FASTENER SYSTEMS FOR ROOF STRUCTURES

INCORPORATION BY REFERENCE

The disclosure and figures of U.S. Provisional Patent Application No. 63/317,230, filed Mar. 7, 2022, are specifically incorporated by reference herein as if set forth in their entireties.

FIELD OF THE INVENTION

The present invention relates to fastener systems, and, more particularly, fastener systems for roof structures.

BACKGROUND OF THE INVENTION

Fasteners are utilized to secure components of a roofing system on a roof deck of a roof structure.

SUMMARY OF THE INVENTION

Briefly described, the present disclosure relates to fastener systems and methods of attaching one or more layers of materials to a roof deck of a roof structure for forming a roof. In embodiments, the roof structure can comprise a roof deck having first and second surfaces; at least one layer positioned over the first surface of the roof deck and having an upper surface defining an exposed, upper most surface of the roof structure; and a plurality of fastener systems applied along the at least one layer and configured to attach the at least one layer to the roof deck. In embodiments, the fastener systems include a plate having first and second surfaces; an aperture extending though the plate from a first end located along the first surface of the plate to a second end located adjacent the second surface of the plate and configured to receive a fastener therein; and a cover portion adapted to substantially enclose the first end of the aperture so as to cover a head of the fastener received within the aperture and protect the fastener from impacts due to objects striking the roof structure, such as hail of other objects, by blunting or hiding the sharp edge of the head of the fastener. The resultant roof structure with the fastener systems installed therealong meets requirements for Very Severe Hail resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies. In embodiments, a plurality of layers, for example, one or more insulation layers, a base layer, a membrane or other protective layer, or combinations thereof, can be positioned along the roof deck and secured thereto by the fastener systems in accordance with the principles of the present disclosure.

In an aspect, a system is provided, comprising a fastener system including a plate having a first surface and a second surface opposite the first surface, an aperture extending from the first surface to the second surface, and a cover portion located in the aperture, wherein the plate is configured to be installed on a portion of roof structure, wherein the roof structure includes a first surface, and wherein the second surface of the plate is juxtaposed with the first surface of the roof structure; and a fastener, wherein the fastener is installed within the aperture of the plate, and wherein the cover portion of the plate is configured to cover the fastener, and wherein the system is configured to conform to or exceed Factory Mutual (FM) Standards for Very Severe Hail (VSH) resistance.

In an embodiment of the fastener system, the cover portion includes at least one flap, wherein the at least one flap is moveable between a first position, in which the at least one flap is substantially planar with the first surface of the plate, and a second position, in which the at least one flap extends obliquely relative to the first surface of plate. In an embodiment, the at least one flap is moveable from its first position to its second position during the installation of the fastener within the aperture of the plate. In an embodiment, the at least one flap is resiliently biased toward the first position.

In an embodiment, the at least one flap includes a plurality of flaps. In another embodiment, the cover portion includes a plug configured to be removably installed within the aperture of the plate. In an embodiment, the first surface of the plate is convex, and in embodiments, the second surface of the plate is substantially flat.

In an embodiment, the plate includes a plurality of protrusions extending outwardly from the second surface of the plate, wherein at least some of the protrusions are configured to grip the first surface of the roof structure, and wherein the protrusions are configured to inhibit lateral movement of the plate relative to the first surface of the roof.

In an embodiment, the plate includes a recessed portion positioned between the first surface of the plate and the second surface of the plate. In an embodiment, the fastener includes a head and a shank, and wherein the head is received through the aperture of the plate and is positioned within the recessed portion of the plate upon installation of the fastener into the roof structure. In an embodiment, the head of the fastener comprises a countersunk head. In embodiments, the fastener comprises at least one of a nail, a screw, a rivet, a bolt, a rod, or a threaded rod.

In an aspect, a roof structure is provided, the roof structure comprising a roof deck, a membrane overlaying the roof deck, and a fastener system configured to secure the membrane to the roof deck, and including a plate having a first surface and a second surface, an aperture extending through the plate from the first surface to the second surface, and a cover portion adapted to cover the aperture. In an embodiment, the roof deck includes a first surface and a second surface. In some embodiments, the first surface of the roof deck comprises an upper surface of the roof structure. In an embodiment, the membrane overlays the first surface of the roof deck, and includes an upper surface, wherein the upper surface of the membrane defines an exposed surface of the roof structure. In an embodiment, the roof structure further includes an insulation layer, positioned between the roof deck and the membrane. In embodiments, during installation of the fastener system to secure the membrane to the roof deck, a fastener is received through the aperture of the plate, with a head of the fastener being positioned below the first surface of the plate and substantially covered by the cover portion to protect the fastener from impact of an object striking the roof structure.

In an embodiment, the plate is composed of a polymer material, and, in embodiments, the plate comprises a height of 0.03 inch to 0.5 inch.

In another aspect, a method is provided, comprising the steps of: installing a plate on a roof deck, wherein the plate includes a first surface and a second surface opposite the first surface, an aperture extending from the first surface to the second surface, and a cover portion located in the aperture, wherein the roof structure includes a first surface, wherein the second surface of the plate is juxtaposed with the first surface of the roof structure; and installing a fastener within the aperture of the plate, wherein the cover portion of the plate is configured to cover the fastener.

In embodiments, the roof structure further comprises a fastener system positioned along the first surface of the roof deck; and in some embodiments, the fastener system comprises a plate positioned over the upper surface of the membrane.

In another aspect, a fastener system comprises a plate including: a first surface and a second surface opposite the first surface, an aperture extending through the plate from the first surface to the second surface, and a cover portion configured to substantially cover the aperture; and wherein the plate is configured to be installed on a roof structure with the second surface of the plate engaging an upper surface of the roof structure; a fastener having a head and shank portion; wherein the head of the fastener is installed within the aperture of the plate with the head of the fastener positioned below the upper surface of the plate; wherein the cover portion of the plate is configured to cover the head of the fastener; wherein the roof structure with the fastener system installed therealong meets requirements for Very Severe Hail resistance according to FM Approvals FM 4470 VSH impact resistance testing standard for Single-Ply Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies.

