Roof mount with integral sealant

Abstract

Apparatuses for roof mounting, as well as methods for assembling and installing roof mounting apparatuses, are provided. An exemplary roof mounting apparatus may include a mount and fasteners configured to engage with a mounting surface. The fasteners may be configured to attach the mount to the mounting surface when engaged with the mounting surface. The roof mounting apparatus may further include a compressible sealant disposed between a bottom of the mount and the mounting surface when the mount is attached to the mounting surface. The sealant is thus compressed upon engagement between the fasteners and the mounting surface, and the compressed sealant may flow to fill a volume of the space between the bottom of the mount and the mounting surface.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of and priority to U.S. Non-Provisional Patent Application No. 18 / 236,353, entitled "ROOF ATTACHMENT WITH INTEGRATED SEALANT," filed August 21, 2023, which in turn claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 399,603, entitled "ROOF ATTACHMENT WITH INTEGRATED SEALANT," filed August 19, 2022, the complete disclosure of which is expressly incorporated herein by reference in its entirety.

[0002]

[0001] This disclosure relates generally to roof attachments, and more particularly to roof attachments with integrated sealants. [Background technology]

[0003] Current roof fixtures typically require some method of preventing water from seeping in through fastener holes or other points where the roof is penetrated to secure the fixture. Roof fixtures often use a sealant or caulking applied during installation of the roof fixture, flashing to divert water that runs off through the roof penetration, or both. Applying sealant to a roof can be a time-consuming and messy process, and the use of flashing can be costly and cause unintended damage. The present invention reveals a cleaner, faster, and more cost-effective method for securing and sealing roof fixtures to a roof surface. Summary of the Invention

[0004]

[0003] Embodiments of the present invention include roof mounting apparatus, as well as methods for assembling and installing the roof mounting apparatus. An exemplary roof mounting apparatus may include a mount and fasteners configured to engage a mounting surface. The fasteners may be configured to attach the mount to the mounting surface when engaged with the mounting surface. The roof mounting apparatus may further include a compressible sealant disposed between the bottom of the mount and the mounting surface when the mount is attached to the mounting surface. The sealant is thus compressed upon engagement between the fasteners and the mounting surface, and the compressed sealant may flow to fill the volume of the space between the bottom of the mount and the mounting surface.

[0005] To explain how the above-mentioned and other advantages and features of the present disclosure can be obtained, a more particular description of the principles briefly described above will be rendered by reference to specific embodiments illustrated in the accompanying drawings, in which the principles herein have been described and explained with added specificity and detail through the use of the accompanying drawings, with the understanding that these drawings depict only exemplary embodiments of the present disclosure and are not intended to limit the scope thereof. [Brief explanation of the drawings]

[0006] [Figure 1]

[0005] FIG. 1 is an isometric view showing an exemplary roof fixture with an integrated sealant in an assembled state. [Figure 2A]

[0006] FIG. 1 is an isometric view showing an exemplary protective cover that may be used with a roof fixture with an integrated sealant. [Figure 2B]

[0007] FIG. 2B is a cross-sectional side view of the protective cover of FIG. 2A. [Figure 2C]

[0008] FIG. 2B is a top view of the exemplary protective cover of FIG. 2A. [Figure 3A]

[0009] FIG. 1 is an isometric view of an exemplary roof fixture with integral sealant in a pre-installed state. [Figure 3B]

[0010] FIG. 3B is a side view of the example roof mount of FIG. 3A in a pre-installed state. [Figure 3C]

[0011] 3B is a bottom view of the example roof mount of FIG. 3A in a pre-installed state. [Figure 4A]

[0012] FIG. 10 is a top view of an exemplary roof fixture with an integral sealant in an alternative embodiment. [Figure 4B]

[0013] FIG. 4B is a side view of the example roof mount of FIG. 4A. [Figure 4C]

[0014] FIG. 4B is an isometric view of the example roof mount of FIG. 4A. [Figure 4D]

[0015] 4B is another isometric view of the example roof mount of FIG. 4A. [Figure 5A]

[0016] 1 is an exploded view of an exemplary roof fixture with an integral sealant in an unassembled state. [Figure 5B]

[0017] 5B is another exploded view of the exemplary roof mount of FIG. 5A in an unassembled state. [Figure 6]

