Note: Descriptions are shown in the official language in which they were submitted.
LIGHTWEIGHT COMPOSITE ROOFING SUPPORT SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to US Non-Provisional Utility
Patent Application No.
17/163,200 filed on January 29, 2021 and to US Non-Provisional Design Patent
Application No.
29/741,731 filed on July 15, 2020.
FIELD OF THE INVENTION
[0002] The subject invention relates generally to a lightweight roofing
support system..
More particularly, it relates to a lightweight composite roofing support
system that is configured
to provide a level, stable, self-supporting platform for roofing workers,
roofing tools, roofing
materials, or a combination thereof, on a pitched or sloped roof.
BACKGROUND
[0003] The removal and/or application of roofing systems and roofing
materials on sloped or
pitched roofs presents long-standing problems, particularly on relatively
steeply pitched roofs,
such as those having a pitch above 8/12 (i.e., 8 feet of vertical rise for
every 12 feet of horizontal
run), problems that are particularly acute on steeply pitched roofs with
pitches ranging from
10/12 to 16/12. Steeply pitched roofs are exceedingly difficult for roofing
workers to work on,
particularly to move, walk, stand, crouch, kneel, sit, or lie on, or
otherwise, whether working to
to remove an old roof or to construct a new roof, and including to distribute
or store roofing tools
or equipment or roofing materials for these purposes.
[0004] Various support systems and structures have been proposed to provide
a platform for
roofing workers, roofing tools, roofing materials, or a combination thereof,
on pitched or sloped
roofs. One common support structure comprises a plurality of spaced apart roof
jacks that are
used to support a jack board between them. The jack board generally provides a
substantially
horizontal surface on which roofing workers can move horizontally across the
roof surface, and
on which they may store roofing tools and roofing materials. A problem
associated with this
system is that the jack stands and jack boards are heavy and require a
substantial expenditure of
time and effort in order to locate, and in order to reposition as the
deconstruction and/or
construction of the roof systems proceed. In addition, attachment of the jack
stands and the jack
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Date Recue/Date Received 2021-05-07
boards generally disadvantageously require anchoring to the roof deck by the
insertion of nails or
screws, or the resulting perforation of the upper portion of the shingles,
underlayment material,
or wooden roof deck, which are all known leakage paths for water from
condensation, rain,
and/or ice, for example.
[0005] Polymer based roof blocks have been proposed but have generally been
unsuitable.
In some cases, polymer roof blocks have been too rigid, such that the blocks
are not non-skid and
unstable and thus have a tendency to slide downwardly in the downslope
direction over the
surface of the pitched roof, particularly if the roof is steeply pitched.
[0006] Therefore, it would be very desirable provide a lightweight
composite roofing support
system that avoids the limitations described above, and a provides a level,
stable, self-supporting
platform for roofing workers, roofing tools, roofing materials, or a
combination thereof, on
pitched or sloped roofs, and particularly steeply pitched or sloped roofs.
SUMMARY OF THE INVENTION
[0007] In one embodiment, a lightweight composite roofing support system is
disclosed.
The lightweight composite roofing support system comprises a longitudinally-
extending core
member comprising a longitudinally-extending first roof contact side
comprising a
longitudinally-extending first edge and an opposed longitudinally-extending
second edge, a
longitudinally-extending second side comprising a second side working surface
having a second
width and a second length that is greater than the second width, the second
side tapering toward
the first edge at a first acute angle (a) from the first roof contact side,
and a longitudinally-
extending third side comprising a third side working surface having a third
width and a third
length that is greater than the third width, the third side tapering toward
the second edge at a
second acute angle (0) from the first contact side that is different than the
first acute angle (a), a
laterally-extending first end comprising an integral first recess defining a
first handle or grip, and
an opposed laterally-extending second end comprising an integral second recess
defining a
second handle or grip, the core member comprising a core material and a wedge-
shaped lateral
cross-section, the core member configured for disposition of a longitudinally-
extending
resiliently compressible cover layer comprising a resiliently compressible
cover material on the
first roof contact side to provide a first roofing support.
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Date Recue/Date Received 2021-05-07
[0008] In another embodiment, a lightweight composite roofing support
system is disclosed.
The lightweight composite roofing support system comprises a longitudinally-
extending core
member comprising a longitudinally-extending first roof contact side
comprising a
longitudinally-extending first edge and an opposed longitudinally-extending
second edge, a
longitudinally-extending second side comprising a second side working surface
having a second
width and a second length that is greater than the second width, the second
side tapering toward
the first edge at a first acute angle (a) from the first roof contact side,
and a longitudinally-
extending third side comprising a third side working surface having a third
width and a third
length that is greater than the third width, the third side tapering toward
the second edge at a
second acute angle (0) from the first contact side that is different than the
first acute angle (a), a
laterally-extending first end comprising an integral first recess defining a
first handle or grip, and
an opposed laterally-extending second end comprising an integral second recess
defining a
second handle or grip, the core member comprising a core material and a wedge-
shaped lateral
cross-section. The lightweight composite roofing support system also comprises
a resiliently
compressible cover layer comprising a resiliently compressible cover material,
the cover layer
disposed on and covering the first roof contact side, the core member and
cover layer comprising
a first roofing support.
[0009] In yet another embodiment, a lightweight composite roofing support
system
connector is disclosed. The lightweight composite roofing support system
connector comprises a
longitudinally-extending connector comprising a first connector end and an
opposed second
connector end joined together by a longitudinally-extending intermediate
portion, the first
connector end configured for selective attachment to or detachment from a
first roof support and
the second connector end configured for selective attachment to or detachment
from a second
roof support, wherein upon attachment the connector is configured to connect
the first roof
support and the second roof support.
[0010] The above features and advantages and other features and advantages
of the invention
are readily apparent from the following detailed description of the invention
when taken in
connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
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Date Recue/Date Received 2021-05-07
[0011] Other features, advantages and details appear, by way of example
only, in the
following detailed description of embodiments, the detailed description
referring to the drawings
in which:
[0012] FIG. 1 is a perspective view of an embodiment of a roofing support
system and roof
support as disclosed herein illustrating an embodiment of a core member as
described herein;
[0013] FIG. 2 is a top view of the roofing support system and roof support
of FIG. 1;
[0014] FIG. 3 is a bottom view of the roofing support system and roof
support of FIG. 1;
[0015] FIG. 4 is a left side view of the roofing support system and roof
support of FIG. 1;
[0016] FIG. 5 is a right side view of the roofing support system and roof
support of FIG. 1;
[0017] FIG. 6 is a front view of the roofing support system and roof
support of FIG. 1;
[0018] FIG. 7 is a rear view of the roofing support system and roof support
of FIG. 1;
[0019] FIG. 8 is a perspective view of another embodiment of a roofing
support system and
roof support as disclosed herein illustrating a core member and attached
resiliently compressible
cover layer as described herein;
[0020] FIG. 9A is a top view of the roofing support system and roof support
of FIG. 8;
[0021] FIG. 9B is a cross-sectional view of FIG. 9A along Section B--B;
[0022] FIG. 10 is a bottom view of the roofing support system and roof
support of FIG. 8;
[0023] FIG. 11 is a left side view of the roofing support system and roof
support of FIG. 8;
[0024] FIG. 12 is a right side view of the roofing support system and roof
support of FIG. 8;
[0025] FIG. 13 is a front view of the roofing support system and roof
support of FIG. 8;
[0026] FIG. 14 is a rear view of the roofing support system and roof
support of FIG. 8;
[0027] FIG. 15 is a perspective view of another embodiment of a roofing
support system and
roof support as disclosed herein illustrating a core member and resiliently
compressible cover
layer comprising a first resiliently compressible cover material and a second
resiliently
compressible cover material as described herein;
[0028] FIG. 16 is atop view of the roofing support system and roof support
of FIG. 15;
[0029] FIG. 17 is a bottom view of the roofing support system and roof
support of FIG. 15;
[0030] FIG. 18 is a left side view of the roofing support system and roof
support of FIG. 15;
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Date Recue/Date Received 2021-05-07
[0031] FIG. 19 is a right side view of the roofing support system and roof
support of FIG.
15;
[0032] FIG. 20 is a front view of the roofing support system and roof
support of FIG. 15;
[0033] FIG. 21 is a rear view of the roofing support system and roof
support of FIG. 15;
[0034] FIG. 22 is a perspective view of another embodiment of a roofing
support system and
roof support as disclosed herein illustrating a core member, selectively
attachable/detachable
base, and resiliently compressible cover layer attached to the base as
described herein;
[0035] FIG. 23 is an exploded perspective view of the embodiment of a
roofing support
system and roof support of FIG. 22;
[0036] FIG. 24 is a bottom view of the core member of the roofing support
system and roof
support of FIG. 22;
[0037] FIG. 25 is an exploded perspective view of another embodiment of a
roofing support
system and roof support as disclosed herein illustrating a core member, a
selectively
attachable/detachable hook and loop attachment device comprising a first sheet
of hook material
or loop material and second sheet of a loop material or a hook material,
respectively, and a
resiliently compressible cover layer that is selectively attachable and
detachable by the
attachment device as described herein;
[0038] FIG. 26 is a bottom view of the core member of the roofing support
system and roof
support of FIG. 25 and the first sheet of hook material or loop material
attached thereto;
[0039] FIG. 27 is a left side view of the core member of FIG. 26;
[0040] FIG. 28 is a right side view of the core member of FIG. 26;
[0041] FIG. 29 is a front view of the core member of FIG. 26;
[0042] FIG. 30 is a rear view of the core member of FIG. 26;
[0043] FIG. 31 is a top view of the resiliently compressible cover layer of
the roofing support
system and roof support of FIG. 25 and the second sheet of hook material or
loop material
attached thereto;
[0044] FIG. 32 is a perspective view of another embodiment of a roofing
support system and
roof support as disclosed herein illustrating a core member with an integral
longitudinally-
extending shelf and attached resiliently compressible cover layer as described
herein;
Date Recue/Date Received 2021-05-07
[0045] FIG. 33 is a top view of the roofing support system and roof support
of FIG. 32;
[0046] FIG. 34 is a bottom view of the roofing support system and roof
support of FIG. 32;
[0047] FIG. 35 is a left side view of the roofing support system and roof
support of FIG. 32;
[0048] FIG. 36 is a right side view of the roofing support system and roof
support of FIG.
32;
[0049] FIG. 37 is a rear view of the roofing support system and roof
support of FIG. 32;
[0050] FIG. 38 is a front view of the roofing support system and roof
support of FIG. 32;
[0051] FIG. 39 is a perspective view of an embodiment of a lightweight
roofing support
system connector as described herein;
[0052] FIG. 40 is a top view of the roofing support system connector of
FIG. 39;
[0053] FIG. 41 is a bottom view of the roofing support system connector of
FIG. 39;
[0054] FIG. 42 is a left side view of the roofing support system connector
of FIG. 39;
[0055] FIG. 43 is a right side view of the roofing support system connector
of FIG. 39;
[0056] FIG.44 is a front view of the roofing support system connector of
FIG. 39;
[0057] FIG. 45 is a rear view of the roofing support system connector of
FIG. 39;
[0058] FIG. 46 is a bottom view of an embodiment of a roofing support
system connector of
FIGS. 39-45 connecting two roof supports to form an extended or extendable
roofing support
system and roof support as described herein;
[0059] FIG. 47 is a schematic side view of a roofing support system and
roof support as
described herein (e.g., FIG. 8) in use on a first sloped roof with a first
roof pitch and the second
side and second working surface facing upslope and providing a horizontal or
substantially
horizontal second working surface and a portable platform for support of a
roofing working or
roofing load;
[0060] FIG. 48 is a schematic side view of a roofing support system and
roof support as
described herein (e.g., FIG. 8) in use on a second sloped roof with a second
roof pitch and the
third side and third working surface facing upslope and providing a horizontal
or substantially
horizontal third working surface and a portable platform for support of a
roofing working or
roofing load;
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Date Recue/Date Received 2021-05-07
[0061] FIG. 49 is a side view of an embodiment of a roofing support system
and roof support
as disclosed herein illustrating an embodiment of a core member with an acute
rounded
triangular cross-section shape on a sloped roof with a roof pitch and the
third side and third
working surface facing upslope and providing a horizontal or substantially
horizontal third
working surface and a portable platform for support of a roofing working or
roofing load;
[0062] FIG. 50 is a schematic illustration of a roofing support system and
roof support as
disclosed herein illustrating that the second side or third side may be
oriented on sloped roofs
with a plurality of roof pitches to provide a horizontal or substantially
horizontal working surface
on these sloped roofs;
[0063] FIG. 51 is a schematic side view of two roofing support systems and
roof supports
(e.g., FIG. 8) in use on a sloped roof with a roof pitch disposed proximate
and on opposing sides
of the roof peak with the third sides and third working surfaces facing
upslope and providing a
horizontal or substantially horizontal third working surfaces and a peak
platform for support of a
roofing worker or roofing load at the roof peak;
[0064] FIG. 52 is a table illustrating representative properties of a core
material comprising
expanded polypropylene (EPP);
[0065] FIG. 53 is a table illustrating representative properties of a cover
material comprising
a flexible polyurethane foam (FPF).
