Note: Descriptions are shown in the official language in which they were submitted.
CA 02126362 2003-07-08
~~,akqro a! the Zav~ n~ tio;p
Various techniques are known in the art for applying
panels to cover a deck or to function as the siding of a wall.
Slate is a particularly desirable type of panel. It is difficult
to mount on a deck by virtue of being a natural product, lacking
true uniformity in dimensions, brittle, and of varying hardness and
characteristics. Conventional mounting is done by nailing the
individual slate panel to a deck through holes previously formed in
the slate. The procedure has not changed essentially for centu-
ries. An alternative procedure is to use hooks that are attached
directly to the deck, and that engage the edges of the slate.
There are significant drawbacks to the hook system, and also to the
nailing procedure, which requires much skilled labor and involves
breakage.
e~~~y o! t,~ie invention
This invention provides a panel mounting assembly for the
application of multiple panels to a tr-ack or a portion of a track.
According to one aspect of the present invention
there is provided a mounting assembly for mounting panels
to a structure for forming a roof or wall for the
structure wherein the structure has framework, said
assembly comprising a plurality of spaced parallel
generally flat mounting tracks, each of said tracks
having a base portion mounted against and to said
framework, each of said tracks having a fastener
accommodating structure, a plurality of rows of mounting
2
CA 02126362 2003-07-08
panels, each of said rows of panels being associated with
a respective one of said tracks, each of said panels
having an outer surface and having two spaced side edges,
surface indentations in said outer surface in each of
said panel side edges, adjacent sets of said panels
having said surface indentations in line with each other
with each surface indentation extending completely to its
edge, a fastener in the form of an intermediary device
engaged in each of said surface indentations, each of
said fasteners being secured to its said track by being
detachably hooked to said fastener accommodating.
structure, each of said panels being imperforate except
for any perforations at said surface indentations, and
said rows of panels being mounted in an overlapping
manner with respect to each other to cover and conceal
said fasteners.
An intermediate device between the slate and a mounting
track which is mounted on the support deck is used. Both the
mounting track and the intermediate device can take several forms,
but, all employ a device that joins the panel to the mounting
track, the mounting track being attached directly to the support
deck.
The mounting track creates a straight line of attachment
for the panels, such as slates, to be applied. This facilitates
alignment and does not require skilled or specialized labor.
2a
°- The intermediate device may be a clip, band, or other
attachment to the slate that, in turn, attaches to the track.
The panel, for most forms of this invention, does not
require nail holes. The nanp~ ,~a~ ~ ,~"a; ~;..a L.. ____ _.
notching, or other alteration to accommodate the device, such as a
clip, in a way to provide alignment, stability, security of
attachment to the mounting track, and to meet other requirements
for a specific application. The number of panels applied by this
system may vary from one to many, depending upon the application,
and can be intermixed with portions of the mounting track to which
panels have been applied by a different system.
The mounting track and the intermediate device may be
made of any appropriate material. The application of tracks would
be suitable for covering buildings or other structures. Where
necessary, dependent portions of the mounting deck would be
provided with weep holes, and securing of the mounting track to the
support deck would be done, in most cases, through elongated holes
to allow for expansion and contraction.
Any of several fastenings of the mounting track to the
support deck may be employed, including, but not limited to nails,
screws, adhesives, and staples.
The concept of this system, consisting of an applied
mounting track and an applied slate component, also includes the
use of adhesives or bonding agents. In this version an adhesive is
applied to the under surface of the panel. An adhesive is also
applied to the surface of the mounting track. The panel is then
3
CA 02126362 2003-07-08
bonded to the mounting track by interaction of these two adhesive
layers. A third independent support or spacer, also adhesive to
the structures it contacts, could be used. This would resemble a
mounting track, but the attachment of this track-equivalent would
be by adhesive or bonding to the panel that lies on top of it and
to the deck on which it lies.