In embodiments of the fastener system, the cover portion comprises at least one flap, wherein the at least one flap is moveable between a first position, in which the at least one flap is substantially planar with the first surface of the plate, and a second position, in which the at least one flap extends obliquely relative to the first surface of plate.

In embodiments, the at least one flap is resiliently biased, such that the at least one flap of the cover is moveable from its second position to its first position after the installation of the fastener within the aperture of the plate so as to cover the head of the fastener.

In embodiments of the fastener system, the cover portion comprises a plug configured to be removably installed within the aperture of the plate.

In embodiments of the fastener system, the first surface of the plate is convex, and wherein the second surface of the plate is substantially flat.

In embodiments of the fastener system, the plate comprises a plurality of protrusions position along and extending outwardly from the second surface of the plate; wherein the plurality of protrusions is configured to grip the surface of the roof structure; and wherein the plurality of protrusions is configured to inhibit lateral movement of the plate relative to the first surface of the roof.

In embodiments of the fastener system, the plate further comprises a recessed portion arranged along between the first surface of the plate and the second surface of the plate; wherein the aperture is configured to receive the head of the fastener when the fastener is installed in the aperture.

In embodiments of the fastener system, the plate comprises a thermoplastic polymer, propylene, polypropylene, polyethylene, nylon, polyvinyl chloride, rubber, polyurethane, acrylonitrile butadiene styrene, acrylo nitrile styrene acrylate, carbon fiber, metal, or combinations thereof.

In embodiments of the fastener system, the fastener comprises a nail, a screw, a rivet, a bolt, a rod, or a threaded rod.

In another aspect, a roof structure comprises a roof deck; at least one layer positioned over the roof deck; a plurality of fastener systems, each comprising: a plate having a first surface, a second surface and an aperture extending between the first and second surfaces; and a cover portion configured to substantially cover the aperture; and a fastener having a head and shank portion configured to penetrate the roof deck; wherein the plate is positioned over the at least one layer; wherein the fastener is installed within the aperture of the plate with the shank portion penetrating the roof deck and with the head of the fastener positioned below the first surface of the plate; wherein the roof structure meets requirements for Very Severe Hail Resistance (VSH) according to FM Approvals FM 4470 USH impact resistance testing standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies.

In embodiments of the fastener structure, the at least one layer comprises a polymer membrane overlaying the roof deck. In some embodiments, the at least one layer comprises at least one insulation layer positioned over an upper surface of the roof deck and a polymer membrane overlying the at least one insulation layer.

In embodiments of the fastener structure, the first surface of the plate comprises a convex surface extending above the second surface; and wherein the second surface comprises a substantially flat surface configured to be substantially flat against the at least one layer.

In embodiments of the fastener structure, the cover portion comprises at least one flap, wherein the at least one flap is moveable between a first position, in which the at least one flap is substantially planar with the first surface of the plate, and a second position, in which the at least one flap extends obliquely relative to the first surface of plate.

In some embodiments, the at least one flap is resiliently biased, such that the at least one flap of the cover is moveable from its second position to its first position after the installation of the fastener within the aperture of the plate so as to cover the head of the fastener.

In embodiments of the fastener structure, the plate comprises a plurality of protrusions position along and extending outwardly from the second surface of the plate; wherein the plurality of protrusions is configured to grip a surface of the at least one layer positioned over the roof deck; wherein the plurality of protrusions is configured to inhibit lateral movement of the plate relative to the first surface of the roof.

In still another aspect, a method comprises positioning a plurality of fastener systems along a roof structure; wherein each of the fastener systems includes: a plate having a first surface, a second surface opposite the first surface, and an aperture extending from the first surface to the second surface; and a cover portion configured to substantially enclose the aperture, wherein the second surface of the plate is placed in engagement with an upper surface of the roof structure; and installing a fastener through the aperture of the plate and into the roof structure; wherein when the fastener is installed, a head of the fastener is positioned below the first surface of the plate with the cover portion covering the head of the fastener.

In embodiments of the method, the roof structure comprises a roof deck having a first surface and a second surface; and further comprising positioning at least one layer over the first surface of the roof deck, the at least one layer having an upper surface defining an exposed surface of the roof structure; and wherein the plurality of fastener systems are positioned along the upper surface of the at least one layer.

In embodiments, positioning the at least one layer over the first surface of the roof deck comprises a first layer positioned over the first surface of the roof deck, and positioning at least one additional layer over the first layer, wherein the at least one additional layer comprising a protective layer configured to resist migration of water therethrough.

In embodiments of the method, the roof structure comprises a roof deck having a first surface and a second surface; and further comprising positioning at least a first layer over the first surface of the roof deck, wherein the plurality of fastener systems are positioned along the first layer to attach the first layer to the roof deck; and applying a protective layer over the first layer and the plurality of fastener systems.

Accordingly, various aspects and embodiments of roof structures, fastener systems and methods of forming roof structures are disclosed. The foregoing and other advantages and aspects of the embodiments of the present disclosure will become apparent and more readily appreciated from the following detailed description, taken in conjunction with the accompanying drawings. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a further understanding of the embodiments of the present disclosure, are incorporated in and constitute a part of this specification, illustrate embodiments of this disclosure, and together with the detailed description, serve to explain the principles of the embodiments discussed herein. No attempt is made to show structural details of this disclosure in more detail than may be necessary for a fundamental understanding of the exemplary embodiments discussed herein and the various ways in which they may be practiced.