DESCRIPTION OF THE EMBODIMENTS
[0066] This invention comprises a lightweight composite roofing support
system comprising
a reversible dual or double-wedge that supports, or acts as a support for, a
load placed on a
sloped or pitched roof. The load may include a roofing worker (person), or
workers, or various
roofing materials or equipment, or a combination thereof. The lightweight
composite roofing
support system may be used without the requirement of fasteners to hold it in
place. As used
herein, roofing workers includes any person performing work on the roof of a
house or other
building for any purpose, including those that repair, remove, or install
roofing materials, as well
as painters, carpenters, siding installers, seasonal light installers,
satellite installers, HVAC
equipment installers, homeowners, and any other person that has occasion to
perform work upon
a sloped or pitched roof, particularly a steeply sloped or pitched roof, as
described herein. As
used herein, roofing material may include any material or equipment or tool
placed on the roof of
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Date Recue/Date Received 2021-05-07
a house or other building either temporarily or permanently, including roofing
construction or
repair materials, such as shingles, metal panels, boards, wooden or composite
sheet or board
underlayment, rolled roofing products, solar panels, vents, nails, staples, or
screws, or materials
or equipment that are placed on or in or protrude from a roof, such as various
antennas, satellite
dishes, chimney materials, skylights, windows, air conditioning components,
and the like. The
lightweight composite roofing support system represents an improvement over
existing roofing
support systems, sloped roof article holders and roof leveling platforms. The
lightweight
composite roofing support system can be used by roofing workers as a stable,
non-skid platform
to walk, stand, crouch, kneel, sit, or lie on, or stack, place or otherwise
stage or store roofing
materials or equipment on. The design allows the dual or double wedge to be
manufactured at
different lengths and for roofing workers as users to move freely along the
length of the wedge
analogous to the manner in which roofing workers would move along a
traditional jack board
that is used in combination with a plurality of roof jacks that are anchored
to the roof with
attachments such as nails or screws. The lightweight composite roofing support
system
advantageously does not require that it be anchored to the roof deck by the
insertion of nails or
screws with the resultant perforation of the upper portion of the shingles,
underlayment, or
wooden roof deck, which are all known leakage paths for water that occurs on
the roof as a result
of condensation, rain, hail, snow, or ice, for example. In one embodiment, the
lightweight
composite roofing support system or dual or double-wedge comprises a molded
polymer support
or core member with a plurality of support sides configured to provide a level
working surface
for at least two different specific roof slopes or pitches, and a
substantially level work surface
over a range of similar roof slopes that are greater than and less than the
specific roof slopes, that
has an attached cover layer or roof contact layer attached to a roof contact
side that is configured
to contact and provide compliance and adhesion to a steeply sloped roof
surface. The core
member also has integral handles or grips formed on opposed ends that may be
used to easily lift
or carry the roofing support system onto the sloped roof (e.g., up a ladder)
or while working on
the sloped roof.
[0067] In
one embodiment, the lightweight composite roofing support system or dual wedge
comprises a molded plastic support or core member with a plurality of support
sides and a
selectively attachable/detachable cover layer or roof contact layer and
integral handles or grips
formed on opposed ends.
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Date Recue/Date Received 2021-05-07
[0068] In one embodiment, the lightweight composite roofing support system
or wedge
comprises a molded plastic support or core member with a plurality of support
sides and a
selectively attachable/detachable base and cover layer or roof contact layer
and integral handles
or grips formed on opposed ends.
[0069] The cross-sectional shape of the molded plastic support or core
member may be
configured with a triangular (e.g., scalene triangular), truncated triangular,
scalene trapezoid, or
irregular quadrilateral shape, for example, to provide a level working surface
to move, walk,
stand, crouch, kneel, sit, or lie on, or stack, place or otherwise store
roofing materials or
equipment on for two different specific roof slopes (e.g. 10/12 and 12/12),
and a substantially
level work surface over a range of roof slopes that are slightly less than or
greater than the
specific roof slopes, by merely rotating the base or roof contact surface of
the wedge 180
degrees. The cover layer or roof contact layer includes a cover or roof
contact material, such as
various open-cell or closed-cell foams, including polyurethane foam, and
natural or synthetic
sponge rubber, and the like that advantageously provide a non-skid attachment
or adhesion to
most roof surfaces, particularly asphalt or fiberglass shingle roof surfaces,
and including
common roofing underlayment materials (e.g. asphalt felt, rubberized felt, and
polymer or
synthetic underlayment) or roof deck materials (e.g. dimensional lumber,
plywood, and oriented
strand board (OSB)). The cover or roof contact material may be configured to
provide a
coefficient of sliding friction, particularly when loaded, that in some
embodiments prevents
sliding movement down the roof, and other embodiments substantially prevents
or resists sliding
movement down the roof. Cost and weight are kept at a minimum while
maintaining robustness
by eliminating moving parts and the need for fasteners, such as nails and
screws, found in related
art devices.
[0070] In one embodiment, a triangular, truncated triangular, scalene
trapezoidal, or irregular
quadrilateral cross-sectional shape may be configured to provide dual or
double-wedge lateral
cross-sectional shape and a level working surface for two different roof
slopes by merely rotating
the wedge 180 degrees. In one embodiment, the level working surfaces of the
support sides
comprise a non-slip material, or include a surface roughness, texture, or
pattern of protruding
traction elements (e.g. raised rectangular, chevron, or wavy bars, or circular
buttons) that provide
a non-slip surface. The lightweight composite roofing support system or dual
or double-wedge
may include integral handles or grips, including integrally molded handles or
grips, for easy
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Date Recue/Date Received 2021-05-07
transportation, including lifting or carrying the system onto a roof, and
repositioning of the
system or wedge on the roof while working.
[0071] As used herein, longitudinal or along the length refers to a
direction that extends
along an article centerline or axis, and may also be used in reference to a
direction that is
generally parallel to a roof peak. The term lateral or along the width or left-
right refers to a
direction that is orthogonal, or substantially orthogonal, to the longitudinal
direction. The terms
up or upward or down or downward refer to the top or bottom of the article, or
to a direction
substantially toward the top or bottom of the article, respectively, and may
also be used in
context in reference to a direction that is generally upward toward a roof
peak or downward
toward the ground. The terms in or inward refer to a direction toward the
center of the article,
and out or outward refers to the opposite direction away from the center or
central portion of the
article. The term upslope or up-roof refers to a direction or placement toward
or closer to the
peak or apex of a sloped roof and, conversely, the term downslope or down-roof
refers to a
direction or placement away from or farther from the peak or apex of a sloped
roof and closer to
the ground.
[0072] Referring to the figures, and particularly FIGS. 1-14 and 47-51, for
example, a
lightweight composite roofing support system 10 is disclosed. The lightweight
composite
roofing support system 10 is a roofing support or platform that supports a
roofing load 2. The
roofing load may be any static or dynamic roofing load 2 placed on a sloped or
pitched roof 36,
including a load from the weight of a roofing worker 6 or workers, or a
roofing material 8, such
as shingles 99 (e.g. asphalt or fiberglass shingles), rolled roofing material
(e.g. tar paper,
adhesive polymer snow and ice shield), structural members (e.g. dimensional
lumber),
underlayment (e.g. sheets of oriented strand board (OSB) and/or plywood), wood
or clay or
ceramic roofing tiles, metal roofing panels, solar shingles (e.g. solar panels
applied directly to the
roof and also serving as the roof covering) or solar roof panels (e.g. solar
panels disposed onto or
above the roofing material) and/or fasteners, or loads associated with any
other construction
materials (e.g. paint containers, siding, all manner of construction tools
and/or equipment, and
the like) placed thereon. In certain embodiments, the lightweight composite
roofing support
system 10 may also be referred to as a roof step or roof platform because it
provides a platform
for a worker, or workers, to move, walk, stand, crouch, kneel, sit, or lie on,
or otherwise use as a
level work surface while working on a sloped or pitched roof 36. The
lightweight composite
Date Recue/Date Received 2021-05-07
roofing support system 10 may be used without the requirement of fasteners to
hold it in place.
In these embodiments, the weight of a roofing load 2 placed on the lightweight
composite
roofing support system 10 together with the coefficient of friction of the
contact surface of the
support system in contact on the surface of the sloped or pitched roof 36
provides sufficient
adhesion to secure the system to the roof. In one embodiment, the system 10
comprises a
composite because it comprises a longitudinally-extending core member 12 made
from a core
material 14 and a longitudinally-extending cover layer 16 made from a cover
material 18.
Referring to the figures, and particularly FIGS. 8-14, in one embodiment, the
lightweight
composite roofing support system 10 described herein comprising longitudinally-
extending core
member 12 and longitudinally-extending cover layer 16 comprises a length of 24
inches and
weighs 60-100 oz., more particularly 70-90 oz., and more particularly 75-85
oz. In another
embodiment, the lightweight composite roofing support system 10 described
herein comprising
longitudinally-extending core member 12 and a longitudinally-extending cover
layer 16
comprises a length of 32 inches and weighs 80-134 oz., more particularly 93-
120 oz., and more
particularly 100-113 oz.
[0073] As illustrated, for example, in FIGS. 1-14 and 47-51, in one
embodiment, the
lightweight composite roofing support system 10 includes a longitudinally-
extending core
member 12 comprising a dual or double-wedge lateral cross-section 22 shape ,
more particularly
a reversible, dual or double-wedge cross-section 22 shape having different
acute wedge angles
(a, 0 that comprises two opposed wedges 11, 13 in an opposed dual or double-
wedge lateral
cross-section 22 shape configuration having different acute wedge angles with
the thin edges of
the opposed wedges 11, 13 facing outwardly. The dual or double-wedge lateral
cross-section 22
shape may be understood from the end views as shown, for example, in FIGS. 4
and 5 and the
cross-sectional view of FIG. 9B. The thin edges of the wedges 11, 13 need not
taper to a sharp
edge or line as in a traditional wedge, but rather may taper to blunted or
rounded edges or
shoulders, such as longitudinally-extending first edge 24 and a longitudinally-
extending second
edge 26 as shown in FIGS. 1, 4 and 5, for example. The blunted or rounded
edges or shoulders
are advantageous because they are damage-resistant and less susceptible to
damage during use
by chipping or breaking off while being used by roofing workers 6 on a sloped
roof 36 in the
manner described herein or when being transported or stored off-roof together
with other roofing
equipment and/or materials as is typical in the roofing industry.
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Date Recue/Date Received 2021-05-07
[0074] In one embodiment, the longitudinally-extending core member 12
comprises a
longitudinally-extending first roof contact side 28 or roof facing side 28.
The first roof contact
side 28 or roof facing side of the core member is the side of the core member
that is oriented to
directly or indirectly contact or face the sloped or pitched roof 36 or
whatever other surface the
lightweight composite roofing support system 10 is to be placed on. While the
core member 12
itself is not generally placed in direct contact with the roof surface or
other contact surface,
although in some configurations it could be, the term first roof contact side
28 or roof facing side
refers to the orientation of this side toward or closest to the sloped or
pitched roof 36, or
whatever other surface the lightweight composite roofing support system 10 is
to be placed on.
