Substrate with membrane seam plates fixed thereon for precise placement of seam plates on roof decking assemblies

Description

FIELD OF THE INVENTION

[0001] The present invention relates generally to roof decking assemblies, and more particularly to a new and improved substrate which has a plurality of seam plates fixedly secured thereon, at predeterminedly spaced locations thereof, for precisely locating the seam plates with respect to the crest portions of an underlying corrugated metal roof decking substructure in order to ensure that when the seam plates are to be fixedly secured to the underlying corrugated metal roof decking substructure by means of suitable fasteners, the fasteners will in fact be fixedly secured within the crest portions of the underlying corrugated metal roof decking substructure, or alternatively, for locating the seam plates at predeterminedly spaced positions with respect to an underlying wood or concrete decking substructure, whereby, roof decking membranes, which are adapted to overlie or be disposed atop any one of several different types of underlying roof decking assemblies, comprising, for example, any one of the aforenoted underlying roof decking substructures and insulation panels mounted upon the underlying roof decking substructures, in order to protect such underlying roof decking assemblies under various environmental conditions, will be properly secured to the underlying roof decking assemblies so as to remain secured to the underlying roof decking assemblies despite environmental conditions comprising uplifting wind forces and the like.

BACKGROUND OF THE INVENTION

[0002] In the building industry, roof decking components, structural members, or substructures conventionally have insulation slabs or panels disposed thereon, and weather-protection membranes are in turn adapted to be secured atop the insulation slabs or panels so as to protect the same from deterioration which would otherwise occur as a result of being exposed to various environmental or weather conditions. The membranes and the underlying insulation slabs or panels are conventionally secured to the underlying roof decking substructures by means of fastener assemblies which may comprise, for example, a combination of roofing, seam, or membrane plates, batten strips, or batten bars, which are adapted to be disposed atop the membranes, whereupon, in turn, suitable threaded fasteners typically secure the plates, batten strips, or batten bars to the underlying roof decking substructures. Examples of such membrane, plate, and batten strip or batten bar mounting systems are disclosed within U.S. Pat. No. 6,250,034 which issued on Jun. 26, 2001 to Hulsey, U.S. Pat. No. 6,055,786 which issued on May 2, 2000 to Hubbard et al., U.S. Pat. No. 6,004,645 which issued on Dec. 21, 1999 to Hubbard, U.S. Pat. No. 5,711,116 which issued on Jan. 27, 1998 to Hasan, U.S. Pat. No. 5,469,671 which issued on Nov. 28, 1995 to Rathgeber et al., and U.S. Pat. No. 4,945,699 which issued on Aug. 7, 1990 to Murphy.

[0003] With reference initially being made to FIG. 1, which corresponds substantially to FIG. 4 of the aforenoted United States Patent to Hulsey, a conventional PRIOR ART roof decking assembly is disclosed and is generally indicated by the reference character 1. A metal roof decking substructure or component is disclosed at 12, and it is seen that the metal roof decking substructure 12 has a corrugated configuration comprising a plurality of transversely spaced crest portions 14 and a plurality of transversely spaced root portions 16 interposed between the crest portions 14. An insulation slab or panel 66 is disposed atop the metal roof decking substructure 12 and is adapted to be secured to the metal roof decking substructure 12 by means of a plurality of transversely spaced threaded fasteners which are adapted to be threadedly engaged within predetermined ones of the transversely spaced crest portions 14 of the metal roof decking substructure 12. Environmental-protection or weather-resistant membranes 54,62, are adapted to be disposed and secured atop the insulation slab or panel 66, and in view of the fact that the roof decking membranes are obviously smaller in size than the entire expanse of the roof decking assembly, the roof decking membranes 54,62 are adapted to be effectively mated together by means of a membrane fastening system 50 which comprises the welding or gluing together of the membranes 54,62 along seam lines 60, 70. Securement of the roof decking membranes 54,62 permits the membranes 54,62 to properly withstand environmental uplifting wind forces 74,78.

[0004] Continuing further, in accordance with conventional roof decking membrane fixation techniques, a seam plate or membrane plate 10 is adapted to be secured upon the upper surface portion of the insulation slab or panel 66, with a seam edge portion of one of the roof decking membranes 62 being interposed between the undersurface portion of the seam plate or membrane plate 10 and the upper surface portion of the insulation slab or panel 66, by means of a plurality of threaded fasteners 68, only one of which is disclosed, so as to effectively fix the roof decking membranes 54,62 to the underlying roof decking assembly comprising the metal roof decking substructure 12 and the insulation slab or panel 66. Various techniques may be employed in connection with the formation of the roof decking membrane seams 60,70 and the actual fixation of the roof decking membranes 54,62 to the underlying metal roof decking assembly 12,66, however, the critically important feature, characteristic of the operation or technique for fixing the roof decking membranes 54,62 to the underlying metal roof decking assembly 12,66, is to ensure that each seam plate or membrane plate 10 is precisely aligned with one of the crest portions 14 of the underlying metal roof decking substructure 12 so as to, in turn, ensure the fact that each one of the threaded fasteners 68 will be properly threadedly engaged within one of the crest portions 14 of the underlying metal roof decking substructure 12. Accordingly, various additional techniques have conventionally been implemented in connection with an attempt to precisely locate the seam plates or membrane plates with respect to the crest portions of the underlying metal roof decking substructure in order to ensure the fact that each one of the threaded fasteners, used for securing the seam plates or membranes upon the underlying membranes, will be properly threadedly engaged within one of the crest portions of the underlying metal roof decking substructure. One such technique comprises the placement of suitable markings upon the membranes, at predetermined positions spaced along the membranes, such that when the membranes are disposed atop the insulation slab or panel in such a manner that the markings are positionally aligned with the crest portions of the underlying metal roof decking substructure, the markings will effectively indicate to installation personnel the locations at which the membrane plates or seam plates are to be placed and secured as a result of the threaded fasteners being threadedly engaged within the crest portions of the underlying metal roof decking substructure.