[0018] FIG. 2 is a side cutaway view showing an exemplary roof mount in an assembled state. [Figure 7A]

[0019] FIG. 1 is an isometric vertical cutaway view showing an exemplary roof fixture in an assembled state with the sealant omitted to reveal the interior of the roof fixture. [Figure 7B] FIG. 1 is an isometric vertical cutaway view showing an exemplary roof fixture in an assembled state with the sealant omitted to reveal the interior of the roof fixture. [Figure 8A]

[0020] 1A-1C illustrate various stages of an exemplary installation of a roof mount on a mounting surface. [Figure 8B] 1A-1C illustrate various stages of an exemplary installation of a roof mount on a mounting surface. [Figure 8C] 1A-1C illustrate various stages of an exemplary installation of a roof mount on a mounting surface. [Figure 8D]1A-1C illustrate various stages of an exemplary installation of a roof mount on a mounting surface. [Figure 8E] 1A-1C illustrate various stages of an exemplary installation of a roof mount on a mounting surface. [Figure 9A]

[0021] FIG. 1 is an isometric view of an exemplary roof fixture in an assembled state. [Figure 9B]

[0022] 9B is a cutaway view of the exemplary roof mount of FIG. 9A. [Figure 9C]

[0023] FIG. 9B is an isometric view of the exemplary roof mount of FIG. 9A in an installed state. [Figure 9D]

[0024] 9B is a cutaway view showing the exemplary roof mount of FIG. 9A in an installed state. [Figure 9E]

[0025] 9B is an isometric view of the exemplary roof mount of FIG. 9A in an installed state with additional roof fasteners installed through additional mount fastener openings into the installation surface. [Figure 9F]

[0026] 9B is a cutaway view showing the example roof mounting fixture of FIG. 9A in an installed state with additional roof fasteners installed through additional mount fastener openings into the mounting surface. [Figure 9G]

[0027] 9B is an isometric view of the example roof fixture of FIG. 9A in an installed state with the connection mechanism engaged with the roof fixture's mount. [Figure 10A]

[0028] 1 is an isometric view of an exemplary roof fixture having a mount and a protective cover with multiple mount fastener openings. FIG. [Figure 10B]

[0029] FIG. 10 is an isometric view of an alternative roof attachment having a mount and a protective cover with multiple mount fastener openings. [Figure 11A]

[0030] FIG. 2 is an exploded view of an exemplary roof mount without a vertical flange in an unassembled state. [Figure 11B]

[0031] FIG. 11B is an isometric view of the roof mount of FIG. 11A in an assembled state. [Figure 11C]

[0032] FIG. 11B is an isometric bottom view of the roof mount of FIG. 11A in an assembled state. [Figure 11D]

[0033] FIG. 11B is a cutaway view showing the roof mount of FIG. 11A in an assembled state. [Figure 12A]

[0034] FIG. 1 is an exploded view showing an exemplary mount without a vertical flange in an unassembled state. [Figure 12B]

[0035] FIG. 12B is a cutaway view of the exemplary mount of FIG. 12A. [Figure 12C]

[0036] FIG. 12B is an isometric bottom view of the exemplary mount of FIG. 12A in an installed state. [Figure 13A]

[0037] 1 is an exploded view of an exemplary roof fixture with an integral sealant in an unassembled state. [Figure 13B]

[0038] FIG. 13B is an isometric view of the roof mount of FIG. 13A in an assembled state. [Figure 13C]

[0039] FIG. 13B is a cutaway view showing the roof mount of FIG. 13A in an assembled state. [Figure 14A]

[0040] 1 is an exploded view of an exemplary roof fixture with an integral sealant in an unassembled state. [Figure 14B]

[0041] FIG. 14B is a cutaway view showing the roof mount of FIG. 14A in an assembled state. [Figure 14C]

[0042] FIG. 14B is an isometric view of the roof mount of FIG. 14A in an assembled state. [Figure 14D]

[0043] FIG. 14B is an isometric view of the roof mount of FIG. 14A in an installed state. [Figure 15A]

[0044] 1 is an exploded view of an exemplary roof fixture with an integrated sealant and multiple feet in an unassembled state; [Figure 15B]

[0045] FIG. 15B is an isometric view of the roof mount of FIG. 15A in an assembled state. [Figure 15C]