The first roof contact side 28 is configured to receive the cover layer 16
made from a cover
material 18 that also faces and is in direct contact with the sloped or
pitched roof 36. The roof
contact side 28 is generally rectangular or rounded rectangular and comprises
a longitudinally-
extending first edge 24 and an opposed longitudinally-extending second edge 26
and has a first
width (wi) and a first length (11) that is greater than the first width. In
one embodiment, the first
roof contact side 28 has a generally flat planar shape. In one embodiment, the
longitudinally-
extending first roof contact side includes a first slot opening 40 comprising
a first slot or pocket
41 that is defined by the first inner slot wall 42 and a first recess lip 43
that protrudes inwardly
toward the longitudinally axis 9 and extends around the periphery of the first
recess 45 that is
formed in the first end 46 of the longitudinally-extending core member 12. The
first recess lip
43 may be spaced apart from the first inner slot wall 42 by any suitable
spacing (dl), which in
one embodiment is 0.5-2.0 inches, more particularly 0.75-1.25 inches. The
first recess lip 43
protrudes inwardly from the first slot base 47, and may protrude inwardly any
suitable height
(hi), which in one embodiment is 0.3-1.0 inches, and more particularly 0.4-
0.75 inches, and have
any suitable thickness (ti) measured from the first end 46 and the first outer
slot wall 49, which
in one embodiment is 0.3-1.0 inches, and more particularly 0.4-0.75 inches.
The first slot base
47 also extends around the periphery of the first recess 45. The first slot or
pocket 41 and first
recess lip 43 define a first handle or grip 48 that may be gripped by a hand
of a roofing worker 6,
for example, for carrying or movement of the roof support 32. In one
embodiment, the
longitudinally-extending first roof contact side includes an opposed second
slot opening 50
proximate the opposed second end 56 that may comprise a minor image of the
first slot opening
40. The opposed second slot opening 50 comprising a second slot or pocket 51
that is defined by
12
Date Recue/Date Received 2021-05-07
the second inner slot wall 52 and a second recess lip 53 that protrudes
inwardly toward the
longitudinally axis 9 and extends around the periphery of the second grip
recess 55 that is formed
in the second end 56 of the longitudinally-extending core member 12. The
second recess lip 53
and second outer slot wall 59 may be spaced apart from the second inner slot
wall 52 by any
suitable spacing (d2), which in one embodiment is 0.5-2.0 inches, more
particularly 0.75-1.25
inches. The second recess lip 53 protrudes inwardly from the second slot base
57, and may
protrude inwardly any suitable height (h2), which in one embodiment is 0.3-1.0
inches, and more
particularly 0.4-0.75 inches, and have any suitable thickness (t2) measured
from the second end
56 and the second outer slot wall 59, which in one embodiment is 0.3-1.0
inches, and more
particularly 0.4-0.75 inches. The second slot base 57 also extends around the
periphery of the
second handle or grip recess 55. The second slot or pocket 51 and second
recess lip 53 define a
second handle or grip 58 that may be gripped by the hand of a roofing worker
6, for example, for
carrying or movement of the roof support 32.
[0075] The longitudinally-extending core member 12 also comprises a
longitudinally-
extending second side 30 comprising a second side working surface 31 having a
second width
(w2) and a second length (12) that is greater than the second width, and
tapering toward the
longitudinally-extending first edge 24 at a first predetermined acute angle
(a) from the first roof
contact side 28. The longitudinally-extending first side 28 and the
longitudinally-extending
second side 30 taper toward one another at the longitudinally-extending first
edge 24. The
longitudinally-extending second side 30 may also be referred to as the second
load-bearing side
30 and is configured to receive and support the roofing load 2 depending on
the orientation of the
lightweight composite roofing support system 10 on the roof 36 and which of
the longitudinally-
extending second side 30 or longitudinally-extending third side 34 is oriented
upslope as shown
in FIGS. 47 and 48. The longitudinally-extending second side 30 comprising a
second side
working surface 31 is a generally flat, planar, continuous surface, that is
configured for use as
described herein by a roofing worker, and in a preferred embodiment will not
include any raised
or recesses features or other surface discontinuities, other than non-skid or
traction elements
described herein, that would be recognized by those of ordinary skill in the
roofing arts as a
potential safety hazard, such as a potential stumbling or tripping hazard to a
roofing worker.
[0076] The longitudinally-extending core member 12 also comprises a
longitudinally-
extending third side 34 comprising a third side working surface 33 having a
third width (w3) and
13
Date Recue/Date Received 2021-05-07
a third length (13) that is greater than the third width, and tapering toward
the longitudinally-
extending second edge 26 at a second predetermined acute angle (13) from the
longitudinally-
extending first roof contact side 28. The longitudinally-extending third side
34 may also be
referred to as the third load-bearing side 34 and is also configured to
alternately receive and
support the roofing load 2 depending on the orientation of the lightweight
composite roofing
support system 10 on the roof 36 and which of the longitudinally-extending
second side 30 or
longitudinally-extending third side 34 is oriented upslope as shown in FIGS.
47 and 48. The
longitudinally-extending third side 34 comprising a second side working
surface 33 is a
generally flat, planar, continuous surface, that is configured for use as
described herein by a
roofing worker, and in a preferred embodiment will not include any raised or
recesses features or
other surface discontinuities, other than non-skid or traction elements
described herein, that
would be recognized by those of ordinary skill in the roofing arts as a
potential safety hazard,
such as a potential stumbling or tripping hazard to a roofing worker.
[0077] In one embodiment, as illustrated in FIG. 47, in a first
configuration or orientation
where the longitudinally-extending first edge 24 is defined by the
intersection of the
longitudinally-extending first side 28 and longitudinally-extending second
side 30 and the
predetermined first acute angle (a) between these sides is configured for
placement facing up-
roof closest to the peak 39 or apex of the sloped roof 36 with the
longitudinally-extending first
roof contact side 28 facing and cover layer 16 in pressing contact against the
sloped roof 36 and
the longitudinally-extending first edge 24 substantially parallel or parallel
to the peak. In this
configuration, the predetermined first acute angle (a) may be selected to be
the same as a
common first roof angle or pitch 38 (e.g., a 10/12 pitch) of the sloped roof
36, which in the case
of a 10/12 pitch (39.81 ) roof 36 means that the predetermined first angle (a)
is also 39.81 , so
that the second side 30 extends in the direction of the first peak 39 as a
substantially horizontal or
horizontal first platform, which advantageously provides a very useful
substantially level or level
longitudinally-extending second side working surface 31 on the sloped roof 36
for use as
described herein. As used herein, substantially parallel includes minor
misorientations of the
longitudinally-extending first edge 24 with the line defined by the first peak
39 such that they are
non-parallel, and the longitudinally-extending second side 30 is not level,
but rather substantially
level although it may be slightly inclining or declining as compared to the
first peak 39 of the
first sloped roof 36. One of ordinary skill in the roofing arts will
understand that substantially
14
Date Recue/Date Received 2021-05-07
parallel orientations still provide a very advantageous and useful
longitudinally-extending second
side working surface 31 of longitudinally-extending second side 30 as compared
to the
alternative of using the steeply first pitched roof 36 as the working surface.
One of ordinary skill
in the roofing arts will also understand that the orientation with the
longitudinally-extending first
edge 24 at the intersection of longitudinally-extending first side 28 and
longitudinally-extending
second side 30 and defining predetermined first acute angle (a) is placed
facing up-roof closest
to the peak 39, and substantially parallel or parallel to the peak, that the
lightweight composite
roofing support system 10 also provides a very advantageous and useful
longitudinally-extending
second side working surface 31 (i.e. second side 30) for first sloped or
pitched roofs 36 with a
range of similar roof pitches that are greater than and less than the
predetermined first acute
angle (a) and the first predetermined roof angle or pitch 38 (e.g. a 10/12
pitch) as illustrated
schematically in FIG. 50. In one embodiment, where the predetermined first
acute angle (a) is
39.81 corresponding to a 10/12 first predetermined roof angle or pitch 38,
the range of similar
roof pitches may comprise a range of 14/12 to 7/12 (excluding 10/12), or more
particularly 12/12
to 8/12 (excluding 10/12), even though the longitudinally-extending second
side working surface
31 of second side 30 is only substantially horizontal, not completely
horizontal, or level on these
roofs. This is because the slight inward or outward slope of the second side
working surface 31
of longitudinally-extending second side 30 over this range of similar roof
pitches is still very
advantageous and much preferred compared to working without the lightweight
composite roof
support system 10 and using the actual roof surfaces of these steeply pitched
roofs 36 as the
working surface to support roofing loads 2, particularly in the case of
roofing workers 6 trying to
move, walk, stand, crouch, kneel, sit, or lie on, or to stack, place or
otherwise stage or store
roofing materials 8 or equipment on, the sloped roof 36 as shown in FIG. 50.
In one
embodiment, the second side working surface 31 comprises a second side non-
skid surface
61over all, or a portion or portions, of the second side working surface 31.
In one embodiment,
the second side non-skid surface 61 comprises a second side surface texture or
surface
roughness, or a predetermined second side pattern, such as an embossed
pattern. The second
side non-skid surface 61 may be formed by adding a non-skid material after
molding, or
integrating a non-skid material or materials to the second side working
surface 31 during
molding, to provide a second side surface texture or pattern, or may be
integrally formed in the
core material of the second side working surface 31 by molding the same into
the surface as an
Date Recue/Date Received 2021-05-07
embossed pattern, for example. In one embodiment, the second side working
surface 31
comprises a second side non-skid surface 61 comprising a plurality of
integrally formed second
side protrusions 60 projecting upwardly from the second side working surface
31 as second side
traction elements 62. The protrusions may have any suitable shape or profile
as viewed from
above, including various circular, rectangular, chevron, herringbone, or whorl
shapes. In one
embodiment, the second side protrusions 60 have a protruding rectangular shape
and are
disposed in an array or pattern comprising a plurality of spaced apart columns
and rows and
comprise a plurality of second side traction bars or elements 62.
[0078] As illustrated in FIGS. 47 and 48, in one embodiment the lightweight
composite
roofing support system 10 is also reversible and configured for an alternate
use in a second
configuration or orientation on another sloped roof or sloped roofs 36' having
a second
predetermined roof pitch 38', or range of pitches, that is different from the
first predetermined
roof pitch 38 or range of pitches. Alternately, in this embodiment, as will
easily be understood
by one of ordinary skill both from FIGS 1-14 and 47-50, the second
configuration or orientation
(FIG. 48) of lightweight composite roofing support system 10 may be reversed,
rotated or
otherwise changed by 180 from the first orientation (FIG. 47) so that
predetermined second
acute angle (0) is placed facing up-roof closest to the second peak 39' or
apex of another or
second steeply pitched roof 36' or roofs having a second predetermined roof
pitch 38', or range
of pitches, that is different than the first predetermined roof pitch 38. In
the second configuration
or orientation, the longitudinally-extending second edge 26 is defined by the
intersection of the
longitudinally-extending third side 34 and the longitudinally-extending first
roof contact side 28
and the predetermined second acute angle (0) between these sides is configured
for placement
facing up-roof closest to the second peak 39' or apex of the second sloped
roof 36' with the
longitudinally-extending first side 28 facing and cover layer 16 in pressing
contact against the
sloped roof 16 and the longitudinally-extending second edge 26 substantially
parallel or parallel
to the peak. In this configuration, the predetermined second acute angle (0)
may be selected to
be the same as a second predetermined roof angle or pitch 38' (e.g., a 12/12
pitch) of the sloped
roof 36, which in the case of a 12/12 pitch (45 ) roof 36 means that the
predetermined second
acute angle (0) is also 45 , so that the longitudinally-extending third side
34 extends in the
direction of the second peak 39' as a substantially horizontal or horizontal
second platform,
which advantageously provides a very useful substantially level or level
longitudinally-extending
16
Date Recue/Date Received 2021-05-07
third side working surface 33 on the second sloped roof 36' for use as
described herein. As used
herein, substantially parallel includes minor misorientations of the
longitudinally-extending
second edge 26 with the line defined by the second peak 39' such that they are
non-parallel, and
third side 34 is not level, but rather substantially level although it may be
slightly inclining or
declining as compared to the second peak 39' of the second steeply sloped roof
36'. One of
ordinary skill in the roofing arts will understand that substantially parallel
orientations still
provide a very advantageous and useful longitudinally-extending third side
working surface 33
of longitudinally-extending third side 34 as compared to the alternative of
using the second
steeply pitched roof 36' as the working surface. One of ordinary skill in the
roofing arts will also
understand that the orientation with the longitudinally-extending second edge
26 at the
intersection of longitudinally-extending third side 34 and longitudinally-
extending first side 28
and defining predetermined second acute angle (13) is placed facing up-roof
closest to the peak
39, and substantially parallel or parallel to the peak, that the lightweight
composite roofing
support system 10 also provides a very advantageous and useful longitudinally-
extending third
side working surface 33 (i.e. third side 34) for second sloped or pitched
roofs 36' with a range of
similar roof pitches that are greater than and less than the predetermined
second acute angle (13)
and the second predetermined roof angle or pitch 38' (e.g. a 12/12 pitch). In
one embodiment,
where the predetermined second acute angle (13) is 45 corresponding to a
12/12 second
predetermined roof angle or pitch 38', the range of similar roof pitches may
comprise a range of
16/12 to 9/12 (excluding 12/12), or more particularly 14/12 to 10/12
(excluding 12/12), even
though the longitudinally-extending third side working surface 33 of
longitudinally-extending
third side 34 is only substantially horizontal, not completely horizontal, or
level on these roofs.