[0005] In addition to the fact that the placement of the membrane plates or seam plates at the individually marked locations is time-consuming, operational problems have been experienced in connection with such technique. For example, in connection with this particular installation technique, it has been experienced that sometimes, during the time that occurs between the placement of the membranes atop the insulation slab or panel and the time that the seam plates or membrane plates are placed upon the membranes, the membranes may have moved, such as, for example, under environmental conditions. Alternatively, due to the multitude of workmen present upon the job site, the seam plates or membrane plates may have been inadvertently moved. In either instance, it is sometimes the case that the seam plates or membrane plates are not in fact properly aligned with the crest portions of the underlying metal roof decking substructure whereby the threaded fasteners will not be properly engaged within the crest portions of the underlying metal roof decking substructure. Accordingly, the seam plates or membrane plates will not be securely fastened to the underlying metal roof decking substructure so as to in turn not be capable of properly maintaining the environmental membranes fixed upon the insulation slab or panel under various environmental conditions.

[0006] Alternatively, if it is realized that a particular fastener has not in fact been properly threadedly engaged within the crest portion of the underlying metal roof decking substructure, the threaded fastener must be removed and reinserted at a different location. This operation is obviously additionally time-consuming, however, still further, additional holes have now been formed within the environmental membranes which could lead to enhanced deterioration of the membranes as well as the underlying insulation slabs or panels. Lastly, when roof decking assemblies, comprising, for example, non-corrugated concrete or wood roof decking substructures, insulation slabs or panels, and environmental membranes, are to be assembled, it is likewise critically important to secure the environmental membranes at predeterminedly spaced locations with respect to the underlying insulation slabs or panels, and the concrete or wood roof decking substructures, so as to ensure the secure fixation of the environmental membranes upon the underlying insulation slabs or panels, and the concrete or wood roof decking substructures, despite the presence of uplifting environmental wind forces.

[0007] As disclosed, for example, within U.S. Pat. No. 5,918,439 which issued to Metzer et al. on Jul. 6, 1999, U.S. Pat. No. 5,724,747 which issued to Poorman on Mar. 10, 1998, U.S. Pat. No. 5,230,158 which issued to Wall on Jul. 27, 1993, U.S. Pat. No. 5,056,234 which issued to Han on Oct. 15, 1991, U.S. Pat. No. 4,679,325 which issued to Sweatman on Jul. 14, 1987, U.S. Pat. No. 4,301,596 which issued to Sedlock on Nov. 24, 1981, U.S. Pat. No. 4,149,320 which issued to Troyer et al. on Apr. 17, 1979, U.S. Patent Application Publication 2001/0034954 of Medford et al. which was published on Nov. 1, 2001, and PCT Patent Application WO 96/30609 of Hungarter which was published on Oct. 3, 1996, various measuring or aligning devices, implements, or tools are also known for use in connection with the installation of roofing shingles, roof framing members, stud members, and the like. None of these devices, tools, or implements, however, would be useable in a viable manner, in connection with the aforenoted installation of seam plates or membrane plates, in order to overcome the various operational disadvantages or drawbacks characteristic of conventional techniques for installing seam plates or membrane plates upon the roof decking assemblies wherein it would be desired to ensure the fact that the seam plates or membrane plates would be properly positioned with respect to the underlying environmental membranes such that when the threaded fasteners, for securing the seam plates or membrane plates to the underlying roof decking substructure, are to be threadedly engaged within the underlying roof decking substructure, the threaded fasteners will in fact be threadedly engaged either within the crest portions of the underlying metal roof decking substructure, or at predeterminedly spaced locations with respect to underlying concrete or wood decking substructures, in order to ensure the secure fixation of the environmental membranes upon the underlying insulation slabs or panels, and the metal, concrete, or wood roof decking substructures, despite the presence of uplifting environmental wind forces.