FIG. 1 is a top plan view of an embodiment of a fastener system for a roof structure according to embodiments of the disclosure;

FIGS. 2 through 5 are side elevational views of embodiments of the fastener system illustrated in FIG. 1;

FIGS. 6 through 8 illustrate an additional embodiment of a fastener system for a roof structure according to embodiments of the disclosure;

FIG. 9 is a schematic view of an example embodiments of a roof structure;

FIGS. 10A through 10C are side elevational views illustrating installation of a fastener system for a roof structure according to embodiments of the disclosure;

FIG. 11 is a perspective view of a roof structure with multiple layers positioned over a roof deck and a plurality of fastener systems securing the layers to the roof deck; and

FIGS. 12 and 13 illustrate embodiments of a roof structure including the fastener system for a roof structure according to embodiments of the disclosure.

DETAILED DESCRIPTION

Fastener systems for roof structures are disclosed herein, which fastener systems 10 are configured for use in attaching one or more components of a roof structure 50 to form a roof that is adapted to withstand impacts from objects striking the roof, including objects impacting against the fastener systems. For example, in embodiments, the fastener systems of the disclosure will be configured to meet or exceed a “Very Severe Hail” (VSH) certification or classification (Class 4—the most stringent certification), the roof structure and components thereof generally must meet the requirements provided under Factory Mutual (FM)® hail-resistant test method ANSI/FM 4473 and 4470, “Approval Standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies for use in Class 1 and Noncombustible Roof Deck Construction,” during which testing, the roof structure and components thereof are subjected to impacts from up to 2-inch ice balls propelled at 152-160 feet per second, resulting in an impact energy of 53-58 ft. lbs. against the roof structure.

Embodiments of fastener systems according to the present disclosure will now be described in further detail with reference to the attached FIGS. 1-12.

Referring to FIGS. 1 and 2, in some embodiments, a fastener system 10 includes a plate 12 having a first surface 14 and a second surface 16 opposite the first surface 14. The plate 12 can be formed from an impact resistant material such as a polymer or metal material, and can be formed with various configurations. For example, in some embodiments, the plate 12 has a circular-shape cross section. In some embodiments, the plate 12 has a square-shaped cross section. In some embodiments, the plate 12 has a rectangular-shaped cross section. In some embodiments, the plate 12 has a triangular-shaped cross section. In some embodiments, the plate 12 has a pentagonal-shaped cross section. In some embodiments, the plate 12 has a hexagonal-shaped cross section. In some embodiments, the plate 12 has a oval-shaped cross section. In some embodiments, the plate 12 has an ellipsoid-shaped cross section. In some embodiments, the plate 12 has a polygonal-shaped cross section. In some embodiments, the plate 12 has a geometric-shaped cross section. In some embodiments, the plate 12 has a non-geometric-shaped cross section. In some embodiments, the plate 12 has a cross-shaped cross section. In some embodiments, the plate 12 has a star-shaped cross section. Other configurations of the plate 12 also can be provided.

In some embodiments, the plate 12 can be substantially solid, while in some embodiments, the plate can include a space between the first and second surfaces; and is other embodiments, the plate 12 can be compressible. In some embodiments, the first surface 14 of the plate 12 is substantially flat. In some embodiments, the first surface 14 is convex. In some embodiments, the first surface 14 has a radius of curvature. In embodiments, the second surface 16 is substantially flat so as to lie against a surface of the roof structure in a substantially flat arrangement; while in some embodiments, the second surface can have a non-flat surface to help promote engagement between the second surface and a portion of the roof structure 50 e.g., an exposed surface 51 of the roof structure. In embodiments, as shown in FIGS. 1 and 11, such exposed upper surface can comprise an upper surface of one or more layers (e.g., an upper surface 110A of a membrane 110) positioned over the roof deck 100 of the roof structure 50.

In some embodiments, as shown in FIGS. 1-6, the plate 12 can be substantially circular, having a diameter D that can be 1 inch to 5 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 1 inch to 4 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 1 inch to 3 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 1 inch to 2 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 2 inches to 5 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 2 inches to 4 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 2 inches to 3 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 3 inches to 5 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 3 inches to 4 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 4 inches to 5 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 1 inch. In some embodiments, the second surface 16 of the plate 12 has a diameter of 2 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 3 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 4 inches. In some embodiments, the second surface 16 of the plate 12 has a diameter of 5 inches.

In some embodiments, the plate 12 has a height H that can be 0.03 inch to 0.5 inch. In some embodiments, the plate 12 has a height of 0.03 inch to 0.4 inch. In some embodiments, the plate 12 has a height of 0.03 inch to 0.3 inch. In some embodiments, the plate 12 has a height of 0.03 inch to 0.2 inch. In some embodiments, the plate 12 has a height of 0.03 inch to 0.1 inch. In some embodiments, the plate 12 has a height or 0.05 inch to 0.5 inch. In some embodiments, the plate 12 has a height of 0.05 inch to 0.4 inch. In some embodiments, the plate 12 has a height of 0.05 inch to 0.3 inch. In some embodiments, the plate 12 has a height of 0.05 inch to 0.2 inch. In some embodiments, the plate 12 has a height of 0.05 inch to 0.1 inch. In some embodiments, the plate 12 has a height of 0.1 inch to 0.5 inch. In some embodiments, the plate 12 has a height of 0.1 inch to 0.4 inch. In some embodiments, the plate 12 has a height of 0.1 inch to 0.3 inch. In some embodiments, the plate 12 has a height of 0.1 inch to 0.2 inch. In some embodiments, the plate 12 has a height of 0.2 inch to 0.5 inch. In some embodiments, the plate 12 has a height of 0.2 inch to 0.4 inch. In some embodiments, the plate 12 has a height of 0.2 inch to 0.3 inch. In some embodiments, the plate 12 has a height of 0.3 inch to 0.5 inch. In some embodiments, the plate 12 has a height of 0.3 inch to 0.4 inch. In some embodiments, the plate 12 has a height of 0.4 inch to 0.5 inch.