This is because the slight inward or outward slope of the third side working
surface 33 of the
longitudinally-extending third side 34 for these roof pitches is still very
advantageous and much
preferred compared to working without the roof support system and using the
roof surfaces of
these steeply pitched roofs 36' as the working surface to support roofing
loads 2, particularly in
the case of roofing workers 6 trying to move, walk, stand, crouch, kneel, or
sit on the roof as
shown in FIG. 50. In one embodiment, the third side working surface 33
comprises a third side
non-skid surface 63 over all, or a portion or portions, of the third side
working surface 33. In one
embodiment, the third side non-skid surface 63 comprises a third side surface
texture or surface
roughness, or a predetermined third side pattern, such as an embossed pattern,
which may the
17
Date Recue/Date Received 2021-05-07
same or different than the second side non-skid surface 61. The third side non-
skid surface 63
may be formed by adding a non-skid material after molding, or integrating a
non-skid material or
materials to the third side working surface 33 during molding, to provide a
third side surface
texture or pattern, or may be integrally formed in the core material 14 of the
third side working
surface 33 by molding the same into the surface as an embossed pattern. In one
embodiment, the
third side working surface 33 comprises a third side non-skid surface 63
comprising a plurality
of integrally formed third side protrusions 65 projecting upwardly from the
third side working
surface 33 as third side traction elements 66. The protrusions may have any
suitable shape or
profile as viewed from above, including various circular, rectangular,
chevron, herringbone, or
whorl shapes. In one embodiment, the third side protrusions 65 have a
protruding rectangular
shape and are disposed in an array or pattern comprising a plurality of spaced
apart columns and
rows and comprise a plurality of third side traction bars or elements 66.
[0079] In one embodiment, even though the second side working surface 31
may incorporate
first non-skid surface 61 that may include traction elements 62 and third side
working surfaces
33 may incorporate second non-skid surface 63 that may include traction
elements 66, these
working surfaces are generally planar and only include features that enhance
the working surface
for use by a roofing worker 6 (e.g., enhance traction or provide a non-skid
surface), including the
ability to move, walk, stand, crouch, kneel, sit, or lie on the surface
safely, and will not include
raised elements or features that protrude above the non-skid surface 63 or
traction elements 66,
such as raised trays or raised edges, or alternately recessed features, such
as recessed trays or
recessed features, that would make these surfaces non-planar and that one of
ordinary skill in the
art would understand to represent potential tripping or loss-of-balance
hazards or otherwise
comprise a safety hazard, since it is understood that the steeply sloped roofs
36 where
lightweight composite roofing support system 10 are particularly advantageous
require the
avoidance and/or elimination of all such hazards.
[0080] In one embodiment the longitudinally-extending core member 12
comprises a dual or
double-wedge lateral cross-section 22 shape that is substantially uniform or
the same along the
longitudinal axis 9, and in other embodiments that is substantially uniform or
the same along the
longitudinal axis except in the regions proximate the opposed first end 46 and
second end 56,
which include first slot opening 40 and first handle or grip recess 45 and
second slot opening 50
and second handle or grip recess 55, respectively (e.g., FIGS. 1-14). In one
embodiment, the
18
Date Recue/Date Received 2021-05-07
dual or double-wedge lateral cross-section 22 comprises a scalene triangular
cross-section shape
that is substantially uniform or uniform along the longitudinal axis 9, and in
other embodiments
is a scalene triangle that is substantially uniform or uniform along the
longitudinal axis except in
the regions proximate the opposed ends, such as second end 56 (e.g. FIG. 49),
which, for
example, includes second slot opening 50 and second handle or grip recess 55,
and has identical
end features to those shown in FIGS. 1-14. The longitudinally-extending first
roof contact side
28 is the hypotenuse of the scalene triangular cross-section shape and the
shorter sides of the
scalene triangle comprise the of the longitudinally-extending second side 30
and longitudinally-
extending third side 34 as shown in FIG. 49.
[0081] In another embodiment, the lateral cross-section 22 comprises an
irregular convex
quadrilateral shape and/or trapezium shape (where none of the sides are of
equal length) and/or a
truncated scalene triangle (that is truncated proximate what would otherwise
be the obtuse angle
of the scalene triangle) that is substantially uniform or the same size along
the longitudinal axis,
and in other embodiments is substantially uniform or the same along the
longitudinal axis except
in the regions proximate the opposed first end 46 and second end 56, which
include first slot
opening 40 and first handle or grip recess 45 and second slot opening 50 and
second handle or
grip recess 55, respectively (e.g., FIGS. 1-14). The longest side of the
irregular convex
quadrilateral and/or trapezium and/or truncated scalene triangle comprises the
longitudinally-
extending first roof contact side 28, and the sides adjacent to the
longitudinally-extending first
side 28 comprise the longitudinally-extending second side 30, and
longitudinally-extending third
side 34. The irregular convex quadrilateral and/or trapezium and/or truncated
scalene triangle
also comprises a fourth side 35 as shown in FIGS. 1-14. In this embodiment,
where the lateral
cross-section 22 comprises an irregular convex quadrilateral and/or trapezium
and/or truncated
scalene triangle the longitudinally-extending fourth side 35 is not parallel
to the longitudinally-
extending first side 28. The longitudinally-extending fourth side 35 is
generally not a working
surface because of the rather extreme slope (e.g., FIGS 47, 48), but rather a
transition surface
that extends between the second side 30 and the third side 34. However, in one
embodiment, the
fourth side 35 may optionally include a plurality of optional recesses or
pockets 60 (e.g., FIG. 1)
formed therein that may be used to temporarily hold and/or store any
predetermined item,
including various construction or roofing materials or equipment described
herein, such as
replacement nails for a nailing gun, for example. In one embodiment
illustrated schematically in
19
Date Recue/Date Received 2021-05-07
FIGS. 4 and 5, the dual or double-wedge lateral cross-section 22 shape may
comprise a scalene
trapezoidal shape and the longitudinally-extending fourth side 35' is parallel
to the
longitudinally-extending first side 28. While useful, a scalene trapezoidal
lateral cross-section
22 generally reduces the width (w2 or w3) of the second side 30 or third side
34 and the
respective size of the second side working surface 31 or third side working
surface 33 as may be
understood in FIGS. 4 and 5.
[0082] The longitudinally-extending core member 12 may have any suitable
configuration
and any suitable size. In one embodiment, the longitudinally-extending core
member 12 has an
integral one-piece configuration, which may be produced by molding or forming
the core
material 14 into the shape of the core member as illustrated in FIGS. 1-14,
for example. While
the size of the core member 12 may be characterized with regard to any of the
sides thereof, in
one embodiment, it is characterized by the size of the longitudinally-
extending first contact side
28. The longitudinally-extending first contact side 28 may comprise any
suitable length (11) and
width (wi). In one embodiment, the size may comprise a length (11) that ranges
from 20 to 144
inches, more particularly 24 to 72 inches, even more particularly 24 to 48
inches, and yet more
particularly 24-36 inches. In one embodiment, the size may comprise a width
(wi) that ranges
from 18 to 48 inches, more particularly 20 to 40 inches, even more
particularly 20 to 30 inches,
and yet more particularly 22-28 inches. In one embodiment, the length (11) is
greater than the
width (wi). In one embodiment, the second side length (12) and third side
length(13) are the same
as the first roof contact side length (11), the second side width (w2) and
third side width (w3) will
scale geometrically with the first roof contact side width (wi) and the
selection of acute angles
(a) and (0) together with the position, including width (w4) and angulation
from horizontal of
longitudinally extending fourth 35. In one embodiment, the length (11) ranges
from 24-48 inches,
the width (wi) ranges from 17-36 inches, the second side length (12) and third
side length(13) are
the same as the first roof contact side length (11), the second side width
(w2) ranges from 8-18
inches, a= 39.81 (e.g., an 10/12 pitch), the third side width (w3) ranges
from 8-18 inches, and
0=45 (e.g., a 12/12 pitch).
[0083] The longitudinally-extending core member may be formed from any
suitable core
material 14, including various metals, engineering thermoplastic or thermoset
polymers, or
composites thereof. In one embodiment, the core material 14 comprises a rigid
or substantially
rigid engineering thermoplastic or thermoset polymer. In one embodiment, the
core material 14
Date Recue/Date Received 2021-05-07
comprises a rigid or substantially rigid engineering thermoplastic or
thermoset polymer
comprising polystyrene (PS), polyethylene (PE), polypropylene (PP),
polyurethane (PU), or
ethylene-vinyl acetate (EVA), or a combination thereof, and more particularly
an expanded foam
comprising polystyrene (EPS), polyethylene (EPE), polypropylene (EPP),
polyurethane (EPU),
or ethylene-vinyl acetate (EEVA), or a combination thereof, which, as used
herein, includes
chemical or physical combinations thereof, including copolymers thereof. In
one embodiment,
the core material 14 comprises a rigid or substantially rigid expanded foam of
EPP having the
properties set forth in FIG. 52, or another expanded polymer foam having
properties within the
ranges set forth in FIG. 52, more particularly a density, compressive
strength, compression set,
tensile strength, and flexural strength within the ranges set forth in FIG.
52. In one embodiment,
the expanded foam comprises EPP or EEVA comprising a density of 1.25-12
lblft3, and more
particularly 2-8 lblft3, and more particularly 3-7 lblft3, and yet more
particularly 3-6 lblft3. The
core member 12 may be molded as an integral or one-piece component to include
all of the
elements described herein by any suitable molding or forming method, including
various
conventional molding methods employed to mold rigid or substantially rigid
engineering
thermoplastic or thermoset polymers, particularly rigid or substantially rigid
expanded
engineering thermoplastic or thermoset polymer foams, including injection
molding. In one
embodiment, as used herein, a rigid or substantially rigid core material 14
may be defined by the
material properties, particularly a compressive strength, compression set,
tensile strength and
flexural strength within the ranges set forth in FIG. 52. In another
embodiment, as used herein, a
rigid or substantially rigid core material may be defined as substantially non-
compressible (i.e.
experiences only a minor amount of elastic deformation) under a predetermined
roofing load 2
(1), including less than 10% elastic deformation under the predetermined
roofing load (1), more
particularly less than 5% deformation, and even more particularly less than 1%
deformation, and
includes ranges of 0.1-10% deformation, more particularly 0.1-5% deformation,
and even more
particularly 0.1-3% deformation. In one embodiment, the predetermined roofing
load 2 may
include the weight of at least one person, which in one embodiment ranges from
100 to 350 lbs.,
or the weight of at least one bundle of shingles, which in one embodiment
ranges from 40-80
lbs., or the weight of at least one roll of underlayment, which in one
embodiment ranges from
16-100 lbs., or a combination thereof. In other embodiments, the predetermined
roofing load 2
may include a plurality of the above items.
21
Date Recue/Date Received 2021-05-07
[0084] As illustrated in FIG. 49 in one embodiment, the roofing support
system 10 and first
roofing support 32 comprises a longitudinally-extending third side 34, and the
dual or double-
wedge shape lateral cross-section comprises a triangular lateral cross-
section, including a
generally or substantially scalene triangular lateral cross-section, with the
longitudinally-
extending third side 34 opposite the first predetermined angle (a) formed by
the convergence,
including the intersection, of the longitudinally-extending third side 34 and
the longitudinally-
extending second side 30. As used herein, generally or substantially with
reference to the cross-
sectional shape includes embodiments where the converging sides do not
actually intersect to
form a vertex, but rather shapes that include one or more blunted edge or
radii (e.g., ri, r2, r3 in
FIG. 49) in place of the vertices (e.g., a blunted or rounded triangular
shape), but where one of
ordinary skill would readily recognize a generally or substantially triangular
lateral cross-
sectional shape or form.
