG. 20 the raised edge 46 is disposed against the head portion of lower panel 10 while the fastener 14A is securing the upper panel 10 to the track segment 12.
  • FIG. 22 shows a fastener 14A which differs from fastener 14 shown in FIGS. 2-4 and FIG. 21 which is of generally R-shape having an inward bend 26. Fastener 14A, however, is of generally inverted U-shape terminating in an inward bend 26A which could be a straight bend as shown in FIG. 20 or an upwardly turned bend as shown in FIG. 22.
  • FIGS. 23 and 24 illustrate further modifications for the fasteners. As shown in FIG. 23 the fastener 14 is provided with a reinforcing rib 52 outside of the connecting portion 50. In FIG. 24 reinforcement is achieved by means of a reinforcing groove 54 at the intermediate portion of the clip.
  • FIG. 25 shows a further modified form of fastener 14B. As with the fasteners 14,14A each fastener is a spring clip having a straight free end or leg 48. Each fastener terminates at its opposite end in a hook structure which preferably includes a bend such as bend 26 or 26A. The intermediate portion 50 or 50A of clips 14 and 14A is a smooth curve. With the clip 14B, however, the portion 50B is flat.
  • FIG. 26 illustrates still yet another form of fastener 14C having its hook end 26C of generally squared off shape.
  • FIGS. 26-27 show the steps in mounting or hooking a fastener over the exposed end of the track segment. As shown in FIG. 26 the fastener or spring clip 14C would be mounted in the slot 16 of panel 10. The panel and fastener as a unit would then be moved toward the track segment 12. Because of the resiliency, particularly of the clip, the hook end 26 would pass over and engage the bent end 28 of track segment 12. FIG. 26 also shows the raised edge 46 to be compressed when the mounting is complete.
  • FIGS. 28-30 show yet another form of mounting track. As shown therein, the base portion includes raised edges 56,56 to function as cushioning pads. Side walls or flanges 58 are also provided along the opposite sides of the track segment. A recessed portion 60 centrally located would receive a fastener 20 through its preformed hole 62. The recessed portion 60 thus functions as a counter sink to prevent the fastener head from projecting outward of the profile of the track segment as shown in FIG. 29. The track segments shown in FIGS. 28-30 have the advantage of providing a stiffening effect through the flanges 58 and the recessed portion 60 while permitting the track segment to be made of a thin material.
  • FIG. 31 illustrates a modified form of track segment similar to the track segment shown in FIG. 30. The track segment of FIG. 31 differs in that it includes an open slot 61 through which a fastener could be inserted.
  • FIG. 32 illustrates the track segment of FIG. 31 mounted against a batten 4. As shown therein a fastener 14D is used for mounting a panel 10 against the fastener 12 and batten 4.
  • FIG. 34 best illustrates the structure of fastener 14D. As shown therein 14D includes an end 48 which would be disposed against the panel 12. A V-shaped spring arm SOD includes a series of keeper projections 59. The spring arm is inserted through the slot 61 and is urged upwardly by its springy nature into contact with the upper edge of slot 61 and held in position by that edge of slot 61 engaged against one of the keeper projections 59.
  • FIG. 33 shows a variation of track segment 12 which is of simple plate form but includes an open slot 61. The plate would be secured in any suitable manner directly against a batten 4 with the open slot 61 disposed above the upper edge of the batten so that a suitable fastener such as fastener 14D could be utilized to mount a panel.
  • FIGS. 35-37 show a variation of a track segment 12A which is in the form of a bracket having a pair of outwardly extending flanges or ends 64 and a centrally located generally U-shaped portion 66. The end flanges 64 function as the base portion of the track segment 12A. Thus, FIG. 35 illustrates holes 68 to accommodate fasteners 20 which are shown in FIG. 36. The U-shaped central portion comprises the exposed portion or fastener accommodating structure for receiving the hook end of clip 14 as illustrated in FIG. 37. As also shown in FIG. 37 the bent portion 26 would be disposed toward the wall or edge 70 of exposed portion 66 so that the wall 70 acts as a stop for the bent portion 26.
  • FIGS. 38-40 show a variation where the track segment 12B is similar to track segment 12A except that it includes a closed bottom wall 72 which would act as a rest or stop for the bottom of clip 14 as illustrated in FIG. 36.