[0008] A need therefore exists in the art for a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to underlying roof decking substructures such that when the threaded fasteners, for securing the seam plates or membrane plates to underlying roof decking substructures, are to be threadedly engaged within underlying corrugated metal roof decking substructures, the threaded fasteners will in-fact be threadedly engaged within the crest portions of the underlying corrugated metal roof decking substructures, or alternatively, when the threaded fasteners are to be threadedly engaged within underlying non-corrugated concrete or wood roof decking substructures, the threaded fasteners will in fact be threadedly engaged within the underlying non-corrugated concrete or wood roof decking substructures at predeterminedly spaced locations, in order to ensure the secure fixation of the environmental membranes upon the underlying insulation slabs or panels, and the metal, concrete, or wood roof decking substructures, despite the presence of uplifting environmental wind forces.

OBJECTS OF THE INVENTION

[0009] Accordingly, it is an object of the present invention to provide a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to the underlying roof decking substructures.

[0010] Another object of the present invention is to provide a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to the underlying roof decking substructures so as to effectively overcome the various operational drawbacks or disadvantages characteristic of the PRIOR ART.

[0011] An additional object of the present invention is to provide a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to the underlying roof decking substructure such that when the threaded fasteners, for securing the seam plates or membrane plates to the underlying roof decking substructures, are to be threadedly engaged within the underlying roof decking substructure, the threaded fasteners will in fact be threadedly engaged within the crest portions of corrugated metal underlying roof decking substructures, or threadedly engaged at predeterminedly spaced locations within non-corrugated concrete or wood roof decking substructures.

[0012] A further object of the present invention is to provide a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to the underlying roof decking substructure such that when the threaded fasteners, for securing the seam plates or membrane plates to underlying roof decking substructures, are to be threadedly engaged within the underlying roof decking substructures, the threaded fasteners will in fact be threadedly engaged within the crest portions of underlying corrugated metal roof decking substructures, or at predeterminedly spaced locations within underlying non-corrugated concrete or wood roof decking substructures, so as to ensure the fact that the seam plates or membrane plates will be securely fastened to the underlying roof decking substructures.

[0013] A last object of the present invention is to provide a new and improved device or implement which will be capable of readily, easily, and rapidly positioning or aligning seam plates or membrane plates with respect to underlying roof decking substructures such that when the threaded fasteners, for securing the seam plates or membrane plates to the underlying roof decking substructures, are to be threadedly engaged within the underlying roof decking substructures, the threaded fasteners will in fact be threadedly engaged within the crest portions of underlying corrugated metal roof decking substructures, or at predeterminedly spaced locations within underlying non-corrugated concrete or wood roof decking substructures, so as to ensure the fact that the seam plates or membrane plates will be securely fastened to the underlying roof decking substructures whereby the environmental membranes will be fixedly maintained in their overlying states upon the roof decking assembly insulation slabs or panels.

SUMMARY OF THE INVENTION

[0014] The foregoing and other objectives are achieved in accordance with the teachings and principles of the present invention through the provision of a new and improved device or implement which comprises, for example, a substrate having a longitudinal extent and upon which a plurality of seam plates or membrane plates are fixedly disposed at predetermined uniformly spaced longitudinal positions which correspond to the transverse spacing defined between the crest portions of underlying corrugated metal roof decking substructures, or which can be secured upon underlying non-corrugated concrete or wood roof decking substructures. The substrate may have a requisite amount of flexibility so as to permit the same to be coiled or otherwise packaged for storage and transportation purposes, however, when the same is to be used at a particular job site, the substrate is uncoiled or unpacked from its storage position. Subsequently, when, for example, the leading one of the seam plates or membrane plates, fixedly secured upon the substrate, is positionally aligned with one of the crest portions of the underlying corrugated metal roof decking substructure, or positionally located at an initial start position, and still further, when such leading one of the seam plates or membrane plates is in fact fixedly secured to the underlying roof decking substructure as a result of one of the threaded fasteners being passed through such leading seam plate or membrane plate and threadedly engaged within the corresponding crest portion of the underlying corrugated metal roof decking substructure, or within the underlying non-corrugated concrete or wood substructure, then the other seam plates or membrane plates are automatically or inherently positionally aligned with subsequent crest portions of the underlying corrugated metal roof decking substructure, or at the predeterminedly spaced locations of the underlying non-corrugated concrete or wood roof decking substructure.

[0015] In this manner, all of the seam plates or membrane plates will be able to be securely fastened to the underlying roof decking substructure, by means of their respective fasteners, whereby the environmental membranes will be fixedly maintained in their overlying states upon the roof decking assembly insulation slabs or panels. In addition, it is noted that in accordance with the principles and teachings of the present invention, the new and improved device or implement of the present invention may comprise, for example, a tape or plastic sheet or strip component, or alternatively, a batten strip, a batten bar, or the like, which comprise conventional devices or implements used in connection with securing environmental membranes to underlying roof decking insulation slabs or panels. Still yet further, the devices or implements have their seam plates or membrane plates fixedly mounted thereon at predeterminedly different spaced locations so as to correspond to the different transverse or lateral center-to-center spacing defined between adjacent crest portions of underlying corrugated metal roof decking substructures, or at predeterminedly spaced center-to-center positions, such that when the seams plates or membrane plates are secured to any of the underlying roof decking substructures, the environmental membranes will be securely fixed to the underlying roof decking substructures so as to operationally withstand environmental conditions, particularly, for example, uplifting wind forces.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Various other objects, features, and attendant advantages of the present invention will be more fully appreciated from the following detailed description when considered in connection with the accompanying drawings in which like reference characters designate like or corresponding parts throughout the several views, and wherein:

[0017]
FIG. 1 is a cross-sectional view of a conventional PRIOR ART roof decking assembly comprising a roof decking substructure, an insulation slab or panel mounted atop the roof decking substructure, and a pair of environmental membranes which are adapted to be fixedly secured atop the insulation slab or panel by means of a seam plate or membrane plate which is fixedly secured to the insulation slab or panel by means of a bolt fastener which is adapted to be threadedly engaged within a crest portion of the underlying roof decking substructure;

[0018]
FIG. 2 is a top plan view of a new and improved substrate implement, constructed in accordance with the principles and teachings of the present invention, as being utilized in conjunction with a corrugated metal roof decking substructure so as to form a first embodiment of a corrugated metal roof decking assembly for enabling the seam plates or membrane plates thereof to be properly aligned or positioned with respect to the crest portions of the underlying corrugated metal roofing decking substructure whereby the seam plates or membrane plates can in fact be fixedly secured to the crest portions of the underlying corrugated metal roof decking substructure so as to, in turn, maintain the environmental membranes fixedly secured atop the insulation slabs or panels of the corrugated metal roof decking assembly despite environmental conditions;

[0019]
FIG. 3 is a top plan view of a second embodiment of a new and improved non-corrugated concrete or wood roof decking assembly showing the new and improved substrate implement, constructed in accordance with the principles and teachings of the present invention, as being utilized in conjunction with a non-corrugated concrete or wood roof decking substructure for enabling the seam plates or membrane plates thereof to be properly aligned or positioned with predetermined positions of the underlying non-corrugated concrete or wood roofing deck substructure whereby the seam plates or membrane plates can in fact be fixedly secured at predetermined positions of the underlying non-corrugated concrete or wood roof decking substructure so as to, in turn, maintain the environmental membranes fixedly secured atop the insulation slabs or panels of the non-corrugated concrete or wood decking substructure despite environmental conditions;

[0020]
FIG. 4 is a top plan view showing a first embodiment of a new and improved substrate implement, constructed in accordance with the principles and teachings of the present invention, upon which the plurality of seam plates or membrane plates are fixedly secured;

[0021]
FIG. 5 is a top plan view showing a second embodiment of a new and improved substrate implement, constructed in accordance with the principles and teachings of the present invention, upon which the plurality of seam plates or membrane plates are fixedly secured; and

[0022]
FIG. 6 is a side elevational view of the new and improved substrate implement of, for example, FIG. 4, wherein the plurality of seam plates or membrane plates, fixedly secured upon the substrate strip, are disposed in a nested mode with respect to each other so as to be conveniently packaged for subsequent use by installation personnel at a particular roof decking job site.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0023] Referring now to the drawings, and more particularly to FIG. 2 thereof, a new and improved seam plate or membrane plate and substrate assembly, which is constructed in accordance with the principles and teachings of the present invention, is disclosed and is generally indicated by the reference character 110. In addition, the new and improved seam plate or membrane plate substrate assembly 110 of the present invention is adapted to be used in conjunction with a corrugated metal roof decking components so as to effectively form a first embodiment of a new and improved corrugated metal roof decking assembly 111. More particularly, it is seen that the new and improved corrugated metal roof decking assembly 111 comprises an underlying corrugated metal roof decking substructure 112 which is similar to the roof decking substructure 12 of the aforenoted Hulsey patent and is therefore seen to comprise a plurality of transversely spaced crest portions 114. The underlying roof decking substructure 112 has an insulation panel or slab, not shown but similar to the insulation slab or panel 66 of the aforenoted Hulsey patent, disposed thereon, and a plurality of environmental or weather-protection membranes 116,118 are disposed atop the insulation slab or panel so as to protect the same from environmental or weather conditions. Respective edge portions 120,122 of adjacent membranes 116,118 are adapted to be overlapped with respect to each other so as to define a membrane seam region 124, and as is conventional in the art, a plurality of membrane plates or seam plates 126, similar to the seam plates or membrane plates 10 of the aforenoted Hulsey patent, are adapted to fixedly secure the seamed edge portions 120,122 of the membranes 116,118 to the crest portions 114 of the underlying corrugated metal roof decking substructure 112.