In some embodiments, the plate 12 includes an aperture 18. In some embodiments, the aperture 18 is substantially centrally-located within the plate 12. In some embodiments, the aperture 18 extends from the first surface 14 to the second surface 16, and in some cases, can extend at least partially through the plate to a depth less than the height H of the plate. For example, as indicated in FIGS. 2-3, the aperture 18 can extend from a first end 18A adjacent the first surface 14, to a second end 18B. The second end 18B can terminate at the second surface 16 of the plate 12. In some embodiments, as shown in FIGS. 4-5, the second end 18A of the aperture 18 can extend below the second surface 16 of the plate 12, and can be substantially enclosed. In some embodiments, the aperture 18 has a circular-shaped cross section. In some embodiments, the aperture 18 has a rectangular-shaped cross section. In some embodiments, the aperture 18 has a triangular-shaped cross section. In some embodiments, the aperture 18 has a pentagonal-shaped cross section. In some embodiments, the aperture 18 has a hexagonal-shaped cross section. In some embodiments, the aperture 18 has an oval-shaped cross section. In some embodiments, the aperture 18 has an ellipsoid-shaped cross section. In some embodiments, the aperture 18 has a polygonal-shaped cross section. In some embodiments, the aperture 18 has a geometric-shaped cross section. In some embodiments, the aperture 18 has a non-geometric-shaped cross section. In some embodiments, the aperture 18 has a cross-shaped cross section. In some embodiments, the aperture 18 has a star-shaped cross section.

In some embodiments, the aperture 18 is a countersunk aperture, e.g., as shown in FIG. 4, the first end 18A of the aperture can be recessed below the first surface 14 of the plate 12. In embodiments, the aperture 18 also can include a portion configured to seat against the head 26 of the fastener 24.

Referring to FIG. 3, in some embodiments, the plate 12 includes at least one protrusion 20. In some embodiments, the at least one protrusion 20 extends outwardly from the second surface 16. In some embodiments, the at least one protrusion 20 includes a plurality of the protrusions 20. In some embodiments, the protrusions 20 are spaced apart from one another. In some embodiments, the protrusions 20 are arranged on substantially the entirety of the second surface 16. In some embodiments, the protrusions 20 include a plurality of teeth. In some embodiments, each of the teeth is conical in shape. In some embodiments, the protrusions 20 include a plurality of barbs.

In some embodiments, the protrusions 20 are configured to penetrate an uppermost layer of a roof structure 50 and inhibit lateral movement of the plate 12 relative to the layer of the roof structure 50 on which the plate 12 is installed. In some embodiments, the protrusions 20 are configured to penetrate an uppermost layer of a roof structure 50 and grip the uppermost layer sufficient to substantially inhibit planar movement of the plate 12 relative to the layer of the roof structure 50 to which the plate 12 is attached, due to wind loads. As used herein, the term “penetrate” means to pierce, and with respect to embodiments of the plate 12, to pierce an outer surface of the uppermost layer of the roof structure 50, while “grip” means to engage or bear against so as to hold the plate substantially in place and inhibit movement along the uppermost layer. In some embodiments, the second surface 16 of the plate 12 is textured.

Referring to FIGS. 4 and 5, in some embodiments, the second surface 16 is concave. In some embodiments, a recessed portion 22 is located between the first surface 14 of the plate 12 and the second surface 16 of the plate 12, with the second end 18B of the aperture 18 projected from the second side of the plate so as to engage the exposed upper surface 51 of the roof structures. In some embodiments, the protrusions 20 are located on a perimeter 23 of the recessed portion 22.

Referring to FIG. 6, in an embodiment, the aperture 18 is sized and shaped to receive a fastener 24. In some embodiments, the fastener 24 is a nail. In some embodiments, the fastener 24 is a screw. In some embodiments, the fastener 24 is rivet. In some embodiments, the fastener 24 is a bolt. In some embodiments, the fastener 24 is a rod. In some embodiments, the fastener 24 is a threaded rod. In some embodiments, the fastener 24 includes an elongated shank portion 25 and a head 26 located at one end of the elongated shank portion 25.

In some embodiments, the head 26 is an enlarged head. In some embodiments, the head 26 is a rounded head. In some embodiments, the head 26 is a flat head. In some embodiments, the head 26 is a countersunk head. In some embodiments, the head 26 is flush with the upper surface of the uppermost layer of the roof structure 50. In some embodiments, the head 26 is substantially flush with the upper surface of the uppermost layer of the roof structure 50. In some embodiments, the head 26 protrudes from the upper surface of the uppermost layer of the roof structure 50. In some embodiments, an upper surface 28 of the head 26 of the fastener 24 is located below the first surface 14 of the plate 12.

In some embodiments, a cover portion 29 is located within the aperture 18. In some embodiments, the cover portion 29 will be configured to substantially enclose the first end of the aperture 18, covering the head 26 of the fastener 24 to substantially blunt and protect the edges of the fastener from impacts, such as from hail or other objects.

In some embodiments, the cover portion is a plug 30. In some embodiments, the plug 30 is configured to be installed within the aperture 18. In some embodiments, the plug 30 is sized and shaped to form an interference fit with the aperture 18. In some embodiments, the plug 30 is removably installed within the aperture 18. In some embodiments, the plug 30 includes external threads and a sidewall 27 formed by the aperture 18 includes internal threads that threadedly engage the external threads of the plug 30. In some embodiments, the plug 30 is threadedly installed within the aperture 18. In some embodiments, the plug 30 is adhered to the plate 12 within the aperture 18 by an adhesive. In some embodiments, the plug 30 is installed in the aperture 18 and sealed by a sealant. In some embodiments, an upper surface 32 of the plug 30 is flush with the first surface 14 of the plate 12. In some embodiments, an upper surface 32 of the plug 30 is substantially flush with the first surface 14 of the plate 12. In some embodiments, the plug 30 covers the head 26 of the fastener 24. In some embodiments, the plug 30 is configured to shield the head 26 of the fastener 24 from external objects. In some embodiments, the external objects are hailstones.