[0085] Referring to FIGS. 1-14 and 47-51, particularly FIGS. 8-14, in one
embodiment, the
lightweight composite roofing support system 10 comprises a longitudinally-
extending core
member 12 comprising a core material 14 as described herein and a
longitudinally-extending
resiliently compressible cover layer 16 comprising a resiliently compressible
cover material 18
that is disposed on and covering the longitudinally-extending first roof
contact side 28. In one
embodiment, the longitudinally-extending core member 12 and the longitudinally-
extending
resiliently compressible cover layer 16 comprise lightweight composite roofing
support system
and first roofing support 32. As used herein, the term "covering" in the
context of the
longitudinally-extending cover layer 16 covering the longitudinally-extending
first roof contact
side 28 comprises covering all or any portion of the longitudinally-extending
first roof contact
side. The term "covering" includes in certain embodiments covering at least a
portion of the
longitudinally-extending first roof contact side 28, and in certain other
embodiments includes
covering all or substantially all of longitudinally-extending first side 28,
and in certain other
embodiments may extend outwardly beyond the edges of the longitudinally-
extending first side
28, such as, for example, extending slightly outwardly of the longitudinally-
extending first side
28, including in the corners as shown in FIG. 9A, for example.
[0086] The longitudinally-extending resiliently compressible cover layer 16
may comprise
any suitable resiliently compressible cover material 18. In one embodiment,
the resiliently
compressible cover material comprises a resiliently compressible elastomer,
including thermoset
22
Date Recue/Date Received 2021-05-07
and thermoplastic elastomers. In one embodiment, the resiliently compressible
cover material
comprises a resiliently or reversibly compressible polymer, including a
resiliently compressible
polymer foam, and including a resiliently or reversibly compressible
elastomeric foam. The
resiliently or reversibly compressible elastomeric foam may include
resiliently or reversibly
compressible thermoset and/or thermoplastic elastomeric foams, and may include
both open-cell
and closed-cell foams. In one embodiment, the cover material 18 comprises a
resiliently or
reversibly compressible polymer, such as a resiliently or reversibly
compressible elastomeric
foam, and comprises polyurethane (PU), polystyrene (PS), polyisocyanurate
(PIR), polyethylene
(PE), polypropylene (PP), poly(ethylene-vinyl acetate) (EVA), poly(vinyl
chloride) (PVC), or a
natural or synthetic rubber, silicone, or a combination thereof which, as used
herein, includes
chemical or physical combinations thereof, including copolymers thereof. In
one embodiment,
the polyurethane (PU) foams may include both open-cell and closed-cell
polyether polyurethane
and polyester polyurethane foams. In one embodiment, the cover material 18
comprises a
resiliently or reversibly compressible open-cell polyether polyurethane foam.
In one
embodiment, the cover material 18 comprises a viscoelastic, low-resilience,
foam or memory
foam, particularly various polyurethane (PU) memory foams. In one embodiment,
the resiliently
compressible cover material comprises a resiliently or reversibly compressible
foam comprising
a flexible foam, particularly a flexible polyurethane foam (FPF). In one
embodiment, the cover
material 18 comprises a resiliently or reversibly compressible flexible open-
cell polyether
polyurethane foam (FPF) having properties within the ranges specified in FIG.
53, or other
resiliently or reversibly compressible open-cell foam having properties within
the ranges
specified in FIG. 53.
[0087]
In one embodiment, the resiliently compressible cover material 18 may be
selected as
a function of the material comprising the surface of the sloped roof 36. In
one embodiment, in
the case of sloped roofs comprising asphalt and plastic rolled roofing
materials, asphalt or
fiberglass shingles, wood (e.g., cedar shakes), which generally have high
surface roughness and
high abrasiveness, the cover material 18 may comprise a resiliently
compressible polymer foam,
such as a flexible open-cell polyether polyurethane foam (FPF) as described
herein. In another
embodiment, in the case of sloped roofs comprising ceramic shingles or tiles,
metal sheets, glass
sheets, and polymer sheets, which generally have low surface roughness and low
abrasiveness,
the cover material 18 may comprise a resiliently compressible polymer or
polymer foam, such as
23
Date Recue/Date Received 2021-05-07
natural or synthetic rubber and rubber foams, as well as silicone and silicone
foams. In another
embodiment, in the case of sloped roofs comprising shingles, tiles, sheets, or
panels comprising
ceramic, metal, glass, and polymer, which generally have low surface roughness
and low
abrasiveness, the cover material 18 may comprise a resiliently compressible
polymer or polymer
foam, such as natural or synthetic rubber and rubber foams, as well as
silicone and silicone
foams. In another embodiment, in the case of sloped roofs comprising shingles,
tiles, sheets, or
panels comprising ceramic, metal, glass, and polymer, which generally have low
surface
roughness and low abrasiveness, but which have been formed to include a shape
or texture of
another material (e.g., glass solar tiles or shingles formed to resemble
scalloped ceramic tiles or
natural slate tiles, or cedar shakes), the cover material 18 may comprise a
resiliently
compressible composite such as an upper layer of a resiliently compressible
polymer foam as
described herein, such as a polyurethane foam, which may be relatively
thicker, attached to a
lower layer (i.e. roof contact layer) of a resiliently compressible polymer or
polymer foam, such
as natural or synthetic rubber and rubber foams, as well as silicone and
silicone foams, which
may be relatively thinner. The composite provides an upper foam to enable
conformity to the
shape and larger texture features of the roof material (e.g., the shape of a
curved or scalloped tile
or flat with texture variation like a slate tile) and a lower layer of
resiliently compressible
polymer or polymer foam, such as natural or synthetic rubber and rubber foams,
as well as
silicone and silicone foams to ensure adhesion to the surface (e.g., glass).
[0088] The resiliently compressible cover layer 16 may comprise any
suitable shape and
size, including in the embodiment of FIGS. 8-14, substantially the same or the
same shape and
size (e.g., area) as the longitudinally-extending first roof contact side 28,
and in other
embodiments (not shown) a different size and shape as described herein. In one
embodiment,
the resiliently compressible cover layer 16 comprises a rectangular shape,
which includes various
rounded rectangular shapes, and comprises the same length and width, including
the same ranges
of length and width, disclosed herein for the longitudinally-extending first
roof contact side 28.
In one embodiment, the resiliently compressible cover layer 16 covers the
first slot opening 40
and the second slot opening 50 in the longitudinally-extending first roof
contact side 28. The
cover layer 16 may have any suitable thickness. In one embodiment, the
resiliently compressible
cover layer 16 has a thickness in the range of 0.020 to 2.5 inches, more
particularly 0.5 to 1.5
inches, more particularly 0.5 to 1.0 inches.
24
Date Recue/Date Received 2021-05-07
[0089] In the embodiment of FIGS. 1-14, the longitudinally-extending core
member 12
extends in the direction of axis 9, and the longitudinally-extending cover
layer 16 is configured
to be attached to and cover the core member. The longitudinally-extending
resiliently
compressible cover layer 16 may be attached to longitudinally-extending first
roof contact side
28 by any suitable attachment 69 or attachment mechanism, including in one
embodiment an
adhesive 70 disposed between them to form an adhesive joint 71 as the
attachment 69. Any
suitable adhesive 70 may be used as the adhesive to form the adhesive joint
71, including those
that are configured to provide a physical bond, or a chemical bond, or both,
between the
longitudinally-extending cover layer 16 and longitudinally-extending first
roof contact side 28
layer. In one embodiment, the adhesive 70 comprises a hot-melt adhesive,
particularly a
formulated hotmelt adhesive that is designed for adhesion to hard-to-adhere
substrates that has a
medium set speed, high heat resistance, and excellent low temperature bond
performance, such
as ADH, Hot Melt Adhesive M535-100N.1 sold by Sonoco0. The adhesive 70 may be
applied
in any suitable conventional manner and method to the upper surface of the
longitudinally-
extending cover layer 16 and/or to the longitudinally-extending first roof
contact side 28 layer,
including in one embodiment as a layer that covers the entirety of one or both
of these surfaces,
and including in another embodiment as a pattern of adhesive applied to one or
both of these
surfaces as described herein. The longitudinally-extending resiliently
compressible cover layer
16 and resiliently compressible cover material 18 may also be molded directly
onto the
longitudinally-extending core member 12 and core material 14, or vice versa,
such as by co-
molding where both elements are formed in a single mold, or by insert molding
where one of the
elements is formed separately and inserted into a mold for molding of the
other element onto it,
and the attachment comprises an integrally molded joint 71 comprising a
physical and/or
chemical bond formed at the interface between them, analogous to an integral
adhesive joint.
The attachment, such as an adhesive joint 71 or chemical bond as an attachment
will have an
adhesive shear strength that is greater than the shear forces at the interface
between the
longitudinally-extending cover layer 16 and the longitudinally-extending first
roof contact side
28 upon application of a roofing load 2 as described herein.
[0090] In one embodiment, the longitudinally-extending core member 12 may
be configured
to receive a plurality of different longitudinally-extending cover layers 16
and cover layer
materials 18. In one embodiment, the longitudinally-extending cover layers 16
and cover
Date Recue/Date Received 2021-05-07
materials 18 may be configured to provide adhesion for use of the lightweight
composite roofing
support system 10 on a plurality of different slope or pitched roof 36 types,
including different
roof decks comprising different deck materials, such as wood (e.g. OSB,
plywood, or cedar
shakes), various asphalt and plastic rolled roofing materials, asphalt or
fiberglass shingles,
plastic/composite/ceramic shingles or tiles, metal sheets, glass sheets,
polymer sheets and other
conventional roofing materials, as well as the glass surface of various solar
shingles and panels.
[0091] As shown in FIG. 51, in one embodiment the lightweight composite
roofing support
system 10 further includes a two roofing supports 32 that are substantially
identical and may
include the features in the embodiments described above. The roofing supports
32 may be
positioned on opposite sides of the peak 39 of a sloped roof as mirror images
of one another with
the longitudinally-extending second edges 26 of the wedges facing one another
with their
respective longitudinally-extending first roof contact sides 28,
longitudinally-extending second
sides 30, and longitudinally-extending third sides 34 all facing in the same
directions. When
placed in the positions shown proximate the peak 39 of a sloped roof 36, the
lightweight
composite roofing support system 10 comprising a plurality of opposed roofing
supports 32 may
be very advantageously used to provide a peak platform 68 that may be used by
roofing workers
6, or to store the roofing materials 8, as described herein, such as a
plurality of bundles 99 of
shingles, proximate the roof peak 39. A peak platform 68 is very desirable and
advantageous
location for storage of roofing materials 8 as they can be easily distributed
downslope to roofing
workers 6 that are progressively applying these materials upslope generally
from the eaves to the
peak 39 of a sloped roof 36. A peak platform 68 is also very desirable as it
provides a stable
platform at the roof peak 39 for vendors of roofing materials 8 to use
automated equipment to lift
the materials to and unload the materials on the roof peak, without the need
to manually unload
the materials and make makeshift platforms at the roof peak generally using
the construction
materials themselves and make makeshifts or temporary platforms (e.g., using
bundles of
shingles), so that the roofing materials are available for distribution
downslope during the
construction of the sloped roof.
[0092] In one embodiment, the pressing engagement of the longitudinally-
extending first
side 28 and the attached longitudinally-extending cover layer 16 is sufficient
to secure or attach
the lightweight composite roofing support system 10 to the sloped roof 36 and
prevent the
26
Date Recue/Date Received 2021-05-07
system and a roofing load 2 (once applied) from sliding down the sloped roof
36 without the use
of fasteners.