The D.=a~inqs:
Figure 1 is a top plan view showing the panel mounting
assembly of this invention;
Figure 2 is a cross-sectional view taken through Figure
1 along the line 2-2;
Figure 3 is an enlarged view of a portion of the assembly
shown in Figure 2;
Figure 4 is a rear plan view of a portion of the assembly
shown in Figures 1~3;
Figure 5 is an exploded view of the components used in
the assembly of Figures 1-4;
Figure 6 is a top plan view of an alternative assembly in
accordance with this invention;
Figure 7 is a side elevational view of the assembly shown
in Figure 6;
Figure 8 is a bottom plan view of a portion of the
assembly shown in Figure 6-7;
Figure 9 is a top view of a portion of the assembly shown
in Figures 6-8;
4
J' ' 'JI ~ a ~~ ~y ~~
Y2I ~~ ~ ~ ~3{_~ < J
Figures 10-13 are perspective views of alternative forms
of mounting track usable in the assembly of this invention;
Figure 13A is a side view of the mounting track shown in
Figure 13;
Figure 14 is a perspective view of a modified mounting
system in accordance with this invention;
Figure 15 is a perspective view of yet another alterna-
tive practice of this invention;
Figure 16 is a side view of a portion of the assembly
shown in Figure 15;
Figure 17 is a perspective view of a further alternative
practice of this invention;
Figure 18 is a plan view of the mounting track used in
the embodiment of Figure 17;
Figure 19 is a perspective view of yet another embodiment
of this invention;
Figure 20 is a perspective view of an alternative
mounting track in accordance with yet another embodiment of this
invention;
Figure 21 is a side view showing use of_the mounting
track of Figure 20;
Figure 22 is an elevational view of a form of slate panel
and mounting members in accordance with this invention;
Figure 23 is a plan view showing the mounting of the
slate panel of Figure 23;
..
Figure 24 is a plan view of yet another practice of this
invention;
Figure 25 is a plan view of a further alternative
mounting track in accordance with this invention;
Figure 26 is a side elevational view showing yet another
practice of this invention;
Figure 27 is a plan view of yet a further panel mounting
assembly in accordance with this invention;
Figure 28 is a cross-sectional view taken through Figure
27 along the line 28-28;
Figure 29 is a perspective view of the clip used in the
panel mounting assembly of Figures 27-28; and
Figure 30 is a perspective view of yet another clip in
accordance with this invention;
Figure 31 is a side elevational view in cross-section
showing the clip of Figure 30 for holding a panel;
Figure 32 is a plan view showing the clip of Figures 30-
31 mounted directly to a deck;
Figure 33 is a cross-sectional view taken through Figure
32 along the line 33-33;
Figure 34 is a plan view showing a modified clip in
accordance with this invention;
Figure 35 is a side view partly in section showing the
clip of Figure 34 mounted to a track;
Figure 36 is a side view in elevation showing the clip
similar to that of Figure 30 mounted to a track; and
6
'~ ' '-, ~~ '~ ~'
Figure 37 is a perspective view of yet another clip in
accordance with this invention;
Figure 38 is a plan view showing a set of the clips of
Figure 37 used for mounting a slate;
Figure 39 is a side elevational view partly in section of
the clip of Figures 37-38 mounting slate panels to a deck; and
Figure 40 is a perspective view of a modified form of
mounting track shown in Figures 38-39.
Detailod Description
To facilitate an understanding of the invention the
following definitions will apply to the description of the
invention.
Panel: this is used synonymously with shingle, tile, or
individual slate piece. Whereas the principle application of this
term would refer to uses in roofing, panels may also be applied to
any surface, vertical, inclined, horizontal and used for purposes
other than roofing. -
Support deck: any surface for which this application
method is suited. It is synonymous with the roof deck, but, where
appropriate should be interpreted as vertical or horizontal wall,
surface, underlying structure, or other term describing the
substrate to which the mounting track is attached.
Mounting track: a horizontal band, ridge, wire,
extrusion, ribbon, or other form, of whatever material, attached to
the deck and to which the panel is attached, usually, but not
always, by means of an intermediary device.
7
Intermediary device: the device is an intermediate
between the panel and the mounting track. It may be in the form of
a clip, a band, or other form that adapts to the panel and that
secures the panel to the mounting track. The slate or panel may
have to be altered to accommodate the device. The device is
coordinated in size and contour to engage the mounting track with
the mechanical properties required. The device may also take the
form of an adhesive or a bonding system that serves as the
intermediary between the panel and the mounting track or to the
panel or the underlying mounting track. The device in that version
combines the function of mounting track and track attachment. For
example, the device could be an extrusion of triangular cross
section, bonded to both the deck and the panel, and offering the
proper support and alignment to the panel. A two part coating
system could be used, with no adhesion being developed until the
two parts, one on the panel and one on the device, come into
contact, and a similar two part system bonding the device to the
deck.