In some embodiments, the plug 30 is composed of plastic. In some embodiments, the plug 30 is composed of a polymer. In some embodiments, the plug 30 is composed of a thermoplastic polymer. In some embodiments, the plug 30 is composed of propylene. In some embodiments, the plug 30 is composed of polypropylene. In some embodiments, the plug 30 is composed of polyethylene. In some embodiments, the plug 30 is composed of nylon. In some embodiments, the plug 30 is composed of polyvinyl chloride (PVC). In some embodiments, the plug 30 is composed of rubber. In some embodiments, the plug 30 is composed of synthetic rubber. In some embodiments, the plug 30 is composed of polycarbonate. In some embodiments, the plug 30 is composed of polyurethane. In some embodiments, the plug 30 is composed of acrylonitrile butadiene styrene (ABS). In some embodiments, the plug 30 is composed of acrylo nitrile styrene acrylate. In some embodiments, the plug 30 is composed of carbon fiber. In some embodiments, the plug 30 is composed of reinforced carbon fiber. In some embodiments, the plug 30 is composed of unreinforced carbon fiber. In some embodiments, the plug 30 includes a coating. In some embodiments, the coating is a polymer coating. In some embodiments, the coating is a rubber coating.

Referring to FIGS. 7 and 8, in some embodiments, the cover portion can include at least one flap 34. In some embodiments, the plate 12 includes the at least one flap 34. In some embodiments, the at least one flap 34 includes a plurality of the flaps 34. In some embodiments, each of the flaps 34 extends radially inwardly from the sidewall 27. In some embodiments, the flaps 34 are integrally molded with the plate 12. In some embodiments, each of the flaps 34 includes a free end 38. In some embodiments, the free end 38 is located proximate to a center point C of the aperture 18.

In some embodiments, the plurality of flaps 34 includes four of the flaps 34. In some embodiments, the plurality of flaps 34 includes two of the flaps 34. In some embodiments, the plurality of flaps 34 includes three of the flaps 34. In some embodiments, the plurality of flaps 34 includes more than four of the flaps 34. In some embodiments, the flaps 34 form an opening 40 of the aperture 18. In some embodiments, the opening 40 is cross-shaped. In some embodiments, each of the flaps 34 is moveable between a first position (relaxed position), in which the flaps 34 are planar, or substantially planar, with the first surface 14 of the plate 12, and a second position (extended position), in which the flaps 34 extend inwardly within the aperture 18 and obliquely relative to the first surface 14 of the plate 12. In some embodiments, the flaps 34 are resiliently biased.

In some embodiments, the plate 12 is composed of plastic. In some embodiments, the plate 12 is composed of a polymer. In some embodiments, the plate 12 is composed of a thermoplastic polymer. In some embodiments, the plate 12 is composed of propylene. In some embodiments, the plate 12 is composed of polypropylene. In some embodiments, the plate 12 is composed of polyethylene. In some embodiments, the plate 12 is composed of nylon. In some embodiments, the plate 12 is composed of polyvinyl chloride (PVC). In some embodiments, the plate 12 is composed of rubber. In some embodiments, the plate 12 is composed of synthetic rubber. In some embodiments, the plate 12 is composed of polycarbonate. In some embodiments, the plate 12 is composed of polyurethane. In some embodiments, the plate 12 is composed of acrylonitrile butadiene styrene (ABS). In some embodiments, the plate 12 is composed of acrylo nitrile styrene acrylate. In some embodiments, the plate 12 is composed of carbon fiber. In some embodiments, the plate 12 is composed of reinforced carbon fiber. In some embodiments, the plate 12 is composed of unreinforced carbon fiber. In some embodiments, the plate 12 includes a coating. In some embodiments, the coating is a polymer coating. In some embodiments, the coating is a rubber coating. In some embodiment, the plate 12 is composed of metal. In some embodiments, the plate 12 is composed of aluminum.

In some embodiments, the plate 12 is configured to be juxtaposed with an upper surface of the uppermost layer of the roof structure 50. In some embodiments, the second surface 16 of the plate 12 is configured to be juxtaposed with the uppermost layer of the roof structure 50. In some embodiments, a sealant is located around the perimeter 23 of the plate 12. In some embodiments, the sealant seals the junction between the perimeter edge of the plate 12 and the upper surface of the uppermost layer of the roof structure 50. In some embodiments, the sealant is a polymer sealant. In some embodiments, the sealant is silicone. In some embodiments, the sealant is an adhesive sealant.

Referring to FIG. 9, in some embodiments, the roof structure 50 can comprise a series of layers, including at least a first layer that comprises a roof deck 100. In some embodiments, the roof deck 100 can comprise a low slope roof deck. For example, in embodiments, the roof deck can comprise a component of a commercial roof. As defined herein, a “low slope roof substrate” is any roofing substrate that is disposed on a roof having a pitch of Y/X, where Y and X are in a ratio of less 4:12, where Y corresponds to the “rise” of the roof, and where X corresponds to the “run” of the roof. In some embodiments, Y and X are in a ratio of less than 3:12, a ratio of less than 2:12, a ratio of less than 1:12, or a ratio of 1:12 to 3:12.

In some embodiments, the roof deck 100 can have a slope of 3 inches per foot or less. In some embodiments, the roof deck 100 has a slope of 0.25 inch to 3 inches per foot. In some embodiments, the roof deck 100 has a slope of 0.25 inch to 2 inches per foot. In some embodiments, the roof deck 100 has a slope of 0.25 inch to 1 inch per foot. In some embodiments, the roof deck 100 has a slope of 1 inch to 3 inches per foot. In some embodiments, the roof deck 100 has a slope of 1 inch to 2 inches per foot. In some embodiments, the roof deck 100 has a slope of 2 inches to 3 inches per foot.