  • FIGS. 41-42 illustrate a further track segment 12C which is similar to track segment 12A except that the wall 70 includes a slot 72. Thus, as shown in FIG. 42 the bent portion 26 of clip 14 would be located and held within slot 72.
  • FIGS. 43-44 show yet another variation of a track segment 12D which is generally similar to that of track segment 12A except that the upper edge of wall 70 terminates in an inwardly bent end 74 which would act as a stop to prevent the bent end 26 of clip 14 from becoming dislodged.
  • 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 FIGS. 35-44 are described and illustrated as being mounted to a side face or front face of a batten. It is to be understood, however, that the invention may be practiced where the track segment is mounted to the lower and more preferably the upper wall of the batten. FIGS. 45-47 illustrate such variation of the invention. FIG. 45, for example, shows a track segment similar to track segment 12A which would be mounted on the top wall of batten 4 with any suitable fastener such as fastener 14E shown more clearly in FIG. 47 being used to mount the panel 10 to the batten 4.
  • FIG. 46 shows a modified form of batten 12E which is essentially a U-shaped bracket similar to bracket 12A or 12C except that it includes a downwardly inclined retaining finger 63 at its slot 72. The fastener 14E includes an upwardly extending inclined projection 65 on the horizontal leg 67 which is joined to vertical leg 69. Vertical leg 69 would be disposed against the panel 10 as shown in FIG. 45, while horizontal leg 67 would be inserted through the U of the bracket until projection 65 is moved past finger 63. The projection 65 and finger 63 are then in the path of movement of each other to resist this engagement of the fastener 14E from bracket track segment 12E.
  • 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.
  • FIGS. 48-51 show further variations of the track segments whereby the track segments could be clipped around the batten 4 without the use of additional fastening elements such as screws or nails. FIGS. 48-50 show a version where an integral tab 76 is formed in the base portion of track segment 12E. Tab 76 has a generally horizontal section 78 and terminates in a bent end 80 which has sufficient springiness to clamp the base portion of track segment 12E around the top of batten 4.
  • The track segment 12F shown in FIGS. 51-53 includes a set of tabs each having a generally horizontal bent section 82 and a generally vertical bent section 84 to snap over batten 4 as best illustrated in FIG. 53. FIG. 53 also shows the exposed end of the track segment 12F to terminate in a horizontal bent portion or stop member 86 rather than being a curved portion such as portion 28 shown in FIG. 50.
  • The track segment 12G shown in FIG. 54 includes a centrally located bent tab similar to tab 76 except that the tab extends a sufficient distance that it terminates in a lower bent section 86 which would extend around the bottom of the batten 4.
  • FIGS. 55-57 show a track section 12H similar to track section 12G except that the tabs are formed at the ends of the track section. As best shown in FIG. 57 the tabs include a horizontal wall 88 which merges into a vertical wall 90 and then terminates in an outwardly bent portion 92 similar to portion 86 of FIG. 54. The bent portion 92 is disposed on the lower side of batten 4 so that the batten is partially encircled so that the portions of four different sides.
  • The track segments shown in FIGS. 48-50 and 51-53 utilize the springiness of the tabs for mounting the track segments to the batten. The track segments shown in FIGS. 54-56 could utilize rigid tabs where there is proper dimensioning. Preferably, however, the bent portion 92 would have some flexibility or springiness.
  • The track section 12I shown in FIGS. 57-58 include bent portions at the ends of the track segment in the form of horizontal sections 94 which extend along the lower portion of batten 4. Portion 94 then terminates in a bent portion 96 along a vertical portion of batten 4. A central tab includes a horizontal wall 98 terminating in a bent portion 100 to partially encircle the top portion of the vertical wall of batten 4 as best shown in FIG. 1.
  • FIG. 59 shows a variation of a track segment 12J similar to track segment 12I except that the tab wall 938 terminates in a straight bend 102 rather than the angled bend of FIG. 58
  • The various track segments described in FIGS. 48-59 thus preferably include a flexible tab having sufficient springiness so that the tabs at least partially encircle the batten to firmly mount the track segments without the need for separate fasteners although such fasteners could be used as a supplement if desired.