This invention overcomes significant difficulties in
economical and effective mounting of panels or tiles to-a support
deck or similar structure. It is to be understood, however, that
although the invention will be described specifically with respect
to slate panels, and tracking, the invention may also be used for
attaching panels made of other materials to surfaces other than
roofs or roof decks.
8
CA 02126362 2003-07-08
Figures 1-5 illustrate one fore of panel mounting
assembly 10. The illustration shows several parallel mounting
tracks 12 mounted to a support deck 14. Figure 5 shows each
mounting track as a single member having a base portion 16 and an
upright leg or offset portion of lip 18 joined at the
bight section 20. As also illustrated in Figure 5, the
base 16 includes an elongated slot 22 for receiving a
suitable fastener 24 (Figure 37 such as a nail, for
securing the mounting track 12 to the support deck 14. By .
using an elongated slot, the position of the panels 28
may be adjusted and this elongation also permits
expansion and contraction of the tracking material.
Figure 5 also shows at least one drain or weep hole 26 at
the lowest portion of the bight 20 of the track 12. Several drain
holes may be needed.
Figure 5 shows a notch or a groove 30 on each vertical
edge of the panel 28. The device that attaches the slate to the
mounting track is shown in Figures 1-5_in the form of a spring clip
32 having a horizontal leg 33 and a vertical leg 34 connected by a
partial loop 36. The horizontal leg 33 would be inserted into the
groove 30 of the slate 28 with the loop 36 coming to lie in the
notch 38 at the edge of the slate which is actually at the
extremity of the groove 30. The vertical leg 34 would fit over the
lip 18 of the track 12 in the space between the base 16 and the lip
18 as shown in Figure 3. The tip 35 of leg 34 may be bent or
formed to prevent snagging.
9
- Clip devices 32 would be applied to opposite vertical
edges of each panel and would engage the mounting track as
previously described. The clip may be bent so as to provide a
clamping action upon the slate in the groove, and, also, may have
its descending or vertical leg bent and the tip formed or angled so
as to prevent snagging of the underlying felt or track. Subsequent
panels would be applied according to the spacing desired so that a
course of panels would result. Each section of mounting track may
be as long as needed for the space to be covered, but, the length
may be restricted for ease of handling, carrying, packing,
shipping, storing, and the like. In some applications overlapping
courses may not be desirable. The system would accommodate such
special requirements with ease.
Figures 6-9 illustrate a variation of the invention in
which a single device-clip engages adjacent slates. The clip 40 is
similar to the clip 32 in that it is a spring type clip. Clip 40
is bent as illustrated to form a pair of U-shaped clamp arms 42
having bight sections 46 and interconnected by a double thickness
vertical leg 44. The preformed groove 30 in the slate panel 28
would accept the clamp arms 42 and confine them completely within
the slate, avoiding protrusion above the slate s upper surface so
as not to interfere with subsequent courses of slate. Furthermore,
the shoulders formed by the groove 30 function as butting surfaces
for the clip, adding to the stability of the panel when mounted to
the mounting track. The edge notch 38 could be dimensioned to
1o
CA 02126362 2003-07-08
further confine the clip within the slate panel and contribute to
the stability of the system. The use of the notch is optional.
In addition to providing attachment of the panel to the
mounting track, the mounting tracks can have other uses during the
mounting process. They could be employed as rails upon which a
carriage would ride. This carriage would contain panels, clips,
and other supplies needed by the applier and would be displaced as
the course of panels is added to.
The mounting track may take various forms,
illustrated in the drawings such as those illustrated in
figures 6, 7 and 10. Figure 10, for example, shows a Z-
shaped track 48 with a base portion 50 connected to an
offset 54 by bent portion 56. Weep holes 57 may be in
bent portion 56. Track 48 would be secured to the support
surface by suitable fasteners through elongated slots 52
similar to those in the base portion 16. Although sharp
bends are shown in Figure 10. less acute bends could be
used, and, the planes of the two sections of the mounting
track need not be parallel, but, could be at an angle to
each other that would facilitate application of the
intermediate angle to devices or hold them better after
they have been applied.