[0093] Referring to FIGS. 15-21, in one embodiment, the lightweight
composite roofing
support system 10 comprises a longitudinally-extending core member 12 as
described herein and
resiliently compressible cover layer 16 comprises a plurality of resiliently
compressible cover
layers 16 of resiliently compressible cover materials 18, which may be the
same cover material
18 differing in some aspect, such as a material property or characteristic
(e.g., thickness, density,
or the like), or different cover materials 18. While described with reference
to FIGS. 15-21, this
embodiment of cover layers 16 and cover materials 18 may be used in any of the
embodiments
of lightweight composite roofing support system 10 described herein in FIGS. 1-
53. A plurality
of resiliently compressible cover layers 16 and resiliently compressible cover
materials 18 may
be employed, for example, to provide variable or different material properties
at different
locations on longitudinally-extending first roof contact side 28. For example,
during
construction, the surface of sloped roofs 16 may be very abrasive, from the
innermost portion
comprising a plywood and/or OSB roof deck to the outermost portion comprising
asphalt or
fiberglass shingles, and it may be desirable to employ a different resiliently
compressible cover
material 18 in the higher wear areas of the cover layer 16, such as the areas
proximate the
laterally-extending first end 46 and/or opposed second end 56, or along all or
a portion of the
longitudinally-extending first edge 24 and/or the longitudinally-extending
second edge 26, since
the edges associated with these locations may experience more abrasion and
wear as the roof
supports 32 are moved (e.g. lifted up and down, dragged, tossed, thrown, slid,
scraped, etc.)
because they frequently are the last point of prior contact and the first
point of new contact or
impact during a move. Any of the resiliently compressible cover materials 18
described herein
may be used to provide a plurality of resiliently compressible cover layers 16
of resiliently
compressible cover materials 18. Thus, for example, in one embodiment, it is
desirable to place
one resiliently compressible cover layer 16 of resiliently compressible cover
material 18 with
higher wear resistance in the locations that are subject to higher wear (e.g.,
high wear areas), and
another resiliently compressible cover layer 16 of resiliently compressible
cover material 18 at
other locations that are subject to lower wear (e.g., low wear areas). In one
embodiment, for
example, the cover layer 16 comprises a plurality of resiliently compressible
cover layers 16
comprising a first resiliently compressible cover layer 16' comprising a first
resiliently
27
Date Recue/Date Received 2021-05-07
compressible cover material disposed in a central portion of the first roof
contact side and second
resiliently compressible cover layers 16" comprising second resiliently
compressible cover
materials 18" disposed proximate the first end 46 and the opposed second end
56 that are
different from the first resiliently compressible cover material 18'. The
difference in the first and
second cover layers 16', 16"and first and second cover materials 18', 18" may
be any
measurable difference in the cover materials, including the density, the
thickness, the wear
resistance, the coefficient of sliding friction on the roof deck material, the
cell type (e.g., closed-
cell, and open-cell), the cell size or porosity, a physical property (e.g.,
elastic modulus, tensile
strength, compressive strength, compression set, indentation force deflection
(IFD), flex fatigue,
tear resistance, or the like). In one embodiment, the first resiliently
compressible cover layer 16'
comprising the first resiliently compressible cover material 18' has a first
thickness and
comprises polyurethane (PU) and the second resiliently compressible cover
layers 16" and
second resiliently compressible cover materials 18" have a second thickness
(t2) that is less than
or equal to the first thickness and comprises polyurethane (PU), poly(ethylene-
vinyl) acetate
(EVA), natural rubber, or synthetic rubber, or a combination thereof.
[0094] Referring to FIGS. 22-24, in one embodiment, the lightweight
composite roofing
support system 10 comprises a longitudinally-extending core member 12 as
described herein,
wherein the longitudinally-extending first roof contact side 28 further
comprises a plurality of
longitudinally spaced apart first side recesses 72 (FIG. 24). The plurality of
longitudinally
spaced apart first side recesses 72 may include any suitable number of first
side recesses, which
in one embodiment comprises a range of 2-10, more particularly 2-8, and even
more particularly
3-6. The first side recesses 72 may have any suitable shape or size, including
various geometric
shapes, including circular, elliptical, triangular, rectangular, and other
polygonal shapes. In one
embodiment, the first side recesses comprise three longitudinally spaced apart
rectangular shape
recesses with the longer sides of the rectangles oriented laterally across the
width of the
longitudinally-extending first roof contact side 28. The first side recesses
72 may have any
suitable recess depth including a range of 0.25 to 1.5 inches, more
particularly 0.5 to 1.25 inches,
and even more particularly 0.5-1.0 inches. The first side recesses 72 may have
any suitable
recess sidewall 73 shape, including vertical recess sidewall, as well as
inwardly (e.g., toward the
center of the recess) and outwardly tapering recess sidewalls, as well as
curved or angled
28
Date Recue/Date Received 2021-05-07
sidewalls, including concave or convex curved or angled sidewalls that are
configured to provide
a snap lock engagement as described herein, or any combination of these
sidewall shapes.
[0095] In the embodiment of FIGS. 22-24, in addition to longitudinally-
extending core
member 12, the lightweight composite roofing support system 10 further
comprises a flexible,
longitudinally-extending integral or one-piece base 74 and cover layer 14
configured to be
disposed on a bottom surface 95 of the base. The base 74 is configured to be
disposed between
the core member 12 and the cover layer 14 and is selectively attachable to and
detachable from
the core member on the first roof contact side 28. The base 74 comprises a
generally planar
longitudinally-extending base member 75, a plurality of longitudinally spaced
apart base
protrusions 76 having protrusion sidewalls 77 extending upwardly from an upper
surface 78 of
the base member and corresponding for purposes of close fit, interference fit,
or snap-fit
engagement in number, shape, size, and protrusion sidewall 77 shape with the
first side recesses
72 and recess sidewall 73 shape. The base 74 and base member 75 also comprises
a
longitudinally-extending first tapered retainer lip 79 attached at a first
base member edge 80 and
configured to extend inwardly and upwardly along the longitudinally-extending
first base edge
24 and a portion of second side 30, a second tapered retainer lip 81 attached
at a second base
member edge 82 and configured to extend inwardly and upwardly along the
longitudinally-
extending second base edge 26 and a portion of third side 34, an upwardly-
extending first recess
insert 83 attached at a first base member end 84 and configured to be disposed
along the first end
46 of core member 12 within first recess 45 adjacent to first inner slot wall
42 by insertion
through first slot opening 40, and an upwardly-extending second recess insert
85 attached at a
second base member end 86 and configured to be disposed along the second end
56 of core
member 12 within second recess 55 adjacent to second inner slot wall 52 by
insertion through
second slot opening 50. The flexible, longitudinally-extending base 74 may be
formed from any
suitable lightweight flexible material, including various metals (e.g.,
aluminum, or magnesium
alloys, or combinations thereof), or engineering thermoplastic or thermoset
polymers, or a
combination thereof. Engineering thermoplastic or thermoset polymers may
comprise
polystyrene (PS), polyester (PEST), polycarbonate (PC), polyethylene (PE),
polypropylene (PP),
polyurethane (PU), or ethylene-vinyl acetate (EVA), or a combination thereof,
and more
particularly an expanded foam comprising polystyrene (EPS), polyethylene
(EPE),
polypropylene (EPP), polyurethane (EPU), or ethylene-vinyl acetate (EEVA), or
a combination
29
Date Recue/Date Received 2021-05-07
thereof, which, as used herein, includes chemical or physical combinations
thereof, including
copolymers thereof. Base 74, and particularly base member 75, may have any
suitable size and
shape, but will generally have the same general shape and size (e.g., length
and width) as the first
roof contact side 28 because it is designed and selected to be applied to and
to be selectively
attachable to and detachable from, and cover, the first roof contact side 28.
Thus, the ranges of
sizes and shapes described herein for first roof contact side 28 are also
generally applicable to the
base 74 and base member 75. Base member 75 may have any suitable thickness,
which in order
to retain flexibility as described herein, will depend on the material
selected, particularly the
mechanical properties including the elastic modulus, to be configured, both
laterally and
longitudinally, to be flexed or elastically bent or deformed outwardly by a
human user of average
strength to allow the first tapered retainer lip 79 to be inserted over and
engage the
longitudinally-extending first base edge 24 and a portion of the second side
30, the
longitudinally-extending second tapered retainer lip 81 to be inserted over
and engage the
longitudinally-extending second base edge 26 and a portion of the
longitudinally-extending third
side 34, the upwardly-extending first recess insert 83 to be disposed along
the first end 46 and
engage the first recess 45 and first inner slot wall 42 through first slot
opening 40, and the
upwardly-extending second recess insert 85 to be disposed along the opposed
second end 56 and
engage the second recess 55 and second inner slot wall 52 through second slot
opening 50, while
at the same time the spaced apart base protrusions 76 and protrusion sidewalls
77 engage the
respective corresponding first side recesses 72 and first recess sidewalls 73,
which in one
embodiment may comprise a press fit engagement, a slight interference fit
engagement, or a
snap-lock or snap-fit engagement with the first roof contact side 28 and the
upper surface 78 of
base member 75 in substantially or near touching contact or touching contact.
In one
embodiment, the base thickness (tB), may comprise 0.010 to 1.0 inches, more
particularly 0.1 to
0.75 inches, and more particularly 0.25 to 0.50 inches. Base member 75 will
generally have a flat
planar lower surface 81 that is configured for disposition of the resiliently
compressible cover
layer 16 thereon. In one embodiment, core member 12 does not include first
side recesses 72
and base member 75 does not include protrusions 76, but all other feature of
the core member 12
of FIGS. 1-7 and base 74 remain the same.
[0096] The first tapered retainer lip 79 may be configured to taper at any
suitable angle,
including in one embodiment first acute angle (a), and extend inwardly and
upwardly along the
Date Recue/Date Received 2021-05-07
longitudinally-extending first edge 24 and a portion of second side 30 to any
suitable extent or
distance, which in one embodiment may include 0.25 to 1.5 inches, more
particularly 0.5 to 1.0
inches. The uppermost edge of first tapered retainer lip 79 may also be
tapered down to the
second side 30 to provide close continuity with the first side working surface
31. The second
tapered retainer lip 81 may be configured to taper at any suitable angle,
including in one
embodiment second acute angle (0), and extend inwardly and upwardly along the
longitudinally-
extending second base edge 26 and a portion of third side 34 to any suitable
extent or distance,
which in one embodiment may include 0.25 to 1.5 inches, more particularly 0.5
to 1.0 inches.
The uppermost edge of second tapered retainer lip 81 may also be tapered down
to the third side
34 to provide close continuity with the second side working surface 34.
[0097] The upwardly-extending first recess insert 83 to be disposed along
the first end 46
and engage the first recess 45 and first inner wall 42 through first slot
opening 40 may comprise
any suitable shape configured for disposition and engagement as described. In
one embodiment,
the first recess insert 83 has the same shape as the opening shape of first
recess 45, namely, an
irregular hexagon shape comprising a lateral edge 87 having a second side end
88 and an
opposed third side end 89, a second side vertical edge 90 extending from the
second side end 88
upwardly toward second side 30, a third side vertical edge 91 extending from
the third side end
89 upwardly toward third side 34, a tapered second side edge 92 configured to
extend upwardly
parallel to second side 30, a tapered third side edge 93 configured to extend
upwardly parallel to
third side 34, a tapered fourth side edge 94 configured to extend parallel to
fourth side 35
between second side edge 92 and third side edge 93.
[0098] The upwardly-extending second recess insert 85 to be disposed along
the second end
56 and engage the second recess 55 and second inner slot wall 52 through first
slot opening 50
may comprise any suitable shape configured for disposition and engagement as
described. In
one embodiment, the second recess insert 85 has the same shape as the opening
shape of second
recess 55, namely, an irregular hexagon shape and comprises a minor image of
first recess insert
83, and may be described as having the same elements.
[0099] In an attached position and condition the base 74 comprising base
member 75 is
disposed against the first roof contact side 28, the first tapered retainer
lip 79 is disposed over
and retains the first edge 24, the second tapered retainer lip 81 is disposed
over and retains the
second edge 26, the first recess insert 83 is disposed in the first recess 45,
the second recess
31
Date Recue/Date Received 2021-05-07
insert 85 is disposed in the second recess 55, and the plurality of spaced
apart base protrusions 76
are disposed in and engage the spaced apart first side recesses 72, and the
cover layer 16 is
attached to the bottom surface 95 of the base. The first side recesses 72/
base protrusions 76 and
recess inserts 83, 85 serve to index the core member 12 and base 74 during
attachment of the
base to the core member.
[00100] In the embodiment of FIGS. 22-24, the cover layer(s) 16 and cover
material(s) 18
may comprise those described in any of the embodiments of lightweight
composite roofing
support system 10 described herein. The cover layer(s) 16 may be disposed on
the base 74 in
any suitable matter using any suitable attachment, including using any cover
layer attachment
described in any of the embodiments of lightweight composite roofing support
system 10
described herein.