  • FIG. 60 shows a track segment 12K which is elongated so as to be of sufficient length whereby the single track segment 12A could be used for mounting more than one of the panels 10. Thus, the invention may be practiced where a set of tracks includes two or more of such track segments 12K, each of which would be provided for a set of mounting panels. Alternatively, the track segment itself could be a single continuous track for accommodating all of the mounting panels in a row of panels. Such continuous track could include the various features previously described for individual track segments such as bent tabs and bent edges. If desired, the track 12K could be of generally Z-shape along the lines described in my prior patents and would have holes 104 for receiving fasteners such as screws 20 located in the base portion 106 of the track 12K. FIG. 61 illustrates such a track 12K or one of the prior track segments to be mounted directly to a batten 4, while FIG. 62 illustrates the track or track segment to be mounted to a deck 108. As shown in FIGS. 61 and 62 the track would include an exposed or offset portion 110 for accommodating a fastener.
  • The tracks or track segments could be formed in various manners. FIG. 63 illustrates a track segment 12L to be an extruded track which could include various other features such as a flange 112 for resting directly on a batten 4. The base portion 114 could be recessed in the sense of having a lower outwardly extending flange 116 which terminates in line with the exposed portion 118 so that the fastener 20 would not extend beyond the profile of the track segment 12L. FIG. 64 also illustrates the exposed portion 118 to terminate in a stop flange 120.
  • FIG. 65 shows a further form of track segment 12M which would be provided in roll form so that the necessary length of the track segment 12M could be cut from the roll 122. The bent portion 124 at the end of the upper or exposed part of track segment 12M might have to be moved outwardly if it is pressed against the main portion of track segment 12M while in the roll form.
  • FIGS. 66-67 illustrate a track segment 12N to be formed by being stamped. Thus the stamped track 12N could include such features as a vertical push out tab 126 or a horizontal push out tab 128 which could be disposed on top of the batten 4. The stamped track segment could also include such features as a lower flange 130 in line with the exposed portion 132 to create a recess for fastener 20. The exposed portion 132 could terminate in a hook 134. Preformed holes 135 could be provided to receive fasteners 20.
  • FIGS. 68-70 illustrate yet another form of track segment 12P. As shown therein the track segment is of plate-like form and includes a pair of punched out edges 136,136 creating a slot 138 through which the lead end of a fastener may be inserted. For example, a fastener 14E such as shown in FIG. 47 could be inserted through slot 138 until its projection 67 passes beyond the inclined edges 136,136 by having either the edges 136,136 and/or the projection 65 resilient. The fastener 14E is able to be effectively mounted to track segment 12P thereby holding the panel 10 in place against batten 4.
  • FIG. 71 shows yet another form of track segment 12Q which is bent so as to have one of its sides terminate in a series of pointed prongs 140 which could function as nails for penetrating a batten 4 such as shown in FIG. 72. Track segment 12Q also has bent sides forming a channel 142 with a bent opposite edge or curl 144.
  • As shown in FIG. 72 a panel 10 would be mounted to batten 4 by inserting a fastener such as fastener 14K through the slot 16 of panel 10. The lead end of fastener 14K could have one or a series of projections 65 that would pass into the channel 142 and be locked in place by engagement with bent edge 144 (shown in FIG. 71). As noted, the track segment 12Q would already be fastened to batten 4 by its integral nails 140 penetrating the batten.
  • FIG. 73 shows a variation where the track segment 12R is generally similar to track segment 12Q but omits the integral nails. Thus track segment 12R includes a channel 142 and bent or curled edge 144. Track segment 12R, however, terminates in a planar wall 146 which would be disposed against batten 4 and secured in any manner such as by fastener 20.
  • FIG. 74 illustrates yet another form of track segment 12S having a planar wall 146 secured to batten 4 by means of fastener 20. Wall 146 merges with perpendicular wall 148 which in turn merges with a loop portion terminating in bent edge 144 spaced slightly from perpendicular wall 148. As shown in FIG. 74 perpendicular wall 148 is disposed on the top edge of batten 4. A fastener such as fastener 14K could be utilized by having one of its fingers or projections 65 pass behind bent edge 144 and then be locked in place.
  • FIG. 75 illustrates yet a further track segment 12T which terminates in a planar wall 146 mounted to batten 4 or to a solid deck by means of any suitable fastener such as fastener 20. Mounting wall 146 then merges with a U-shaped portion 150 which in turn merges with a reverse U-shaped portion 152 terminating in bent edge 144 for engagement with a projection or finger 65 of a suitable fastener.