Figures 11 and 12 show variations of the mounting
track employing principles similar to those just
described. Track 58 of Figure 11 has a base 62 connected
to offset 64 with weep holes 60 in the connecting
portion. Track 66 of Figure 12 includes lower and upper
11
CA 02126362 2003-07-08
base portions 70,72 interconnected by arcuate ribs 78
connected to each other by backbone 76 to form a bulge
68. Mounting slots 80 are in base 70. Figure 12 further
illustrates open areas 74 between the ribs 78 of bulge
68.
lla
CA 02126362 2004-02-06
Figures 13 and 14; 15 and 16; and 17, 18 and 19 show
variations of an intermediate device that takes the form of a band
encircling a panel that may be grooved, notched, or both, and
joined to the mounting track by projections in the track itself or
by a sliding clip arrangement attached to the track. The
proj ections may be in the form of f fingers bent upward from the
lower edge of a track, or fingers formed as cutouts along the upper
edge of a Z-shaped track. In both cases these fingers engage a
band looped around the slate and retained by notch, groove, or a
combination of notch and groove.
As shown in Figures 13 and 13A a mounting track 82 has a base
84 with an offset 86 interconnected by bight portion 88. Fingers 90
are formed in offset 86. Figure 14 shows track 82 mounted to panel
92 by a loop or band 96 which functions as the intermediary device.
Band 96 is located in notches 94 of panel 92 and is held by fingers
90. The ends of band 96 are locked together by a suitable fastener
98.
In Figures 15-16 the mounting track 100 is secured to support
14 by fastener 104. Track 100 mounted against panel 108 has a
center portion 102 with elevated edges 106. These elevated edges
permit a clip 110 with elongated tongue 116 to slide along the
track. As shown in Figure 15 clip 110 is in the form of sliders 112
and 112A having ends 114 which bend around elevated edges 106 of
track 100. The tongue 116 is an extension of slider 112. The
tongue engages the slate 100, using notches, a groove 30, or a
combination of both, and is secured by passing it under the sliding
clip 110 for the next slate. A section of this is seen in Figure
16, and a variation that dispenses with the sliding clip, but that
uses a projecting finger arrangement on the track to hold a ribbon
that passes from grooved slate to grooved slate or from notched
slate to notched slate is seen in Figure 7.
Appropriately grooved or notched, or grooved and notched,
slates would be used as might be used in the previously described
arrangements (Fig. 17; Fig. 18). As shown adjacent panels 118, 118
have notches 120. Track 122 has fingers 126 formed in base 124
12
CA 02126362 2004-02-06
which could be pressed back into base 124 so that only a selected
finger 126A would extend between panels 118 and 118 to receive a
ribbon 128.
In Figure 19 a ribbon 130 similar to that used in Figure 17
is employed, and is secured to the support deck directly by nailing
132 or stapling 134 between the slates 118.
Figure 20 and Figure 21 illustrate a system in which a
spacing strip 136 consisting of a foam or other appropriate
material is used between a ribbon and the support deck. The foam
spacer 142 may be bonded to the metal ribbon 138. The entire
structure is then stapled 144 or otherwise fastened to the track
deck. A bent clip 32 is then applied to a grooved, notched, or
grooved and notched slate, along both vertical edges, and the
descending part of that clip (intermediary device) is then placed
through the foam, between the ribbon and the support deck 14. If
used in this fashion the foam 142 serves as a spacer for the
initial placement of the metal ribbon 138, with the metal ribbon
actually holding the slate by means of the attached clip. A
modification of this version would dispense with the foam entirely,
inserting the clip directly behind the ribbon that would be spaced
from the track by a partially driven staple or nail. Furthermore,
additional variations of this could be used in which the foam is
replaced by some other appropriate material, such as paper or
corrugated paper with the openings oriented to accept the
descending member of the clip (device).