[0024] In accordance with the particularly unique and novel feature characteristic of the present invention, the new and improved seam plate or membrane plate substrate assembly 110 comprises a support strip or substrate 128 upon which the plurality of seam plates or membrane plates 126 are fixedly mounted by any suitable means, such as, for example, a suitable adhesive, or by alternative means, as will be more fully disclosed hereinafter. In view of the fact that it is known in the building industry that the construction of the underlying corrugated metal roof decking substructures 112 is such that the crest portions 114 thereof are transversely spaced from each other by means of predetermined center-to-center distances D which may comprise, for example, three inches (3.00″) six inches (6.00″), or twelve inches (12″), the plurality of membrane plates or seam plates 126 are fixedly secured upon the support strip or substrate 128 at predetermined transversely spaced distances of between three inches (3.00″) and twenty-four inches (24.00″), depending upon particular installation requirements, such as, for example, the environmental conditions prevailing at the particular site and to which the roof decking assembly will be operationally exposed.

[0025] In this manner, the transversely spaced positional placement of the plurality of membrane plates or seam plates 126 upon the support strip or substrate 128 matches or corresponds to the transverse spacing defined between the crest portions 114 of the particular underlying corrugated metal roof decking substructure 112 onto which the membranes 116, 118 are being secured. Alternatively, depending, for example, upon the particular environmental requirements for securing the environmental membranes 116,118 to the underlying corrugated metal roof decking assembly 111, that is, to ensure the maintenance of the environmental membranes 116,118 to the underlying corrugated metal roof decking assembly 111 under uplifting wind forces, the seam plate or membrane plates 126 may only need to be fixedly secured to alternative ones of the crest portions 114 of the underlying corrugated metal roof decking substructure 112. Accordingly, the seam plates or membrane plates 126 need not be secured to the support strip or substrate 128 at each position spaced three inches (3.00″) or six inches (6.00″) apart, but may alternatively be secured at, for example, positions which are spaced six inches (6.00″), twelve inches (12.00″), eighteen inches (18.00″), or twenty-four inches (24.00″) apart.

[0026] It can thus be readily appreciated that as a result of the aforenoted structure of the new and improved seam plate or membrane plate implement assembly 110, and in particular, in view of the particular or predetermined transverse spacing of the plurality of membrane plates or seam plates 126 upon the support strip or substrate 128, which effectively matches or corresponds to the predetermined transverse spacing defined between adjacent ones of the crest portions 114 of the underlying corrugated metal roof decking substructure 112, then once a first or leading one of the seam plates or membrane plates 126 is aligned with and fixed within a particular one of the crest portions 114 of the underlying corrugated metal roof decking substructure 112, the other or remaining ones of the seam plates or membrane plates 126 will be inherently aligned with their respective ones of the crest portions 114 of the underlying corrugated metal roof decking substructure 112. Accordingly, when all of the seam plate or membrane plates 126 are to be fixedly secured to the crest portions 114 of the underlying corrugated metal roof decking substructure 112 by means of suitable threaded fasteners, not shown, proper fixation of the seam plates or membrane plates 126 to the crest portions 114 of the underlying corrugated metal roof decking substructure 112 is inherently or automatically ensured.

[0027] With reference now being made to FIG. 3, the new and improved seam plate or membrane plate and substrate assembly 110, which has been constructed in accordance with the principles and teachings of the present invention, can likewise be utilized in conjunction with, for example, a non-corrugated concrete or wood roof decking components so as to effectively form a second embodiment of a new and improved non-corrugated concrete or wood roof decking assembly 211. It is to be noted that in view of the similarities between the first and second embodiments of the new and improved corrugated, metal and non-corrugated concrete or wood roof decking assemblies 111,211, components of the non-corrugated concrete or wood roof decking assembly 211 which correspond to those components of the corrugated metal roof decking assembly 111 have been designated by means of corresponding reference characters except that the reference characters will be within the 200 series. More particularly, it is seen that the new and improved non-corrugated concrete or wood roof decking assembly 211 comprises an underlying non-corrugated concrete or wood roof decking substructure 212 which is similar to the corrugated metal roof decking substructure 112 of the first embodiment of the corrugated metal roof decking assembly 111 as disclosed within FIG. 2 except that the non-corrugated concrete or wood roof decking substructure 212 does not comprise any transversely spaced crest portions. Nevertheless, the underlying roof decking substructure 212 has an insulation panel or slab, not shown, but, again, similar to the insulation slab or panel 66 of the aforenoted Hulsey patent, disposed thereon, and a plurality of environmental or weather-protection membranes 216, 218 are disposed atop the insulation slab or panel so as to protect the same from environmental or weather conditions. Respective edge portions 220,222 of adjacent membranes 216, 218 are adapted to be overlapped with respect to each other so as to define a membrane seam region 224, and as is conventional in the art, a plurality of membrane plates or seam plates 226, similar to the seam plates or membrane plates 126 of the first embodiment of the corrugated metal roof decking assembly 111 as disclosed within FIG. 2, as well as the seam plates 10 of the aforenoted Hulsey patent, are adapted to fixedly secure the seamed edge portions 220,222 of the membranes 216,218 to the underlying noon-corrugated concrete or wood roof decking substructure 212.