  • FIG. 76 illustrates a fastener variation. This type of fastener may be considered as a fastener within a fastener in that the fastener includes a straight leg 48 that would be disposed against the panel 10 with a connecting portion 50 located in the slot 16 of panel 10. The connecting portion terminates in a bent edge 154 that is disposed against bent edge 28 of a suitable track segment 12. This portion of fastener 14L is generally similar to fasteners 14B and 14C of FIGS. 25-26. A distinctive feature of fastener 14L, however, is that it includes a resilient bent portion 156 punched out from connecting portion 50. Portion 156 is resiliently biased against the opposite side of panel 10 opposite to straight leg 48 to firmly anchor the panel 10 in place.
  • FIGS. 77-79 are included to illustrate how the batten itself may function as a track or track segment. FIG. 77 shows the batten 4 to be able to function as a track by locating the slot 16 of the panel 10 in line with and partially above the top edge of the batten. Thus, a fastener such as fastener 14 could be inserted through the slot 16 and disposed around the batten 4 without the need for any other track or track segment.
  • FIG. 78 illustrates how a portion or all of a batten 4 could be modified by having a notch 158 formed in the top edge of the batten to create a reduced thickness section 160 that would function as the track or track segment. As noted the entire batten could be notched or the notches could be placed only where it is intended to secure a fastener.
  • FIG. 79 illustrates a variation where a recess 162 is formed in a batten 4 and a spline or other form of track segment 164 is inserted in the recess 162 so that the spline acts as a track segment. The recess 162 could extend the entire length of batten 4 and a single or multiple splines could be inserted in the recess. Alternatively batten 4 could be recessed only at selected locations where it is desired to have a track segment.
  • FIGS. 80-83 show a further practice of this invention wherein the track 12U includes a hook or downward projection 166 which is located to function as a catch for the contact by the bend in an R-shaped fastener such as fastener 14 in much the same manner as illustrated in FIG. 3. Track 12U also includes a downwardly extending guide ledge or flange 168 which would be, for example, disposed against a batten 170. The use of a guide ledge such as ledge or flange 168 assures proper positioning of the segment while facilitating its mounting.
  • An alternative to what is shown in FIGS. 80-83 would be to dimension the base of the track so that the intermediate portion is located at an edge of the batten (the edge opposite where guide ledge 168 is located) and to extend the intermediate portion downwardly below the base so that such extension would be the guide ledge thereby eliminating the guide ledge 168.
  • FIGS. 84-86 show variations of the track 12U. FIG. 84, for example, shows the track 12U mounted to batten 170 which is mounted to rafter 2. Any suitable mounting fastener 172 may be used.
  • FIG. 85 shows a track 12U which is mounted by fastener 172 directly to the deck 174.
  • The variation shown in FIG. 86 illustrates the track 12U mounted directly to a roof rafter 2.
  • The track 12U shown in FIGS. 80-86 could be an elongated continuous track or could be a track segment or pedestal.
  • FIGS. 87-90 illustrate a track segment or pedestal 12V mounted to any suitable support such as a batten 170. Track segment 12V is provided with a suitable number of holes or openings 178 for accommodating suitable fasteners such as screws or nails.
  • FIG. 91 shows the inclusion of weep holes 179 in any of the various forms of tracks 12 located in the upper fastener accommodating portion, as illustrated, or preferably in the upstanding or intermediate portion of the track. The weep holes function to prevent the trapping of moisture.
  • FIG. 92 shows a plurality of track segments or pedestals 12 which could take any of the previous suitable forms wherein the track segments 12 are attached to a batten 170 at spaced locations so that each track segment or pedestal 12 supports a single panel 10.
  • FIGS. 93-96 illustrate a variation of the invention wherein the track 12W includes a hollow portion so that the track is integral with the batten 180. The track 12W can be extruded hollow which would eliminate the need for a batten so that the tracks could be mounted on a roof having open structure of rafters without a deck or battens. Alternatively, the track can be an extension of a solid batten.
