ROOF MOUNTING SYSTEM

Abstract

The present invention relates to a roof mounting system with a locating and waterproofing device (100) which is formed from a water impermeable medium. The device has a short edge (104) which is dimensioned to rest against and be secured to a batten (121) and a long edge (106), whose upper portion rests on an upper surface of the batten (121). A lower portion of the locating and waterproofing device rests on a lower slate or stone (10A) and is sandwiched between the lower slate or stone (10A) and an upper slate or stone (10B) so that a continuous barrier (102) is formed along the long edge (106) to provide a water resistant barrier and to create a void (116) between the lower slate or stone (10A) and the upper slate or stone (10B).

Claims

1. A locating and waterproofing device (100) is formed from a water impermeable medium, the device has a short edge (104) which is dimensioned to rest against, and be secured to a batten (121); and a long edge (106), whose upper portion rests on an upper surface of the batten (121) and whose lower portion rests on a lower slate or stone (10A) and is sandwiched between the lower slate or stone (10A) and an upper slate or stone (10B), wherein a continuous barrier (102) is formed along the long edge (106) to provide a water resistant barrier and to create a void (116) between the lower slate or stone (10A) and the upper slate or stone (10B).

2. A locating and waterproofing device (100) according to claim 1 wherein the continuous barrier (102) is formed as a curved corner between the short edge (104) and the long edge (106).

3. A locating and waterproofing device (100) according to claim 1 wherein the continuous barrier (102) is formed as a bead which is bonded to the long edge (106).

4. A locating and waterproofing device (100) according to claim 1 when used with thin slates wherein the upstanding short edge (104) with the planar member (10) beyond the continuous barrier (102) for fixing in the close boarded configuration.

5. A locating and waterproofing device (100) according to claim 1 wherein a raised portion (108) is provided on the long edge (106) between the continuous barrier (102) and a tip (112) of the long edge (106).

6. A locating and waterproofing device (100) according to claim 5 wherein the raised portion (108) is an undulation formed integrally with the long edge (106).

7. A locating and waterproofing device (100) according to claim 5 wherein the raised portion (108) is formed as a bead which is bonded to the long edge (106).

8. A locating and waterproofing device (100) according to claim 1 wherein a strip (15) is provided on the long edge (106).

9. A locating and waterproofing device (100) according to claim 1 is formed from a synthetic plastics material.

10. A locating and waterproofing device (100) according to claim 9 wherein the synthetic plastics material is polypropylene and/or glass reinforced polymers (GRP).

11. A locating and waterproofing device (100) according to claim 1 wherein the device is provided in a length less than 6.0 m, preferably less than 4.0 m and most preferably less than 2.0 m.

12. A locating and waterproofing device (100) according to claim 1 wherein the thickness of the device is between 0.5 mm and 1.5 mm, preferably 1 mm

13. A locating and waterproofing device (100) according to claim 1 wherein the length of the short edge (104) is between 1.0 cm and 3.5 cm, preferably between 2.0 cm and 3.5 cm and most preferably between 2.5 cm.

14. A locating and waterproofing device (100) according to claim 1 wherein the length of the long edge (106) is between 20 cm and 60 cm, preferably according to the corresponding variable size of slates being used

15. A roof mounting system includes the locating and waterproofing device (100) according to claim 1 and further comprises at least one foam member (15) which is located on a lower surface of the lower slate or stone (10A) member.

16. A method of installing a locating and waterproofing device (100), resting a short edge (104) of the device (100) against a batten (121) and securing the device to the batten (121) using a securement means so that a long edge (106) of the device rests on an upper surface of the batten (121) and so that a lower portion of the device (100) rests on a lower slate or stone (10A); placing an upper slate or stone (10B) on the locating and waterproofing device (100), so that the locating and waterproofing device (100) is sandwiched between the lower slate or stone (10A) and thereby forming a continuous barrier (102) along the long edge (106) to provide a water resistant barrier; and creating a void (116) between the lower slate or stone (10A) and the upper slate or stone (10B).

17. A method of installing a locating and waterproofing device (100) according to claim 16 and securing the upper slate or stone (10B) with a slate hook 300.