[0028] In accordance with the particularly unique and novel feature characteristic of the present invention, the new and improved seam plate or membrane plate substrate assembly 210 comprises a support strip or substrate 228 upon which the plurality of seam plates or membrane plates 226 are fixedly mounted by any suitable means, such as, for example, a suitable adhesive, or by alternative means, as will be more fully disclosed hereinafter. In view of the fact that it is known in the building industry that in order to achieve a viable roof decking assembly 211 wherein the environmental membranes 216,218 must be secured to the underlying non-corrugated concrete or wood roof decking substructures 212 at predeterminedly spaced positions such that the environmental membranes 216,218 will be maintained secured to the underlying non-corrugated concrete or wood roof decking substructures 212 despite the presence or existence of significant uplifting wind forces, then the plurality of membrane plates or seam plates 126 are fixedly secured upon the support strip or substrate 128 at predetermined transversely spaced distances D′ of between three inches (3.00″) and twenty-four inches (24.00″) depending upon the particular installation requirements, that is, for example, the environmental conditions prevailing at the particular site and to which the roof decking assembly 211 will be operationally exposed.

[0029] In this manner, the transversely spaced positional placement of the plurality of membrane plates or seam plates 126 upon the support strip or substrate 128 matches or corresponds to the predetermined transverse spacing defining those locations at which the environmental membranes 216,218 are in fact to be secured to the particular underlying non-corrugated concrete or wood roof decking substructure 212. Accordingly, depending, for example, upon the particular environmental requirements for securing the environmental membranes 216,218 to the underlying non-corrugated concrete or wood roof decking assembly 211, that is, to ensure the secured fixation of the environmental membranes 216,218 to the underlying non-corrugated concrete or wood roof decking assembly 211 under uplifting wind forces, the seam plates or membrane plates 126 may only need to be fixedly secured, for example, at positions which are spaced six inches (6.00″), twelve inches (12.00″), eighteen inches (18.00″), or twenty-four inches (24.00″) apart.

[0030] In accordance with further structural features characteristic of the new and improved seam plate or membrane plate implement assembly 110 as constructed in accordance with the principles and teachings of the present invention, it is noted that while the substrate 128 upon which the plurality of seam plates or membrane plates 126 have been fixedly secured has been described as a support strip, the substrate can alternatively comprise other types of substrates and still satisfactorily perform or satisfy the operational objectives of the present invention. For example, in lieu of a strip-type substrate comprising a single ply of plastic material, the substrate can comprise, or be fabricated from, a suitable paper, film, fabric, metal wire, or metal sheet, or still further, the substrate can comprise a batten bar or a batten strip. Still yet further, as disclosed, for example, within FIG. 4, the seam plate or membrane plate implement assembly, generally indicated by the reference character 310, can comprise a dual-ply tubular substrate 328 which is in the form of a single flattened strip, which is fabricated from a suitable thermoplastic film or sheet material, and which has a plurality of seam plates or membrane plates 326 fixedly secured thereon by means of, for example, a suitable annular or peripheral heat-sealed region 330. Alternatively still further, as disclosed, for example, within FIG. 5, the seam plate or membrane plate implement assembly, generally indicated by the reference character 410, can comprise a plurality of substrates 428-1,428-1, which may be in the form of single or dual-ply flattened strips, which are fabricated from suitable thermoplastic film or sheet materials, which are secured together at a longitudinally oriented seamed region 429, and which have a plurality of seam plates or membrane plates 426 fixedly secured thereon by means of, for example, a suitable annular or peripheral heat-sealed region 430. It is noted that in conjunction with the disclosures of the seam plate or membrane plate implement assemblies 310,410, component parts thereof, which correspond to the component parts of the seam plate or membrane plate implement assembly 110, have been denoted by means of similar reference characters except that such corresponding or similar reference characters are within the 300 and 400 series, respectively.

[0031] It is noted still further, in accordance with a critically important feature of the present invention, that it is desired that the seam plate or membrane plate implement assemblies 110,310,410 be readily portable, be capable of being stored, and be capable of being easily transported so as to be useable at different job sites. Accordingly, it is also desirable that the seam plate or membrane plate implement assemblies 110,310,410 have a requisite amount of flexibility so as to be capable of being formed or packaged, for example, into a coiled structure such as, for example, the coiled structure disclosed within U.S. Pat. No. 5,711,116 which issued to Hasan on Jan. 27, 1998, or the similarly coiled structure disclosed within U.S. Pat. No. 5,469,671 which issued to Rathgeber et al. on Nov. 28, 1995. In accordance with the disclosures of such patents, the assemblies 110,310,410 can, for example, be fabricated from suitable plastic materials. As can therefore be readily appreciated, as a result of fabricating the seam plate or membrane plate implement assemblies 110,310,410 in a coiled format, the seam plate or membrane plate implement assemblies 110,310,410 may be easily transported to a particular job site, uncoiled from its stored coil mode, and effectively dispensed over a roof decking assembly, as needed, in order to fixedly secure the seam plates or membrane plates 126,326,426, and the underlying environmental membranes 116,118,216,218, to the crest portions 114 of the underlying corrugated metal roof decking substructure 112, or alternatively, to the underlying non-corrugated concrete or wood decking substructures 212, respectively.