[00101] Referring to FIGS. 25-31, in one embodiment, the lightweight composite
roofing
support system 10 comprises a longitudinally-extending core member 12 as
described herein,
wherein the longitudinally-extending first roof contact side 28 further
comprises a first side
recess 72 (FIG. 26). In one embodiment, the first side recess 72 comprises a
single recess 72, but
in other embodiments may comprise a plurality of longitudinally spaced apart
first side recesses
72 (e.g., FIG. 24 with 3 recesses) in any suitable number as described herein.
The first side
recesses 72 may have any suitable shape or size, including various geometric
shapes, including
circular, elliptical, triangular, rectangular, and other polygonal shapes. In
one embodiment (FIG.
26), the first side recess 72 comprises an I-shaped recess. In these
embodiments, the first side
recesses 72 may have any suitable recess depth including a range of 0.01 to
0.5 inches, more
particularly 0.025 to 0.375 inches, and even more particularly 0.05 to 0.25
inches. The first side
recesses 72 may have any suitable recess sidewall 73 shape, including vertical
recess sidewall, as
well as inwardly (e.g., toward the center of the recess) and outwardly
tapering recess sidewalls,
as well as curved sidewalls, including concave or convex curved sidewalls, or
any combination
of these sidewall shapes. In this embodiment, the first side recess 72 lowers
the attachment
interface below the plane of longitudinally-extending first roof contact side
28 such that the shear
forces applied to the attachment during use of lightweight composite roofing
support system 10
advantageously do not occur in the plane of the first roof contact side.
[00102] In the embodiment of FIGS. 25-31, in addition to longitudinally-
extending core
member 12, the lightweight composite roofing support system 10 further
comprises a hook and
32
Date Recue/Date Received 2021-05-07
loop attachment device 100 disposed between the core member and the cover
layer 16. The
attachment device 100 comprising a first sheet 101 of a loop material 102
comprising a plurality
of hooks or a hook material 103 comprising a plurality of loops that is
disposed in and attached
to the first side recess 72 and a second sheet 104, respectively, of hook
material 103 comprising
a plurality of loops or loop material 102 comprising a plurality of hooks that
is attached to the
cover layer 16, wherein in an attached position and condition the first sheet
101 and the second
sheet 104 are in pressed interlocking engagement with the respective plurality
of hooks lockingly
engaging the plurality of loops, and wherein the cover layer 16 is selectively
attachable to and
detachable from the core member 12 using the attachment device 100. The first
sheet 101 and
second sheet 104 may have any suitable size and shape, including the same size
and shape as the
shape of the first side recess 72, which in one embodiment may be I-shaped.
The attachment
device 100 may be described as a hook and loop attachment device 100 and also
as a selectively
attachable and detachable attachment device 100 that provides a selectively
attachable and
detachable attachment of the cover layer 16 to the core member 12. The use of
selectively
attachable and detachable attachment device 100 allows for the easy removal
and replacement of
a worn cover layer 16 with a new replacement cover layer by peeling the first
sheet 101 and
second sheet apart 103 as the cover layer becomes worn during use on a sloped
roof 36 or roofs.
This also enables the lightweight composite roofing support system 10 to
include kitting of a
plurality of replacement cover layers 16 as described below that include the
second sheet 108
attached thereto with a core member 12 that has the first sheet attached
thereto to extend the
service life of the lightweight composite roofing support system 10 by
selectively removing
cover layers 16 as they become worn in use and replacing the worn cover layers
with new cover
layers 16 from the kit. Alternately, it allows the kitting of a plurality of
cover layers 16 as
described below that include the second sheet 108 attached thereto as a
replacement pack of
cover layers 16 to also extend the service life of the lightweight composite
roofing support
system 10 indefinitely by buying additional kits of the cover layers 16 and
replacing the cover
layers as they become worn during use.
[00103] The first sheet 102 comprises the loop material 102 comprising the
plurality of hooks
or the hook material 103 comprising the plurality of loops and is disposed
within and attached to
the first side recess 72. The first sheet 101 has an adhesive side 105 that is
configured to receive
an adhesive 106, which may be applied directly to the adhesive side 105 or to
the recess surface
33
Date Recue/Date Received 2021-05-07
107 of the first side recess 72. The adhesive 106 attaches the first sheet 101
to the recess surface
107 within the first side recess 72. The first sheet 101 has an opposed side
108 that comprises
the loop material 102 comprising the plurality of hooks or the hook material
103 comprising the
plurality of loops. Any adhesive 106 suitable to permanently adhere the first
sheet 101 to the
recess surface 107 may be used, including the adhesives 70 described herein.
[00104] The second sheet 104 comprising, respectively with regard to the
selection first sheet
101 and whether it includes a hook material or loop material to be the
opposite or mating
material, the hook material 103 comprising a plurality of loops or the loop
material 102
comprising the plurality of loops is disposed on and attached to the cover
layer 16. The second
sheet 103 has an adhesive side 109 that is configured to receive an adhesive
110, which may be
applied directly to the adhesive side 109 or to the attachment surface 111 of
the cover layer 16 in
the shape of the second sheet. The adhesive 110 attaches the second sheet 103
to the attachment
surface 111 of the cover layer 16, generally by pressing the second sheet 103
against the cover
layer 16. The second sheet 103 has an opposed side 112 that comprises,
respectively, the hook
material 103 comprising the plurality of loops or the loop material 102
comprising the plurality
of hooks. Any adhesive 110 suitable to permanently adhere the second sheet 103
to the
attachment surface 111 may be used, including the adhesive 106 or adhesive 70
described herein.
[00105] In the embodiment of FIGS. 25-31, the longitudinally-extending first
roof contact
side 28 comprises a peripherally-extending rim 112 that encloses and defines a
sidewall 113 of
the first side recess 72. The peripherally-extending rim may have any suitable
rim thickness (tR).
The thickness will be selected to maximize the area of the first side recess
while also reducing
the potential for chipping or breakout of the rim 112 and sidewall 113 during
use of the
lightweight composite roofing support system 10. In one embodiment, rim
thickness (tR)
comprises a range of 0.25 to 1.0 inches, more particularly 0.25 to 0.75
inches, and even more
particularly 0.375 to 0.5 inches.
[00106] Referring to FIGS. 32-38, in one embodiment, the lightweight composite
roofing
support system 10 comprises a longitudinally-extending core member 12 as
described herein,
which further comprises an integral longitudinally-extending shelf 114 that
also extends
outwardly and laterally away from at least one of the second side 30 or the
third side 34 and
comprises a lower surface 115 that is coplanar with and by virtue of being
integral with forms a
part of the first roof contact side 28 and that, respectively, subsumes at
least one of the second
34
Date Recue/Date Received 2021-05-07
edge 24 or third edge 26. The longitudinally-extending core member 12
comprising the integral
longitudinally-extending shelf 114 may be formed from the same core materials
14 described
herein and may have the same sizes and same lateral cross-section 22 shapes of
the core
members described herein apart from the integration of the lateral cross-
section 122 shape of the
shelf 114. The lateral cross-section shape 122 of the shelf 114 may be
understood from the left
and right end views (FIGS. 35 and 36) to be substantially rectangular in
embodiments without
the integral upwardly-protruding longitudinally-extending rim 117 (as
demarcated by the vertical
phantom lines), and generally L-shaped with the integral upwardly-protruding
longitudinally-
extending rim 117. The longitudinally-extending core member 12 comprising the
integral
longitudinally-extending shelf 114 may have the same ranges of lengths
described herein. The
integral longitudinally-extending shelf 114 may have any suitable width (ws),
which in one
embodiment ranges from 6 to 20 inches, more particularly 8 to18 inches, and
more particularly
to 18 inches, and yet more particularly (12 to 16 inches). The integral
longitudinally-
extending shelf 114 may have any suitable shelf thickness (ts), which in one
embodiment ranges
from 0.5 to 2.0 inches, more particularly 0.75 to 1.75 inches, and more
particularly 0.75 to 1.50
inches. It is desirable to make the shelf 114 as thin and strong as possible
while maintaining
flexural and tensile strength sufficient to support the desired shelf loads 98
and avoid failure of
the shelf in bending due to application of these loads. In this regard, in one
embodiment, the
longitudinally-extending core member 12 comprising the integral longitudinally-
extending shelf
114 may be molded with a variable density which is a lower density in the
upper portions (du) of
core member away from the shelf and higher density (&) in the integral
longitudinally-extending
shelf 114 and portions of the longitudinally-extending core member 12
proximate the shelf as
illustrated schematically in FIGS. 35 and 36 as demarcated by optional
interface 116. Variable
density of the core material 14 within the core member 12 may be employed in
any of the
embodiments of core member 12 described herein, and the density may be
infinitely variable or
discretely variable throughout all or any portion of the core member 16 cross-
section 22, and be
lower in the upper portions and higher in the lower portions, or vice versa,
and may also be
varied longitudinally, laterally, or both, within core member 12. The shelf
114 is configured to
hold roofing material 8 as described herein, including various tools and
equipment, particularly
roofing tools and equipment, and particularly a bundle or bundles of shingles
99 for use by a
roofing working 6 that is disposed on and using the lightweight composite
roofing support
Date Recue/Date Received 2021-05-07
system 10 that includes the integral shelf 114. The integral shelf 114 may be
very
advantageously used to provide a portable platform that may be used to store
the roofing
materials 8 as described herein, such as a bundle or bundles of shingles 99,
in a plurality of
locations on the sloped roof 36 as the roofing materials are being installed
and may be easily
moved upslope or downslope or side-to-side from the eaves to the peak 39 of a
sloped roof 36 to
facilitate installation. This is a very desirable and advantageous location
for storage of roofing
materials 8 as they can also be easily distributed upslope or downslope or
side-to-side to roofing
workers 6 that are also installing materials on the sloped roof 36. In one
embodiment, the
integral longitudinally-extending shelf 114 further comprises an integral
upwardly-protruding
longitudinally-extending rim 117 on a distal edge or end 118 of the shelf to
assist in retaining
items that are placed on the shelf.
[00107] Referring again to FIGS. 32-38, the lightweight composite roofing
support system 10
comprises a longitudinally-extending core member 12 as described herein and
the longitudinally-
extending cover layer 16 comprising cover material 18 will be sized to also
cover all or
substantially all of the first roof contact surface, including the portion
associated with the lower
surface 115 of the shelf 114. Representative ranges of the width (wi') of the
first roof contact
side 28 comprising the shelf 114 and associated cover layer 16 may be obtained
by adding their
representative ranges as described herein without the shelf (wi) to the
representative ranges of
the width (ws) of the shelf described herein, for example, (18 to 48 inches) +
(6 to 20) inches =
wi'= (24 to 68 inches), more particularly (20 to 40) inches + (8 to18) inches
= wi'= (28 to 58
inches), even more particularly (20 to 30 inches) + (10 to 18 inches) = wi'=
(30 to 48 inches),
and yet more particularly (22 to 28 inches) + ( 12 to 16 inches) = wi'= (32 to
44 inches).
[00108] In the embodiment of FIGS. 32-38, the cover layer 16 and cover
material 18 may
comprise those described in any of the embodiments of lightweight composite
roofing support
system 10 described herein. The cover layer 16 may be disposed on the first
roof contact side in
any suitable manner using any suitable attachment, including using any cover
layer attachment
and associated features in the first roof contact side 28 required for
implementation of any of the
embodiments of the lightweight composite roofing support systems 10 described
herein,
including the embodiments of FIGS. 1-31.
[00109] Referring to FIGS. 1-46, and particularly FIGS. 1-14 and 39-46, the
lightweight
composite roofing support system 10 and roof support 32 may comprise a
lightweight composite
36
Date Recue/Date Received 2021-05-07
roofing support system connector 120. The lightweight composite roofing
support system
connector 120 is configured to connect the first end 46 of one roofing support
32 to the second
end of another roofing support 32. Using a plurality of roofing connectors 120
and roofing
supports 32, the length of lightweight composite roofing support system 10 may
be extended to
any desired length, including a length that extends entirely from side-to-side
across the length of
any sloped roof. Thus, the connectors 120 and roof supports 32 can provide an
extended roof
platform 123 that extends entirely from side-to-side across any sloped roof
36, allowing roofing
workers to freely move, walk, stand, crouch, kneel, sit, or lie on, or
otherwise use the extended
roof platform and to distribute or store roofing tools or roofing materials
across all or any portion
of the length of any sloped roof, as well as to store or stage roofing
materials across all or any
portion of the length of any sloped roof. The extended roof platform 123 also
allows very
advantageous and easier distribution of roofing materials 8 from a central
peak platform 68
across the sloped roof 36 near the roof peak 39 where they can be distributed
downslope to areas
where the materials are being applied to the roof deck.