  • FIG. 97 shows a track 12X similar to track 12U except that it has an inclined intermediate portion in its generally Z-shape. FIG. 98 shows a variation of the track 12X which includes a plurality of locking projections 182 for engaging an expandable or fastener or clip 14. For example, under wind conditions the R-shaped clip might tend to expand. With the track 12X illustrated in FIG. 98 the leg of the R-shaped clip would engage one of the locking projections 182 to assure a firm locking of the clip or fastener to the track.
  • FIGS. 99-100 illustrate a feature of the invention which would lend itself to ease of assembly or mounting of the system to a roof. As shown therein, the individual track segments or pedestals 12 are pre-mounted spaced from each other on a carrier sheet or tape 184 in any suitable manner such as by being adhesively secured to the carrier sheet. The remote surface of carrier sheet 184 is adhesive coated and includes a removable protective liner 186. In practice a plurality of segments or pedestals 12 would be mounted spaced apart a suitable distance such as 10 inches to correspond to their location on a roof. A workman would bring a carrier sheet having the desired number of segments 12 to the intended location on the roof. The protective liner 186 would be removed and the carrier sheet 184 would be placed on the roof. The segments or pedestals 12 would then be mounted through the use of suitable fasteners 172. The carrier sheet could remain on the roof when the segments 12 have been attached or could be removed prior to attachment of the segments. By mounting the segments or pedestals on a carrier such as on an extruded sheet 184 of plastic or tape which would be of a length generally corresponding to the length of the pedestal or segment there would be a prespacing of the segments or pedestals which facilitates the assembly of the individual segments or pedestals on the roof.
  • 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.
  • FIG. 101 illustrates a track segment 12 to include a hump or arcuate upper edge 188 to permit the panel 10 to rock or pivot. This maximizes ventilation and distributes stress which is particularly desirable for slate panels.
  • 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.
  • FIGS. 102-105 illustrate a fastener 14 in the form of a resilient R-shaped clip. The fastener or clip 14 includes a straight free leg 190 which merges into a curved intermediate portion or head 192 which is thickened or otherwise stiffened 202. Intermediate portion 192 merges into an inwardly turned portion 194 which in turn merges into a bend or ramp 196 and terminates in a curved ramp free end 198. As shown in FIGS. 104 and 105 the corners 200 of the clip are rounded so as not to dig into the panel, particularly where the panel is slate. This R-shaped structure can accommodate different thicknesses of panels. For example, FIGS. 108-109 illustrate the clip 14 when used with a track or track segment 12U. As shown in FIG. 108 both panels 10,10 are of uniform thickness and are received between the straight leg 190 and the fastener accommodating portion of track 12U. The bent portion 196 of clip 14 is disposed against the hook or projection 166. FIG. 109 shows the same arrangement wherein the panels 10,10 are of differing thickness which would be greater than the thickness of the two panels shown in FIG. 108. As indicated by the arrows in FIG. 109 the resilient clip 14 is expanded sufficiently to accommodate the thicker panels.
  • Clip 14 of FIG. 106 differs from clip 14 of FIGS. 102-105 in that the straight free leg 190 of FIGS. 102-105 is in FIG. 106 an undulated or curved leg 204. This curvature creates open areas which would assist in moisture removal as compared to a straight leg having complete surface to surface contact.
  • FIG. 107 shows a variation of the clip shown in FIG. 106 wherein the straight free leg 190 is provided with dimples or projections 206 which perform the same function as the undulations 204 of FIG. 106 in assisting in moisture removal. FIGS. 106-107 thus show the use of spaced projections such as undulations or dimples on the panel contacting surface of the track to assist in moisture removal.
  • The inclusion of limited panel contacting surfaces on the clip, such as shown in FIGS. 106-107, could be accomplished with other structures such as a dog leg or hump on the free leg of the clip or from springiness of the free end.
  • FIG. 110 illustrates a further variation of the clip 14 wherein a tongue 206 is provided for engagement with the projection 166 of the track 12U. Tongue 208 may be formed by being stamped out from either the inwardly turned portion 194 or from the bend and free end 196,198.
  • The clip 14 in its various forms illustrated in FIGS. 102-110 have a number of distinct advantages. The curved ramp or bent portion 196 engages the nose or catch/projection 166 of the track. This gives a progressive gentle sloping surface. If the ramp 196 were not curved it would cause the angle of engagement with the track to become more vertical or perpendicular. Engagement of the clip with the catch 166 on the track effectively prevents dislodgement of the clip. This is particularly important in conditions where the wind might tend to push the panel or slate upwardly and cause the clip to open. When the wind tends to move the clip open the head or loop 192 of the clip bottoms against the nose 166 of the track to prevent dislodgement.