[0032] With reference lastly being made to FIG. 6, in lieu of the packaging of the seam plate or membrane plate implement assemblies 110,310,410 as coiled structures in accordance with the aforenoted Hasan and Rathgeber et al. patents, any one of the seam plate or membrane plate implement assemblies 110,310,410 may be packaged in such a manner that the seam plates or membrane plates 126,326,426 may be disposed in a stacked nested array, as denoted by means of the arrows N, with the substrates 128,328, or 428-1,428-1 being folded over upon themselves in pleated arrays. Again, the fabrication and packaging of the seam plate or membrane plate implement assemblies 110,310,410 in such a nested format permits the seam plate or membrane plate implement assemblies 110,310,410 to be disposed, for example, within suitable packaging cartons which may subsequently be transported to a particular job site, unpacked from its stored nested mode, and effectively dispensed over a roof decking assembly, as needed, in order to fixedly secure the seam plates or membrane plates 126,326,426, and the underlying environmental membranes 116,118,216,218, to the crest portions 114 of the underlying corrugated metal roof decking substructure 112, or alternatively, to the underlying non-corrugated concrete or wood decking substructures 212, respectively.

[0033] Thus, it may be seen that in accordance with the principles and teachings of the present invention, there has been provided a new and improved a seam plate or membrane plate implement assembly which comprises a support strip or substrate having a longitudinal extent and upon which a plurality of seam plates or membrane plates are fixedly disposed at predetermined uniformly spaced longitudinal positions which correspond to the transverse spacing defined between the crest portions of an underlying corrugated metal roof decking substructure, or alternatively, correspond to the transverse spacing defined between predetermined positions at which the seam plates or membrane plates are desired to be secured to an underlying non-corrugated concrete or wood roof decking substructure. The substrate may have a requisite amount of flexibility so as to permit the same to be coiled or folded for storage and transportation purposes, and when the same is to be used at a particular job site, the substrate may be uncoiled or unfolded from its storage mode. Subsequently, when, for example, the leading one of the seam plates or membrane plates, fixedly secured upon the strip or substrate, is positionally aligned with one of the crest portions of the underlying corrugated metal roof decking substructure, or disposed at an initial position with respect to an underlying non-corrugated concrete or wood decking substructure, and still further, when the leading one of the seam plates or membrane plates is in fact fixedly secured to the underlying roof decking substructure as a result of one of the threaded fasteners being passed through such leading seam plate or membrane plate and threadedly engaged within the corresponding crest portion of the underlying corrugated metal roof decking substructure, or within the non-corrugated concrete or wood decking substructure, then the other seam plates or membrane plates are automatically or inherently positionally aligned with subsequent crest portions of the underlying corrugated metal roof decking substructure, or with predeterminedly desired positions of the underlying non-corrugated concrete or wood decking substructure. In this manner, all of the seam plates or membrane plates are able to be securely fastened to the underlying roof decking substructures, by means of.their respective fasteners, whereby the environmental membranes will be fixedly maintained in their overlying states upon the roof decking assembly insulation slabs or panels so as to thereby desirably protect the same.

[0034] Obviously, many variations and modifications of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the present invention may be practiced otherwise than as specifically described herein.