In some embodiments, the roof deck 100 is a steep slope roof deck. Examples of such a roof deck can include roof decks for residential roofs, and in some embodiments, roof decks for commercial roofs. As defined herein, a “steep slope roof deck” is any roof deck that is disposed on a roof having a pitch of Y/X, where Y and X are in a ratio of 4:12 to 12:12, where Y corresponds to the “rise” of the roof, and where X corresponds to the “run” of the roof. In embodiments, the roof deck can have a slope in a ratio of 5:12 to 12:12, a ratio of 6:12 to 12:12, a ratio of 7:12 to 12:12, a ratio of 8:12 to 12:12, a ratio of 9:12 to 12:12, a ratio of 10:12 to 12:12, or a ratio of 11:12 to 12:12. In some embodiments, the roof deck can have a slope in a ratio of 4:12 to 11:12, a ratio of 4:12 to 10:12, a ratio of 4:12 to 9:12, a ratio of 4:12 to 8:12, a ratio of 4:12 to 7:12, a ratio of 4:12 to 6:12, a ratio of 4:12 to 5:12, a ratio of 5:12 to 11:12, a ratio of 6:12 to 10:12, or a ratio of 7:12 to 9:12.

In some embodiments, the roof deck 100 is composed of wood. In some embodiments, the roof deck 100 is composed of plywood. In some embodiments, the roof deck 100 is composed of oriented strand board (OSB). In some embodiments, the roof deck 100 is composed of a wood plank. In some embodiments, the roof deck 100 is composed of steel. In some embodiments, the roof deck 100 is composed of concrete. In some embodiments, the roof deck 100 is composed of structural concrete. In some embodiments, the roof deck 100 is composed of lightweight structural concrete. In some embodiments, the roof deck 100 is composed of gypsum. In some embodiments, the roof deck 100 is composed of cementitious wood fiber. In some embodiments, the roof deck 100 includes a vapor retardant material.

In some embodiments, the roof structure 50 further comprises additional layers positioned over a first surface of the roof deck, e.g. as shown in FIGS. 11-13. For example, as shown in FIGS. 12-13, the roof structure can include a first, e.g. layer 102 that is positioned along and overlays the upper surface of the roof deck 100. In some embodiments, the layer 102 can include an insulated material. In some embodiments, the layer 102 includes an uninsulated material. In some embodiments, the roof structure 50 need not include the layer 102.

In some embodiments, the roof structure 50 can further include additional layers such as a second layer that, in embodiments, can comprise a first insulation layer 104. In some embodiments, the first insulation layer 104 overlays the layer 102 such that the layer 102 is between the roof deck and the first insulation layer 104. In some embodiments, the first insulation layer 104 overlays the roof deck 100, without the layer 102 therebetween.

In some embodiments, the first insulation layer 104 is composed of polyisocyanurate. In some embodiments, the first insulation layer 104 meets standards under ASTM C 1289. In some embodiments, the first insulation layer 104 is composed of gypsum. In some embodiments, the first insulation layer 104 meets standards under ASTM C 1278. In some embodiments, the first insulation layer 104 is composed of cellular glass. In some embodiments, the first insulation layer 104 meets standards under ASTM C 552. In some embodiments, the first insulation layer 104 is composed of expanded polystyrene insulation (EPS). In some embodiments, the first insulation layer 104 is composed of expanded polystyrene (XPS). In some embodiments, the first insulation layer 104 meets standards under ASTM C 578. In some embodiments, the first insulation layer 104 is composed of glass faced gypsum. In some embodiments, the first insulation layer 104 meets standards under ASTM C 1177. In some embodiments, the first insulation layer 104 is composed of mineral fiber.

In some embodiments, the first insulation layer 104 meets standards under ASTM C 726. In some embodiments, the first insulation layer 104 is composed of perlite. In some embodiments, the first insulation layer 104 meets standards under ASTM C 728. In some embodiments, the first insulation layer 104 is composed of wood fiber. In some embodiments, the first insulation layer 104 meets standards under ASTM C 208. In some embodiments, the first insulation layer 104 is composed of lightweight insulating concrete (LWIC). In some embodiments, the first insulation layer 104 is composed of any one or a combination of the foregoing materials. In some embodiments, the first insulation layer 104 is loose laid. In some embodiments, the roof structure 50 need not include the first insulation layer 104.

The roof structure 50 further can include an additional, third layer that, in embodiments, can comprise a second insulation layer 106. In some embodiments, the second insulation layer 106 overlays the first insulation layer 104. In some embodiments, the second insulation layer 106 is composed of any one or a combination of the materials as described above with respect to the first insulation layer 104. In some embodiments, the roof structure 50 need not include the second insulation layer 106. In some embodiments, the second insulation layer 106 overlays the first layer 102. In some embodiments, the second insulation layer 106 overlays the roof deck 100.

In some embodiments, the roof structure 50 also can include a fourth layer that can comprise a base sheet 108. In some embodiments, the base sheet 108 overlays the second insulation layer 106. In some embodiments, the base sheet 108 can comprise an anchor sheet. In some embodiments, the anchor sheet is composed of a fabric. In some embodiments, the anchor sheet is composed of a nonwoven fabric. In some embodiments, the anchor sheet can include a coating. In some embodiments, the coating is a polymer coating. In some embodiments, the coating is polypropylene. In some embodiments, the anchor sheet is commercialized by GAF of Parsippany, N.J. under the trade name STORMSAFE™ anchor sheet.

In some embodiments, the base sheet 108 can comprise a slip sheet. In some embodiments, the slip sheet is composed of building paper. In some embodiments, the base sheet 108 is commercialized by GAF of Parsippany, N.J. under the trade name VERSASHIELD® SOLO™ fire-resistant slip sheet. In some embodiments, the roof structure 50 need not include the base sheet 108.

In some embodiments, the roof structure 50 further can include a fifth layer that, in embodiments, includes a membrane 110. In some embodiments, the membrane 110 overlays the base sheet 108. In some embodiments, the membrane 110 overlays the second insulation layer 106. In some embodiments, the membrane overlays the first insulation layer 104. In some embodiments, the membrane overlays the second insulation layer 106. In some embodiments, the membrane 110 overlays the first layer 102. In some embodiments, the membrane 110 overlays the roof deck 100.