  • 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.
  • FIG. 111 illustrates a particularly advantageous practice of this invention for addressing moisture problems. As shown in FIG. 111 the head 210 of each panel or slate 10 is disposed against the support member such as batten 170 which are mounted across rafters 2. Each panel 10 is mounted in an inclined orientation and is secured in place by an appropriate fastener or clip 14 which extends upwardly from the outer surface of the panel 10. Each clip extends upwardly a distance which would cause the overlying panel to be parallel to the underlying panel. Thus, as shown in FIG. 111 the four panels 10 are each parallel to each other and are vertically spaced away from each other to create an open area or air layer between vertically adjacent panels which would be particularly effective in dissipating moisture.
  • Although FIG. 111 illustrates the head of each panel 10 against a batten 170, the panels could be against a deck or against a track, etc.
  • 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.
  • FIGS. 112-118 illustrate a particularly advantageous technique for creating a roofing system through use of the components of this invention in the manner similar to mass production.
  • FIG. 112 shows the initial step in mounting the components. As shown in FIG. 112 the panel such as slate 10 is provided with kerfs 16 on its opposite side edges. A suitable fastener or clip 14 is then premounted into each kerf. FIG. 112 shows one of the clips 14 already in place with the other clip in the stage of being assembled to the panel. This preassembly step could be performed at any suitable location and need not be done, for example, on the roof.
  • FIGS. 113-114 illustrate a next sequence in the mounting technique. This step involves placing each preassembled panel/clip on the roof in a ready to mount orientation. This step could be done by one workman while another workman is preassembling further panels/clips. As shown in FIGS. 113-114 the preassembled panel/clip would simply be placed where the preassembly rests in the vicinity of a track or track segment awaiting the final installation.
  • FIGS. 115-116 illustrate the next step in installing the roofing system. In this step the preassembled panels/clips are now disposed in the general orientation they would take when being mounted on the tracks 12. FIG. 116 shows the lower clip 14 in its fully installed position while the upper preassembled panel/clip has not yet been moved into that final position. Thus, FIG. 116 shows the upper clip 14 not yet in full contact with the track or track segment 12.
  • FIGS. 117-118 illustrate the components in their final assembled condition where each clip 14 is engaged with its corresponding track or track segment 12 and where the panels 10 are disposed parallel to, but spaced apart from each other where they overlap. This air gap or layer of air enhances air circulation and diminishes capillary action. The air gap could be made sufficiently thin that a panel is supported by the fastener column (track/clip) and the support beneath the head 210 of the panel whereby there can be a downward flexing to gain support and prevent breakage. Notably this system provides a two point support enhancing the ability of the panel or slate to move and to distribute loads offering the benefit of reducing breakage and/or using thinner less costly lighter panels.
  • 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 FIG. 118. The column of support at the foot of the panel in combination with the support at the head of the panel permits rocking and improved support.
  • 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 FIG. 118, where the head of the panel contacts the track immediately above the downwardly extending projection or catch. This arrangement could be varied to move the bearing surface away from the end of the track. This could be accomplished in various manners such as by having an extension of the intermediate generally vertical portion of the Z-shaped track extend outwardly a greater distance than the free end of the track so that the panel is disposed against this intermediate extension. Alternatively, the free end or fastener accommodating surface of the track could be inclined downwardly so that the vertical connecting portion or intermediate portion has the greatest dimension whereby the panel is mounted directly against that intermediate portion.
  • 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 (60)

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.
US11/560,409 2005-11-17 2006-11-16 Mounting system for roofs and the like Abandoned US20070119117A1 (en)

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US11/560,409 US20070119117A1 (en) 2005-11-17 2006-11-16 Mounting system for roofs and the like

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Also Published As

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WO2007059525A2 (en) 2007-05-24
AU2006315114A1 (en) 2007-05-24
EP1957724A2 (en) 2008-08-20
WO2007059525A3 (en) 2008-08-07
CA2630007A1 (en) 2007-05-24

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