Claims

1. (Cancelled)
2. The assembly as set forth in claim 19, wherein: said plurality of seam plates are fixedly mounted upon said at least one substrate at predeterminedly spaced positions which correspond to predetermined distances defined between predetermined crest portions of the underlying corrugated roof decking substructure, when the underlying roof decking substructure comprises a corrugated roof decking substructure, so as to ensure said plurality of seam plates can be fixedly secured to the predetermined crest portions of the underlying corrugated roof decking substructure.
3. The assembly as set forth in claim 19, wherein: said plurality of seam plates are fixedly mounted upon said at least one substrate at predeterminedly spaced positions which will ensure the secure fixation of the environmental membranes to the underlying roof decking substructure in such a manner that the environmental membranes will exhibit uplifting wind force resistance so as to remain fixed to the underlying roof decking substructure despite being exposed to significant uplifting wind forces.
4. The assembly as set forth in claim 19, wherein: said at least one substrate comprises a substrate selected from the group comprising a suitable tape, paper, film, fabric, metal wire, metal sheet, batten strip, and batten bar.
5. The assembly as set forth in claim 19, wherein: said at least one substrate comprises at least a pair of substrates fixedly connected together along at least one longitudinally extending seam portion.
6. The assembly as set forth in claim 19, wherein: said at least one substrate comprises a flattened tubular member; and said plurality of seam plates are fixedly secured upon said tubular member by means of heat-sealed peripheral regions.
7. The assembly as set forth in claim 19, wherein: said substrate is fabricated from a suitable material which exhibits a sufficient amount of flexibility so as to permit said at least one substrate to be rolled into a coiled form.
8. The assembly as set forth in claim 19, wherein: said substrate is fabricated from a suitable material which exhibits a sufficient amount of flexibility so as to permit said at least one substrate to be folded in a pleated array in order to permit said seam plates to be stacked in a nested array with respect to each other.
9. The assembly as set forth in claim 19, wherein: said predeterminedly spaced positions, at which said plurality of seam plates are mounted upon said at least one substrate, are located at least three inches (3.00″) apart and up to approximately twenty-four inches (24.00″) apart.
10. (Cancelled)
11. The assembly as set forth in claim 20, wherein: said underlying roof decking substructure comprises a corrugated roof decking substructure, comprising a plurality of crest portions spaced from each other by means of predetermined distances; and said plurality of seam plates are fixedly mounted upon said at least one substrate at predeterminedly spaced positions which correspond to predetermined distances defined between predetermined ones of said plurality of spaced crest portions of said underlying corrugated roof decking substructure so as to ensure said plurality of seam plates being fixedly secured to said predetermined ones of said crest portions of said underlying corrugated roof decking substructure.
12. The assembly as set forth in claim 20, wherein: said plurality of seam plates are fixedly mounted upon said at least one substrate at predeterminedly spaced positions which will ensure the secure fixation of said environmental membranes to said underlying roof decking substructure in such a manner that said environmental membranes will exhibit uplifting wind force resistance so as to remain fixed to said underlying roof decking substructure despite being exposed to significant uplifting wind forces.
13. The assembly as set forth in claim 20, wherein: said at least one substrate comprises a substrate selected from the group comprising a suitable tape, paper, film, fabric, metal wire, metal sheet, batten strip, and batten bar.
14. The assembly as set forth in claim 20, wherein: said at least one substrate comprises at least a pair of substrates fixedly connected together along at least one longitudinally extending seam portion.
15. The assembly as set forth in claim 20, wherein: said at least one substrate comprises a flattened tubular member; and said plurality of seam plates are fixedly secured upon said tubular member by means of heat-sealed peripheral regions.
16. The assembly as set forth in claim 20, wherein: said at least one substrate is fabricated from a suitable material which exhibits a sufficient amount of flexibility so as to permit said at least one substrate to be rolled into a coiled form.
17. The assembly as set forth in claim 20, wherein: said at least one substrate is fabricated from a suitable material which exhibits a sufficient amount of flexibility so as to permit said at least one substrate to be folded in a pleated array in order to permit said seam plates to be stacked in a nested array with respect to each other.
18. The assembly as set forth in claim 11, wherein: said crest portions of said corrugated roof decking substructure are spaced apart from each other by distances within the range of three inches (3.00″) to twelve inches (12.00″); and said predeterminedly spaced positions, at which said plurality of seam plates are mounted upon said at least one substrate, are located at least three inches (3.00″) apart and up to approximately twenty-four inches (24.00″) apart.
19. An assembly for facilitating the fixed mounting of roof membrane seam plates at predetermined locations upon an underlying roof decking substructure, comprising: at least one substrate having a longitudinal extent; and a plurality of seam plates, for fixing environmental membranes to an underlying roof decking substructure, fixedly mounted upon said at least one substrate, at predetermined positions spaced along said longitudinal extent of said at least one substrate, so as to define with said at least one substrate an integral product entity, such that when one of said plurality of seam plates is fixedly secured at a first location along the underlying roof decking substructure by means of a fastener, the remaining ones of said plurality of seam plates. fixedly attached to said at least one substrate at said predetermined positions spaced along said longitudinal extent of said at least one substrate, will inherently be disposed at remaining ones of predetermined locations along the underlying roof decking substructure at which said seam plates are to be fixedly secured by the fasteners so as to ensure the proper fixation of said seam plates to the underlying roof decking substructure whereby, in turn, the fixation of the environmental membranes, to the underlying roof decking substructure, will likewise be ensured.
20. A roof decking assembly for facilitating the fixed mounting of roof membrane seam plates at predetermined locations upon an underlying roof decking substructure, comprising: a roof decking substructure; an insulation panel disposed atop said roof decking substructure; a plurality of environmental membranes adapted to be fixedly secured atop said insulation panel; at least one substrate having a longitudinal extent; and a plurality of seam plates, for fixing said environmental membranes to said underlying roof decking substructure, fixedly mounted upon said at least one substrate, at predetermined positions spaced along said longitudinal extent of said at least one substrate, so as to define with said at least one substrate an integral product entity, such that when one of said plurality of seam plates is fixedly secured at a first location along said underlying roof decking substructure by means of a fastener, the remaining ones of said plurality of seam plates, fixedly attached to said at least one substrate at said predetermined positions spaced along said longitudinal extent of said at least one substrate, will inherently be disposed at remaining ones of predetermined locations along said underlying roof decking substructure at which said seam plates are to be fixedly secured by the fasteners so as to ensure the proper fixation of said seam plates to said underlying roof decking substructure whereby, in turn, the fixation of said environmental membranes, to said underlying roof decking substructure, will likewise be ensured.

Substrate with membrane seam plates fixed thereon for precise placement of seam plates on roof decking assemblies

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