Description

BRIEF DESCRIPTION OF FIGURES

[0079] FIG. 1 is a schematic illustration of a cross-sectional view of a traditional double lap roof;

[0080] FIG. 2 is a schematic illustration of an exploded view of a traditional stone roof installed in the double lap format;

[0081] FIG. 3 is a schematic illustration of a cross-sectional view of a stone roof using the roof mounting system according to one embodiment of the present invention to provide a single-lap format roof;

[0082] FIG. 4 is a schematic illustration of an exploded view of a stone roof installed in the single lap format using the roof mounting system according to one embodiment of the present invention;

[0083] FIG. 5 is a schematic illustration of a cross-sectional view of a stone roof using the roof mounting system according to one embodiment of the present invention;

[0084] FIG. 6 is a schematic illustration of a cross-sectional view of the foam wedge in the perp join of the roof mounting system according to one embodiment of the present invention;

[0085] FIGS. 7 and 8 are schematic illustrations of a cross-sectional view and a perspective view of an locating and waterproofing device of the roof mounting system according to one embodiment of the present invention;

[0086] FIGS. 9 and 10 are schematic illustrations of a cross-sectional view and a perspective view of the locating and waterproofing device of the roof mounting system according to a further embodiment of the present invention;

[0087] FIG. 11 is a schematic illustration of a cross-sectional view of the abutment feature of the roof mounting system according to one embodiment of the present invention;

[0088] FIG. 12 is a schematic illustration of a cross-sectional view of a ridge system utilising a roof mounting system and ventilation rail according to one embodiment of the present invention;

[0089] FIG. 13 is a schematic illustration of a cross sectional view, when used with thin stone slates, and when incorporating the hook fixing method;

[0090] FIG. 14 is a schematic illustration of a cross sectional view of ae valley junction of two rooves;

[0091] FIG. 15 is a schematic illustration of a cross sectional view of the soaker embodiment required for a wall abutment; and

[0092] FIG. 16 is a schematic illustration of a ridge vent system that utilises the rib engagement system as shown in FIG. 7.

DETAILED DESCRIPTION

[0093] With reference to FIGS. 3 to 6, a single-lap format roof covering is illustrated using the roof mounting system 1 according to embodiments of the present invention.

[0094] The timber roof is constructed using rafters (R) and covered in a roofing membrane M) and then overlaid in an opposite direction using timber spas known as ‘battens’ (T). Battens are specifically positioned up the roof and over roof at a set distance called the ‘gauge’ (G). Battens are often nail fixed into position through the membrane and into the rafters.

[0095] Starting by using the longest stones (or other suitable roof material such as slate, tiles or slabs) from the selection available to the roofer, these stones are laid on the roof in a line transversely across the roof called a course (FIG. 4), using a random selection of the widths (BR) available for that length (BD) (or height or gauge) on that course.

[0096] The first course or ‘eaves course’ is a shorter stone for example at 17″ (43.2 cm) long and this is the start of installing the slates and usually overhangs into the gutter.

[0097] A waterproofing element (F) composed of water-impermeable material is provided. The waterproofing element (F) is a permanently resilient front plate composed of glass reinforced polymer (GRP). It is however to be understood that in some embodiments, the waterproofing element may be composed of metal (for example aluminium) or other suitable plastics.

[0098] The waterproofing element (F) comprises a planar member 10 defining a lower surface 11 and further comprises at least one abutment feature 12 extending from the lower surface of the planar member 10, at or adjacent a first end thereof, configured for abutment with a roof batten. The abutment feature 12 has a first end 13 located adjacent the lower surface 11 of the planar member 10 and an opposed free end 14. A pre-adhered foam strip 15 is located adjacent the second opposed end of the planar member 10.

[0099] The waterproofing element (F) is shaped and dimensioned such that the lower surface 11 of the planar member 10 is to be positioned adjacent the upper surfaces 2 of a pair of adjacent roof materials 4 in the underlying first course and to extend across a join (VJ) provided therebetween to prevent water ingress therethrough.

[0100] The waterproofing element (F) is arranged to extend from adjacent or at the rear trailing edge 6 and towards the front leading edge 8 of the underlying roof materials 4.

[0101] For ease of installation the waterproofing element (F) may have a pre-determined length and in order to adequately cover the width of the whole roof the waterproofing element (F) can be easily lapped over each at the point that they abut each other. A strip of adhesive tape may be provided onto the sides of the lapped section so that this lap joined is permanently sealed during installation.

[0102] In one embodiment, the water proofing element (F) may be cut to size as required for a particular pair of adjacent roof materials and the join provided therebetween.