In some embodiments, the membrane 110 is composed of a polymeric material. In some embodiments, the membrane 110 is composed of thermoplastic polyolefin (TPO). In some embodiments, the membrane 110 is composed of carbon black TPO. In some embodiments, the membrane 110 is composed of a single ply TPO roofing membrane. In some embodiments, non-limiting examples of TPO membranes are disclosed in U.S. Pat. No. 9,359,014 to Yang et al., which is incorporated by reference herein in its entirety.

In some embodiments, the membrane 110 is composed of polyethylene terephthalate (“PET”). In some embodiments, the membrane 110 is composed of ethylene tetrafluoroethylene (“ETFE”). In some embodiments, the membrane 110 is composed of an acrylic such as polymethyl methacrylate (“PMMA”). In some embodiments, the membrane 110 is composed of ethylene propylene diene monomer (EPDM) rubber. In some embodiments, the membrane 110 is composed of polyvinyl chloride (PVC).

In an embodiment, the membrane 110 includes a flame retardant additive. In some embodiments, the flame retardant additive may be clays, nanoclays, silicas, carbon black, metal hydroxides such as aluminum hydroxide, metal foils, graphite, and combinations thereof. In some embodiments, the membrane 110 is composed of metal. In some embodiments, the membrane 110 is composed of aluminum. In some embodiments, the membrane 110 is composed of galvanized aluminum. In some embodiments, the membrane 110 is composed of an FR-4 glass-reinforced epoxy laminate material. In some embodiments, the membrane 110 includes a coating. In some embodiments, the coating is a resin-based coating such as a KYNAR coating.

In some embodiments, the membrane 110 can comprise the uppermost layer of the roof structure 50, with the upper surface 110A of the membrane defining the exposed upper surface 51 of the roof structure. In some embodiments, the base sheet 108 is the uppermost layer of the roof structure 50. In some embodiments, the second insulation layer 106 is the uppermost layer of the roof structure 50. In some embodiments, the first insulation layer 104 is the uppermost layer of the roof structure 50. In some embodiments, the layer 102 is the uppermost layer of the roof structure 50.

In some embodiments, the fastener 24 is configured to fasten the membrane 110 to the roof deck 100. In some embodiments, the fastener 24 is configured to fasten the base sheet 108 to the roof deck 100. In some embodiments, the fastener 24 is configured to fasten the second insulation layer 106 to the roof deck 100. In some embodiments, the fastener 24 is configured to fasten the first insulation layer 104 to the roof deck 100. In some embodiments, the fastener 24 is configured to fasten the layer 102 to the roof deck 100. In some embodiments, the fastener 24 is configured to fasten roofing shingles to the roof deck 100. In some embodiments, the roofing shingles are asphalt shingles. In some embodiments, the fastener 24 is configured to fasten photovoltaic shingles to the roof deck 100.

Referring to FIG. 10A, in some embodiments, the elongated shank portion 25 of the fastener 24 is inserted within the opening 40 of the aperture 18. In some embodiments, the elongated shank portion 25 pierces the roof deck 100. In some embodiments, the elongated shank portion 25 pierces the layer 102. In some embodiments, the elongated shank portion 25 pierces the first insulation layer 104. In some embodiments, the elongated shank portion 25 pierces the second insulation layer 106. In some embodiments, the elongated shank portion 25 pierces the base sheet 108. In some embodiments, the elongated shank portion 25 pierces the membrane 110. In some embodiments, the flaps 34 are in their first, relaxed position.

Referring to FIG. 10B, in some embodiments, the fastener 24 is further installed such that the head 26 engages the flaps 34 and drives them from their first position to their second position. In some embodiments, the flaps 34 flex inwardly to facilitate the movement of the fastener 24 into the aperture 18. Referring to FIG. 10C, in some embodiments, the fastener 24, and particular the head 26, travels through the aperture 18 and past and clears the flaps 34, and the fastener 24 is installed in a installed position in the roof deck 100. In some embodiments, the flaps 34 “snap back” from their second position to their first position. In some embodiments, the flaps 34 cover the head 26 of the fastener 24. In some embodiments, the plug 30 is installed in the aperture 18 and above the flaps 34.

Referring to FIG. 11, in some embodiments, each fastener system 10 is installed on the roof structure 50. In some embodiments, the fastener systems 10 are installed on the uppermost layer of the roof structure (e.g. along one or more layers applied over the roof deck such as a membrane 110, a base layer, insulation layer, or other layer, or combinations thereof), along an outermost facing surface 51 of the roof structure. For example, in some embodiments, such as shown in FIGS. 11 and 12, the plates 12 are juxtaposed with an upper surface 110A of the membrane 110. In some embodiments, each of the fasteners 24 is installed within a corresponding one of the plates 12 as described above. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the membrane 110.

In some embodiments, as further illustrated in FIG. 12, the elongated shank portions 25 of the fasteners 24 are driven through the base sheet 108. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the second insulation layer 106. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the first insulation layer 104. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the layer 102. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the roof deck 100. In some embodiments, the heads 26 of the fasteners 24 are flush with the membrane 110.

Referring to FIG. 12, in some embodiments, the plates 12 of the fastener systems 10 are juxtaposed with the base sheet 108. In some embodiments, the plates 12 are juxtaposed with the second insulation layer 106. In some embodiments, each of the fasteners 24 is installed within a corresponding one of the plates 12 as described above. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the base sheet 108. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the second insulation layer 106. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the first insulation layer 104. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the layer 102. In some embodiments, the elongated shank portions 25 of the fasteners 24 are driven through the roof deck 100. In some embodiments, the heads 26 of the fasteners 24 are flush with the base sheet 108. In some embodiments, the heads 26 of the fasteners 24 are flush with the second insulation layer 106.