Figure 22 and Figure 23 show a system for using slates 146
that have holes punched in them. Essentially, nail shaped devices
152,162 with heads 154,164 similar to those found on nails are
placed into the slate holes. Slate holes characteristically are
conical, having a larger and a smaller end 148,150. The nail heads
are placed so as to seat in the crater at the end of the hole that
is larger, and the extension of the nail would then be joined to an
equivalent nail placed in the other hole of the slate. The second
nail and the first nail would be constructed to enable their
meeting in a permanent joint. The illustration shows this joint
13
CA 02126362 2004-02-06
being formed by having one nail 152 hollow 158, partially slitted
160, to accept a smaller, solid end 168 of the opposing nail 162,
forming a jammed fit. This produces a continuous shallow U-shaped
rod, having ends 156 and 166, that stretches from one nail hole to
the other and that would be supported by engaging finger-like
projections 90 on a track similar to that illustrated in Figure 13.
The ends of the nail-shaped devices could also be threaded
through a perforated ribbon 170 (see Figure 24) where the
14
CA 02126362 2003-07-08
nail shaped device is designated 174 and is threaded through holes
172.
Figure 25 shows a different form of attachment in that a
rectangular grid 176 of wires is applied to the support deck 14.
The horizontal wires or rods 178 are laid on top of the
vertical wires ,180, and, thereby, are spaced from the deck .
14. These horizontal rods 178 Would then be used to replace
the tracks and the hooks or clips (devices) would attach to
these horizontal members of the rectangular grid.
The grid method of application is also particularly
advantageous because it may be used on support decks of unconven-
tional surface. It has the ability to span gaps in the deck, and
is exceedingly economical in the labor required for installation.
A wide range of material could be used for the grid itself,
including those materials already having wide acceptance in the
roofing industry. Furthermore, the system has adaptability to
various deck contours upon which slate application might otherwise
be prohibitively complicated, or for which skilled labor would be
expensive or unobtainable.
The grid 176 would be of a size and dimensions to enable
the desired placements of panels mounted that would then be
attached by an intermediate device to the horizontal member 178.
For example, the grid opening might be 7 inches square. The cost
could be reduced by having the horizontal members made of metal,
fitted into notches in plastic vertical members.
_.
' The recesses formed by notching or grooving panels are
unique. These recess differ significantly from the holes that
conventional practice employs. These notches and recesses,
particularly the notches, provide the ability to mount the slate
panels with various techniques that do not require the use of
tracks or strips, but, also may be combined with tracks and clips
or bands.
Figure 26 shows a fabric type fastener in which an
adhesive or other bonding agent is used to attach a hook-and-loop
pair to the undersurface of the panel 186 and to the support track
14. In Figure 26 the strip 182 with loops 184 is secured to track
14 while the strip with hooks 188 is secured to panel 186.
Figures 27-29 show an alternative panel mounting assembly
in accordance with this invention. As shown therein the panels 28
would be mounted directly to the support deck 14 without the use of
mounting tracks. This is accomplished by means of a clip 190.
Clip 190 has some similarities to the clip 40 shown in Figures 6-9
in that the same clip is used for attachment to a pair of side by
side panels 28. Use is also made of the notches or grooves 30
which extend inwardly from the sides of the panels and of the
notches 38 located at the side edges. -
As shown in Figures 27-29 clip 190 includes a pair of
aligned clamp arms 192 which are integral with each other by an
intermediate portion 194 which is in the same plane as clamp arms
192, but offset from the clamp arms. Thus, intermediate portion
194 could be placed directly against the support deck 14 (as shown
16
°
. 4~. - a C'g rs '.;a
:. . .. r...
3.~ ._v Sues =,~' . . , -.
in Figure 28) and secured to the support deck in any preferably
manner such as by staples 196. This arrangement which provides a
spring fit overcomes the major disadvantages of commercial nailing.
Figure 30 illustrates an alternative clip 200 in
accordance with this invention. Clip 200 could be made of wire or
thin ribbon material having sufficient resiliency to be spring
mounted to panel 28. In the use of clip 200, however, it is not
necessary to provide a groove, such as groove 30, on the upper
surface of panel 28 because of the thinness of clip 200. Instead
an edge notch 38 would be used in which the clip 200 would be
mounted. As shown in Figure 31 clip 200 includes spring arms 202,
204 interconnected by intermediate portion 206 with an extended leg
208 extending from the bend 210 of clip 200.