[0103] The abutment feature 12 of the waterproofing element (F) is provided in the form of a downwardly extending lip incorporating a locating curve 101 that is extending from the lower surface 11 of the planar member 10. The lip 12 has an inner surface 16 configured to abut an underlying roof batten (T) and an opposed outer surface 18. The inner surface 16 of the lip 12 together with an adjacent portion of the lower surface 11 of the planar member 10 and in conjunction with 101 form a hook portion. The lip (in particular the hook portion) of the waterproofing element is placed to hook over and abut a portion of the underlying roof batten (T). It is to be understood that the abutment feature 12 may extend at any suitable angle relative to the plane defined by the planar member. Preferably, the abutment feature 12 (e.g. lip) extends substantially perpendicular to the plane defined by the planar member.

[0104] Referring now to a preferred embodiment of the invention shown in FIG. 13 is suitably adjusted for the installation of thin stone slates 1a whereby the planar member 10 incorporates a locating and waterproofing device upwards curve 102, the curve, in conjunction with the capillary void 116 resists the further transfer of water and facilitates the use standard slate slates hooks 300.

[0105] Once in position between adjacent courses of roof materials, the foam strip 15 of the waterproofing element 10 prevents wind driven rain from penetrating underneath the leading edge of the roof material 4.

[0106] FIG. 6 illustrates the system 1 further comprising foam wedges 34 which are shaped and dimensioned such that at least an apex of the wedge 34 can be received within a join formed between adjacent roof materials. The wedges 34 may be elongate in shape and extend along a length of the join between the adjacent roof materials. The system 1 may comprise a plurality of foam wedges, each wedge being configured to be received within a corresponding join formed between adjacent roof materials. The foam wedge 34 is configured to prevent rain from being driven between the join whilst also allowing water vapour to pass through the join and the wedge to prevent the build-up of moisture in the void created by the height of the battens.

[0107] Once the waterproofing element (F) is in position, an abutment feature 20, 120 as illustrated in any of FIGS. 7 to 11 is then selected.

[0108] The abutment feature 20, 120 has an elongate body portion 22, 122 configured to be located between an upper surface 9 of the planar member 10 of the waterproofing element (F), and lower surfaces 5 of overlaying roof materials; the curved internal profile of 20 at 202 having the same radius of curvature as the curved external profile of 10 at 101 a first engagement feature 24, 124 configured to engage a roof batten (T), and a second engagement feature 26, 126 configured to be received within and to engage an opening 28 provided in a lower surface of an overlaying roof material 4.

[0109] The roof material, for example stone, can be cut using for example circular diamond coating cutting wheels to provide a uniform slot in the underside of the covering 4 towards the rear trailing edge 6 of the covering 4. The second engagement feature 26, 126 of the abutment feature 20, 120 is shaped and dimensioned to be received within and to engage with this slot 28.

[0110] The abutment feature 20, 120 is positioned on top of the waterproofing element (F) at the rear trailing end 6 of the roof material 4 such that the first engagement feature 24, 124 abuts the outer surface 18 of the lip 12. The first engagement feature 24, 124, in some embodiments, is dimensioned to extend beyond the free end 14 of the lip 12 of the waterproofing element (F).

[0111] The first engagement feature 24, 124 of the abutment feature 20, 120 further provides a guide feature 30, 130 in the form of a portion of reduced thickness extending between the inner and outer surfaces thereof. The installer inserts a fixing member 32, 132, such as for example a screw, through the guide feature to engage the batten located behind the mounting element 20, 120.

[0112] The second engagement feature 26 may comprise a plurality of protrusions 23 (for example ribs) extending outwardly from the axis defined by the second engagement feature 26, as shown in FIGS. 7 and 8. The free end of the second engagement feature 126 may provide a hooked portion, as shown in FIGS. 9 and 10. The hooked portion may extend at any angle from the axis defined by the second engagement feature, for example extending at about 120°. In one embodiment, as illustrated in FIG. 11, the abutment feature 120 may further comprise a mounting portion 150 comprising a mounting body portion 152 configured to be mounted on the second engagement feature (in the form of an upstanding portion). The mounting portion 150 comprises a plurality of spaced apart protrusions 154 in the form of ribs extending outwardly away from an axis defined by the mounting body portion 152 and the axis defined by the second engagement feature 226.

[0113] The outwardly extending protrusions are resiliently deformable and help improve the grip between the opening or slot of the roof material located and the second engagement feature 26, 126, 226 in order to provide a more secure roof covering.