[00110] Referring to FIGS. 1-14 and FIGS. 39-46, the longitudinally-extending
connector 120
comprises a laterally-extending first connector end 124 and an opposed
laterally-extending
second connector end 126 joined together by a longitudinally-extending
intermediate portion
128. The first connector end 124 is configured for selective
engagement/disengagement or
insertion/removal within the second slot 51' of the second core member 12' and
second roof
support 32' and the second connector end 126 is configured for selective
engagement/disengagement or insertion/removal within the first slot 41 of the
first core member
12 and first roof support 32, wherein upon engagement, the connector 120 is
configured to
connect the first roof support 32 and the second roof support 32'. FIG. 46
illustrates the first core
member 12 and the second core member 12' with their compressible cover layers
16, 16'
removed for purpose of illustrating the connection or joint formed by the
connector 120. In
normal use, the portions of the compressible cover layers 16, 16' that extend
over first slot
opening 40 and second slot opening 50' would be longitudinally and/or
laterally manually
compressed to reveal the first slot opening 40 and second slot opening 50' and
enable insertion
of the connector 120 with the second connector end 126 inserted into the first
slot 41 and the first
connector end 124 inserted into the second slot 51'. Upon insertion of the
connector 120, the
portions of the compressible cover layers 16, 16' that would extend over first
slot opening 40 and
37
Date Recue/Date Received 2021-05-07
second slot opening 50' would be released and spring back over and cover the
first slot opening
40 and second slot opening 50'. The portions of the compressible cover layers
16, 16' that
extend over first slot opening 40 and second slot opening 50' act as a
retainer and prevent the
connector from coming back out of the first slot 41 through the first slot
opening 40 and/or the
second slot 51' through second slot opening 50' during use.
[00111] The laterally-extending first connector end 124 and an opposed
laterally-extending
second connector end 126 may have any suitable lateral cross-section shapes or
sizes. In one
embodiment, the first end lateral cross-section 130 shape of the first
connector end 124
comprises an irregular hexagon and the shape of the second slot 51' also
comprises a mating
irregular hexagon cross-section shape, and second end lateral cross-section
132 shape of the
second connector end 126 comprises an irregular hexagon that is a mirror image
of the first
connector end 124 and the shape of the first slot 40 also comprises a mating
irregular hexagon
cross-section shape that is a mirror image of the second slot 51'. The size,
particularly the first
end width (wEi), of the first connector end 124 should be the same as, or
slightly greater than, the
width (d2) of the second slot 51' to provide, respectively, touching contact
or an interference fit
between them in order to promote retention of the first connector end 124
within the second slot
51'. The size, particularly the second end width (wE2), of the second
connector end 126 should
be the same as, or slightly greater than, the width (di) of the first slot 40
to provide, respectively,
touching contact or an interference fit between them in order to promote
retention of the second
connector end 126 within the first slot 40. In one embodiment, the first
connector end 124 has
the same first end lateral cross-section 130 shape as the opening shape of
first recess 45, namely,
an irregular hexagon cross-section shape comprising a lateral edge 134 having
a second side
edge end 135 and an opposed third side edge end 136, a second side vertical
edge 137 extending
from the second side edge end 135 upwardly toward second side 30, a third side
vertical edge
138 extending from the third side edge end 136 upwardly toward third side 34,
a tapered second
side edge 139 configured to extend upwardly parallel to second side 30, a
tapered third side edge
140 configured to extend upwardly parallel to the third side 34, a tapered
fourth side edge 141
configured to extend parallel to fourth side 35 between second side edge 139
and third side edge
140.
[00112] The second connector end 126 may comprise any suitable second end
lateral cross-
section 132 shape configured for disposition and engagement as described. In
one embodiment,
38
Date Recue/Date Received 2021-05-07
the second connector end 126 has the same second end lateral cross-section 132
shape as the
opening of the second recess 55, namely, an irregular hexagon shape and
comprises a minor
image of the first end lateral cross-section 130 shape of the first connector
end 124, and may be
described as having the same elements as the first connector end 124.
[00113] The first connector end 124 also comprises a first base 142. In one
embodiment, the
first base 142 comprises a flat planar base and is configured in the inserted
or installed condition
and position to be coplanar with the first roof contact side 28'. The second
connector end 126
also comprises a second base 143. In one embodiment, the second base 143
comprises a flat
planar base and is configured in the engaged, inserted or installed condition
and position to be
coplanar with the first roof contact side 28.
[00114] The lightweight composite roofing support system connector 120 also
comprises the
longitudinally-extending intermediate portion 128. The intermediate portion
128 may have any
suitable intermediate portion cross-section shape, which in one embodiment is
the same as first
end lateral cross-section 130 shape and second end lateral cross-section 132
shape with a reduced
size as shown in FIGS. 39-46.
[00115] The lightweight composite roofing support system connector 120 is
formed from and
comprises connector material 144. Connector material 144 may comprise any of
the core
materials 14 described herein, and may be selected to be the same material as
core material 14 or
different than core material 14. Since the cross-section area or size of the
intermediate portion
128 is less than the lateral cross-section 22 of the core members 12, 12', in
one embodiment the
connector 120 will comprise connector material 144 that has one or more of a
higher density,
compressive strength, compression set, tensile strength, or flexural strength
as the core material
14 to ensure consistent strength of the extended platform 123 along its
length, and more
particularly that the strength is at least as high in the connector 120 at the
interface between roof
supports 32 and 32' at first end and second end 51' as it is in the
intermediate portions of the
supports.
[00116] Referring to FIGS. 8-14, and 46, in one embodiment, the lightweight
composite
roofing support system connector 120 is configured for use with a first roof
support 32 and the
second roof support 32' (the first and second roof supports 32, 32' being
identical or having the
same essential feature and differing, if at all, only in length (e.g., (11,
li') with the (') used only to
differentiate between them), each comprising: a longitudinally-extending core
member 12, 12'
39
Date Recue/Date Received 2021-05-07
comprising a longitudinally-extending first roof contact side 28, 28'
comprising a longitudinally-
extending first edge 24, 24' and an opposed longitudinally-extending second
edge 26, 26', a
longitudinally-extending second side 30, 30' comprising a second side working
surface 31, 31'
having a second width (w2 W2') and a second length (12,12') that is greater
than the second width,
the second side 30, 30' tapering toward the first edge 24, 24' at a first
predetermined acute angle
(a) from the first roof contact side 28, 28', and a longitudinally-extending
third side 34, 34'
comprising a third side working surface 33, 33' having a third width and a
third length that is
greater than the third width, the third side 34, 34' tapering toward the
second edge 26, 26' at a
second predetermined acute angle (13,13') from the first contact side 28, 28'
that is different than
the first predetermined acute angle (a, a'), a laterally-extending first end
46, 46' comprising an
integral first recess 45, 45' defining a first handle or grip 48, 48', and an
opposed laterally-
extending second end 56, 56' comprising an integral second recess 55, 55'
defining a second
handle or grip 58, 58', the core member 12, 12' comprising a core material 14,
14' and a wedge-
shaped lateral cross-section 22, 22' shape. The first roof support 32 and the
second roof support
32' also each comprise a cover layer 16, 16' comprising a compressible cover
material 18, 18',
the cover layer 16, 16' disposed on and covering the first roof contact side
28, 28', wherein the
first recess 45, 45' defines a first slot 41, 41' that opens into the
longitudinally-extending first
roof contact side 28, 28' proximate the first end 46, 46' and the second
recess 55, 55' defines a
second slot 51, 51' that opens into the first roof contact side 28, 28'
proximate the second end
56, 56', the first connector end 124 is configured for mating engagement
within the second slot
51' of the second roof support 12', the second connector end 126 configured
for mating
engagement within the first slot 41, respectively, of the first roof support
32. FIG. 46 illustrates
an installed or inserted position and condition of the connector 120 within
the first roof support
32 and the second roof support 32'. In one embodiment, the first connector end
124 comprises
an irregular hexagonal first end lateral cross-section 130 shape and second
connector end 126
comprises an irregular hexagonal second end lateral cross-section 132 shape,
and the first slot 41
comprises an irregular hexagonal lateral first slot cross-section 130 shape
illustrated by the shape
of recess 45 opening and the second slot 51' comprises an irregular hexagonal
lateral second slot
cross-section shape illustrated by the shape of recess 55' opening. In one
embodiment, irregular
hexagonal first end lateral cross-section 130 shape and irregular hexagonal
second end lateral
cross-section 132 shape are minor images of one another.
Date Recue/Date Received 2021-05-07
[00117] In other embodiments, the connector 120 may have another first end
lateral cross-
section 130 shape and another second end lateral cross-section 132 shape. For
example,
referring to the embodiment of a core member 12 comprising a triangular
lateral cross-section
22, more particularly a rounded or blunted scalene triangular lateral cross-
section, as described
herein and illustrated in FIG. 49, a suitable connector 120 would have the
irregular pentagon
cross-section shape of the periphery of the handle or grip 58, and could be
described using the
same elements as set for herein for connector 120, except that there would be
no tapered fourth
side edge 141 configured to extend parallel to fourth side 35 between second
side edge 139 and
third side edge 140, rather second side edge 139 and third side edge 139 would
taper to and
intersect one another. This lightweight composite roofing support system
connector 120 also
comprises the longitudinally-extending intermediate portion 128. The
intermediate portion 128
may have any suitable intermediate portion cross-section shape, which in one
embodiment is the
same as first end lateral cross-section 130 shape and second end lateral cross-
section 132 shape,
namely, an irregular pentagon with a size or cross-sectional area smaller than
the first end lateral
cross-section 130 and the second end lateral cross-section 132.
[00118] The terms "a" and "an" herein do not denote a limitation of
quantity, but rather
denote the presence of at least one of the referenced items, and may include a
plurality of the
referenced items. The modifier "about" used in connection with a quantity is
inclusive of the
stated value and has the meaning dictated by the context (e.g., includes the
degree of error
associated with measurement of the particular quantity). Furthermore, unless
otherwise limited
all ranges disclosed herein are inclusive and combinable (e.g., ranges of "up
to about 25 weight
percent (wt.%), more particularly about 5 wt.% to about 20 wt.% and even more
particularly
about 10 wt.% to about 15 wt.%" are inclusive of the endpoints and all
intermediate values of the
ranges, e.g., "about 5 wt.% to about 25 wt.%, about 5 wt.% to about 15 wt.%",
etc.). The use of
"about" in conjunction with a listing of items is applied to all of the listed
items, and in
conjunction with a range to both endpoints of the range. Finally, unless
defined otherwise,
technical and scientific terms used herein have the same meaning as is
commonly understood by
one of skill in the art to which this invention belongs. The suffix "(s)" as
used herein is intended
to include both the singular and the plural of the term that it modifies,
thereby including one or
more of that term (e.g., the metal(s) includes one or more metals). Reference
throughout the
specification to "one embodiment", "another embodiment", "an embodiment", and
so forth,
41
Date Recue/Date Received 2021-05-07
means that a particular element (e.g., feature, structure, and/or
characteristic) described in
connection with the embodiment is included in at least one embodiment
described herein, and
may or may not be present in other embodiments.
[00119] It is to be understood that the use of "comprising" in conjunction
with the
components or elements described herein specifically discloses and includes
the embodiments
that "consist essentially of" the named components (i.e., contain the named
components and no
other components that significantly adversely affect the basic and novel
features disclosed), and
embodiments that "consist of' the named components (i.e., contain only the
named components).
[00120] While the invention has been described in detail in connection with
only a limited
number of embodiments, it should be readily understood that the invention is
not limited to such
disclosed embodiments. Rather, the invention can be modified to incorporate
any number of
variations, alterations, substitutions or equivalent arrangements not
heretofore described, but
which are commensurate with the spirit and scope of the invention.
Additionally, while various
embodiments of the invention have been described, it is to be understood that
aspects of the
invention may include only some of the described embodiments. Accordingly, the
invention is
not to be seen as limited by the foregoing description, but is only limited by
the scope of the
appended claims.
42
Date Recue/Date Received 2021-05-07