Figures 32-33 show the use of clip 200 for being mounted
directly to a deck 14, thus eliminating the need for a track. The
clip 200 and its panel 28 could be secured to the track by, for
example, staples 212 as shown in F-figures 32-33 which could be
applied by an automatic tool such as a staple gun without straining
the panels. Figure 33 illustrates how a pair of legs 208 overlap
each other and are mounted to deck 14 by staples 212.- I~ desired,
the legs 208 could be slid under the staples where the staples are
premounted to the deck slightly spaced from the deck. Figure 33
best illustrates how the edge notch 38 would be formed in a
standard chamfered slate edge without forming a top surface groove.
Such edge notches 38 in the panel's vertical edges would be much
simpler and easier to manufacture than conventional holes which due
17
1:
to the nature of the material must be individually punched or
drilled. The edge notches 38 could be formed or sawed, for
example, along a rack of panels in one operation. In the case of
roofing slate, the notch 38 need only recess enough for the clip to
enter the full thickness of the panel, that is, beyond the
customary chamfered edge.
Figures 34-35 illustrate a further variation of this
invention wherein a Z-type clip 214 made of thin ribbon material
similar to clip 200 is used for mounting panels 28 to a track 12.
In this practice of the invention an edge notch 38 is formed and
the clips 214 are mounted perpendicular or turned 90° from the type
of mounting described, for example, with respect to the embodiments
of Figures 1-9. Thus, a leg 216 of each clip would extend on the
outer surface of panel 28 while the other leg 218 would hook onto
track 12 .
Figure 36 shows a modification of the clip 214 wherein
the clip 220 has a pair of spring arms 222, 224 provided by the bend
226 with a further leg 228 extending from bend 230. As illustrated
the spring arms 222,224 are mounted in edge notch 38 in an
orientation similar to clip 214 where arm 222 is on the outer
surface of panel 28. The spring arms 224 and 228 _in turn are
hooked over and secured to track 212.
It is to be understood that although Figures 34-36 have
been described with respect to track 12 other forms of track may be
used for clips 214 and 220.
18
c.. 'ro cl ~ a n
!:~~ _~. r~r E..,'
Clips 200 and clips 214 and 220 have in common that each
clip is formed from a thin, flat, springy material and includes
oppositely extending arms or legs. One of the arms would be
disposed on the outer surface of the panel and the other arm would
be disposed in an opposite direction and would be used for mounting
the clip end panel to either the deck (clip 200) or a track (clips
212 and 220).
Figures 37-40 show yet another form of this invention
wherein the intermediary member 240 is in the form of a thin flat
springy material having a clip end 242 and an outwardly extending
leg 244 which terminates in an inclined end 246.
Intermediary member 240 could be used with any suitable
track, such as track 248 shown in Figure 40. As shown therein
track 248 includes a base portion 250 and an offset portion 252 so
that a space would be created below offset portion 252. In use a
plurality of such tracks would be mounted spaced from each other as
shown in Figures 38-39. A pair of clips 240 would be secured to
panel 28 by being inserted into notches 38 with the panel 28 firmly
gripped by the clip ends 242. The leg 244 would be inserted in the
space between offset 252 of track 248 and deck 14 as best shown in
Figure 39. If desired, base portion 250 could be provided with a
plurality of weep holes 254 as illustrated in Figure 40.
If desired, a cushioning strip 256, which is partially
shown in Figure 40, could be mounted on the upper surface of base
member 250 to cushion the panel 28. The cushioning strip would
also compensate for any irregularities in the panel thus providing
19
a smoother laying roof and diminishing breakage by distributing tha
forces due in particular to walking on the roof.
An advantageous feature of the embodiment of Figures 3~_
40 is that the track 248 could be made of an inexpensive material
such as wood or easily extrudable products. Figure 40 illustrates
the track to be formed from a one piece member. The individual
parts 250,252, however, may simply be two slats of wood Secured
together so as to form a general Z arrangement.
An alternative structure for the track would be simply to
provide longitudinal spacers on the roof deck and then secure
horizontal or transverse slats on top of the spacers so that the
legs 244 of clip 240 could be inserted under the Slats against some
stop member,
Reduction of any unsupported span may be achieved by
beveling the track which effectively extends the bearing surface
downwardly. The placement of the cushioning strip 256 can also
have a similar effect on a track of rectangular cross-section.
It is to be understood that the various embodiments
described are exemplary practices of the invention and that
features from one embodiment may be used with features from other
embodiments. _ _