[0114] As illustrated in FIGS. 7 and 8, the inner surface of the first engagement feature 24 comprises a plurality of spaced apart protrusions 34 in the form of ribs extending outwardly from the axis defined by the first engagement feature 24. The protrusions 34 extend substantially parallel to each other and in a direction extending towards the elongate body 22 of the abutment feature 20. In use, these protrusions about the trailing rear edge of an adjacent roof material providing improved grip to help retain the mounting system 1 and overlaying roof materials in position on the structure.

[0115] The abutment feature 20 of FIGS. 7 and 8 has axially aligned first and second engagement features 24, 26 resulting in the element 20 having a substantially cross-shaped transverse cross-section. In contrast, the abutment feature 120 of FIGS. 9 and 10 has a substantially Z-shaped transverse cross-section.

[0116] With reference to FIGS. 9 and 10, the first engagement feature 124 is located at or adjacent a first side portion 140 of the elongate body portion 122 of the abutment feature 120. The second engagement feature 126 is located at or adjacent a second opposed side portion 142 of the elongate body portion 122 of the abutment feature 120.

[0117] It is to be understood that the configuration of the abutment feature 20, 120 may be selected depending on the particular requirements for the roof covering and underlying roof structure.

[0118] In some embodiments where thin roof materials are used, such as for example slate, the waterproofing element (F) of the present invention may be used in combination with a slate hook 300 rather than the locating and waterproofing device as described herein and as shown in FIG. 13.

[0119] Once the roof mounting system 1 has been installed along the roof materials of the first course, the second course of roof materials are positioned along the upper surface 9 of the waterproofing element and the elongate body 22 of the abutment feature 20, 120. The second engagement feature 26, 126 is received within the corresponding slot 28 of the roof material 4 by pressing.

[0120] The process is then continued for a third and subsequent courses until the roof covering is complete as shown in FIG. 12. When the installation of the stone reaches the apex of the roof then this upper section must be capped. Traditionally this is done with the uses of a stone ridge cap that is set in place using cement mortar. Modern construction methods require that apex of the roof is ventilated and therefore the use of a specialist ridge vent system is required.

[0121] So that the ridge is adequately ventilated a vent can be joined to the stone utilising a standard slot in the stone that having the same mounting method of 26 and 23 with the embodiment incorporating a vented strip that is used to remove the moist air that accumulates in the void below the GRP and above the membrane FIGS. 12, 16, 17.

[0122] The roof mounting system of the present invention therefore enables a roof covering to be provided in a single lap format thereby saving materials, time, labour and reducing the overall weight of the resultant roof covering whilst also improving the waterproofing properties of the roof covering.

[0123] The roof mounting system of the present invention prevents the ingress of water through the perp join provided between adjacent roof materials by the use of the waterproofing element (F) and as a result the roof covering does not require the use of a double lap format (DL).

[0124] The roof mounting system 1 of the present invention can be applied to various roof geometries as discussed below:

[0125] When two planes of a roof meet at an internal junction, a valley is formed, and it is necessary to form a waterproof join between the adjacent roof materials. In order to ensure that the traditional appearance of the roof is maintained, the waterproof element (F) is joined onto a waterproof under valley (V) (as shown in FIG. 14) that is not visible and yet ensures that the water cannot enter the roof through the cut mitre (BV) in the stone valley join. So that the installer might ensure a straight join when installing this invisible junction on the roof, the valley incorporates a centre line (VC) that provides an accurate location for the cut and also acts to stop debris that might permeate through the open joint in the mitre from entering onto the water channels (VW) so as to ensure that the rain water might flow uninhibited down the valley.

[0126] By the design of the valley any excessive rain water flows down the upper surface of the mitre and does not have the chance to enter the valley through the gap in the stone mitred. The water channels (VW) have additional water stops (VS, VL) that further prevent the water in the valley from tracking into the roof. The valley also has a flat section that allows battens (T) and front plate to overlap the valley and ensure that water cannot enter through the valley.

[0127] When a roof abuts a wall then there must be a specific join made (FIG. 15). The method of abutment is called a soaker (U), normally these soakers are from metals such as lead. Because the front plate is from GRP then metal cannot be used so a GRP soaker must therefore be used. These soakers incorporate an adhesive strip (US) to enable the weatherproof joining of the soaker onto the front plate. The soakers are bent perpendicular by way of an elongated ‘S’ and by this required shape the soaker can accommodate the lower sharp corner of the stone and return to close the gap at the top edge. The soakers are cut specifically to fit the specific size of each piece of stone.

[0128] It is appreciated that variation to the aforementioned embodiments may be made without departing from the scope of the invention as defined by the claims.