Referring to FIG. 13, in some embodiments, the membrane 110 overlays the plates 12 of the fastener systems 10. In some embodiments, the membrane 110 overlays the base sheet 108. In some embodiments, the membrane 110 overlays the second insulation layer 106. In some embodiments, the membrane 110 is attached to the base sheet 108. In some embodiments, the membrane 110 is attached to the second insulation layer 106. In some embodiments, the membrane 110 is attached to the second insulation layer 106 by an adhesive. In some embodiments, the membrane 110 is attached to the base sheet 108 by an adhesive. In some embodiments, the membrane 110 is self-adhered to the second insulation layer 106 or the base sheet 108. In some embodiments, the membrane 110 is fully adhered to the second insulation layer 106 or the base sheet 108. In some embodiments, the membrane 110 is spot adhered to the second insulation layer 106 or the base sheet 108. In some embodiments, the membrane 110 is ribbon adhered to the second insulation layer 106 or the base sheet 108.

In some embodiments, the fastening system 10 is configured to be a component of a roof structure that conforms to standards under Factory Mutual's (FM) Severe Hail (SH) test standards. In some embodiments, the FM Severe Hail test consists of a 1¾ inch steel ball dropped almost 18 feet on a rigid substate with a single-ply membrane. In some embodiments, the fastening system 10 is configured to be a component of a roof structure that conforms to standards under Factory Mutual's (FM)® Very Severe Hail (VSH) test standards, e.g. under hail-resistant test method ANSI/FM 4473 and 4470, “Approval Standard for Single-Ply, Polymer-Modified Bitumen Sheet, Built-Up Roof (BUR) and Liquid Applied Roof Assemblies for use in Class 1 and Noncombustible Roof Deck Construction.” In some embodiments, the FM Very Severe Hail test consists of a 2-inch diameter ice ball shot out of a pressurized air cannon towards a rigid test substate with a single-ply membrane. The ice ball impacts the test substrate at approximately 110 miles per hour. The pass/fail criteria requires a substrate and membrane inspection after impact. Observing any of the following items results in a failure: (1) cuts or punctures in the membrane; (2) adhesion loss between the membrane and substrate; and (3) cracks or damage to the top or bottom of the substrate.

In embodiments, the plate 12 of each fastener system 10 is configured to increase a radius of the area being impacted so as to help substantially absorb the impact energy from external objects, while the receipt of the fastener head of a fastener within the recess of the fastener system, and the application of the cover thereover, protects the fastener head from impact of the external objects, for example, in some embodiments, hailstones. As a result, the narrow, and in some cases, sharp radiused fastener heads of such fasteners will be hidden and protected from impact of objects, such as hail or other objects, so as to help minimize the potential for failure of the roof structure at locations where the fasteners penetrate the upper layers (e.g. the membrane layer) of the roof structure.

As indicated in FIGS. 10A-10C, a method of forming a roof structure further is provided. In embodiments, the method includes the steps of positioning one or more fastener systems along a roof structure; wherein each of the fastener systems includes: a plate having a first surface, a second surface opposite the first surface, and an aperture extending from the first surface to the second surface; and a cover portion configured to substantially enclose the aperture; and wherein the second surface of the plate is placed in engagement with an upper surface of the roof structure. A fastener is installed through the aperture of the plate and into the roof structure. The fastener is installed through the second surface of the plate and at least partially penetrates into the roof structure.

For example, in embodiments, the fastener penetrates one or more layers of the roof structure and into a roof deck below the one or more layers. In embodiments, the one or more layers can include a at least a first layer applied to the roof deck. In other embodiments, additional layers, which can include at least a second layer, also can be applied over the roof deck. Still further, in some embodiments, a third layer, fourth layer, and in some embodiments, a fifth layer, or still further layers, also can be applied to the roof deck.

By way of a non-limiting example, in embodiments, the method can include applying at least one layer that, in embodiments, can comprise a membrane 110 (FIG. 1) to an upper surface of the roof deck 100, with the membrane forming an exposed surface of the roof structure 50, configured to provide water resistance and/or water shedding properties (e.g., being configured to resist migration of water therethrough, and/or configured to direct water away from the roof deck). The plates 12 of one or more fastener systems 10 can be positioned along the membrane, with the second surface 16 of each of the plates 12 juxtaposed with the upper surface of the membrane. Fasteners 24 are installed within the aperture 18 of each of the plates 12. In embodiments, when the fasteners are installed, the shank portion of each fastener will penetrate the membrane and roof deck therebelow, and the head of each fastener will be positioned below the first surface of the plate, with the cover portion covering the head of the fastener, such as indicated in FIG. 10C, so as to protect the head of the fastener from direct impacts from objects such as hail, or other objects.

In some embodiments, as illustrated in FIGS. 12-13, one or more additional layers can be applied between the roof deck and the membrane. For example, in embodiments, a base layer can applied below the membrane layer; and in some embodiments, one or more insulation layers (e.g., a first insulation layer and a second insulation layer) also can be applied over the upper surface of the roof deck. Combinations of such layers also can be applied over the roof deck and secured with the fastening systems. In embodiments, one or more of the insulation layers can be applied to the upper surface of the roof deck, followed by the base layer (if needed) and the membrane can then be applied thereover. The fastener systems thereafter can be positioned along the upper surface of the membrane and their fasteners installed, to secure the layers to the roof deck. In some embodiments, the base and/or insulation layers also could be secured with the fastener systems, and the membrane then applied thereover, as indicated in FIG. 13.

The foregoing description generally illustrates and describes various embodiments of the present disclosure. It will, however, be understood by those skilled in the art that various changes and modifications can be made to the above-discussed construction of the present disclosure without departing from the spirit and scope of the disclosure as disclosed herein, and that it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as being illustrative, and not to be taken in a limiting sense. Furthermore, the scope of the present disclosure shall be construed to cover various modifications, combinations, additions, alterations, etc., above and to the above-described embodiments, which shall be considered to be within the scope of the present disclosure. Accordingly, various features and characteristics of the present disclosure as discussed herein may be selectively interchanged and applied to other illustrated and non-illustrated embodiments of the disclosure, and numerous variations, modifications, and additions further can be made thereto without departing from the spirit and scope of the present disclosure as set forth in the appended claims.

FASTENER SYSTEMS FOR ROOF STRUCTURES

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