[0046] FIG. 15B is a side view of the roof mount of FIG. 15A in an installed state. [Figure 16A]

[0047] FIG. 1 is a cutaway view showing an exemplary roof mount in an installed state and used to attach a rail. [Figure 16B]

[0048] FIG. 16B is an isometric view of the roof mount of FIG. 16A. [Figure 16C]

[0049] FIG. 16B is another isometric view of the roof mount of FIG. 16A. [Figure 17A]

[0050] FIG. 1 is an isometric view of an exemplary roof mount having channels disposed along the length of the mount in an assembled state. [Figure 17B]

[0051] FIG. 17B is an isometric cutaway view showing the roof mount of FIG. 17A in a partially installed state. [Figure 18A]

[0052] 1 is an exploded view illustrating an exemplary roof fixture having a mount configured as an enclosable container in an unassembled state. [Figure 18B]

[0053] FIG. 18B is an isometric bottom view of the roof mount of FIG. 18A in an assembled state. [Figure 18C]

[0054] FIG. 18B is a cutaway view showing the roof mount of FIG. 18A in an assembled state. DETAILED DESCRIPTION OF THE INVENTION

[0007]

[0055] Various embodiments of the present disclosure are described in detail below. While specific implementations are described, it should be understood that this is done for purposes of illustration only. A person skilled in the art will recognize that other components and configurations can be used without departing from the spirit and scope of the present disclosure.

[0008]

[0056] FIG. 1 shows an isometric view of an exemplary roof fixture 100 with an integrated sealant 103 in an assembled state 151. The roof fixture 100 may comprise a mount 101, a protective cover 200 (further described in connection with FIGS. 2A-2C ), a volume of sealant 103 (illustrated in FIG. 5A ), one or more roof fasteners 104, and, in some embodiments, one or more connection mechanisms 105 (illustrated in FIG. 8D ). The roof fixture 100 may have several states, such as an unassembled state 150 (illustrated in FIGS. 5A-5B ), an assembled state 151 (also illustrated in FIGS. 7A-7B ), a pre-installed state 152 (illustrated in FIG. 8A ), and an installed state 153 (illustrated in FIG. 8C ). FIG. 1 shows the roof fixture 100 in the assembled state 151.

[0009]

[0057] 2A-2C illustrate a protective cover 200 representing one example of the present invention. FIG. 2A shows an isometric view of the protective cover 200 that may be used with a roof mount having an integrated sealant. As illustrated, the protective cover 200 may include multiple locking tabs 202 and stop tabs 204. An exterior wall 209 may completely or partially encase or surround the shape of the protective cover 200 and substantially conform to the mount perimeter 113 (illustrated in FIG. 3A). The stop tabs 204 may take the form of several geometric shapes, such as the stop tabs 204 shown protruding from the cover fastener openings 206 or the stop tabs 204 protruding inward from the exterior wall 209. A mesh 207, cage, or screen-like plane may be disposed across the bottom of the protective cover 200. The mesh 207 may take the form of a grid-like pattern, a honeycomb pattern, or a complex pattern in which various openings or apertures are disposed throughout the mesh 207. In other exemplary embodiments, such as shown in FIG. 13A , a single opening may be formed by the distal edge of exterior wall 209. The multiple and variously shaped openings or apertures formed by mesh 207 may be sized to allow sealant 103 to flow therethrough when roof mount 100 is transitioned to installed state 153, but may be small enough to easily prevent foreign objects, such as pebbles or human fingers, from passing through. The mesh pattern may be configured to allow multiple mounting feet 112 (illustrated in FIG. 3C ) to pass through the openings in mesh 207 so as to come into direct contact with mounting surface 1001 (illustrated in FIG. 10A ).

[0010]

[0058] Protective cover 200 may have one or more stop tabs 204 positioned to abut mount 101 (illustrated in FIG. 1) when locking tab 202 is substantially engaged with locking feature 115 (illustrated in FIG. 3A ). In other exemplary embodiments, one or more locking tabs 202 simply engage top surface 116 (illustrated in FIG. 3A ) of mount 101. One or more stop tabs 204 may also abut mount 101, such as on lower surface 111 (illustrated in FIG. 3B ) or one or more mount feet 112, or on one or more of peripheral feet 124 (illustrated in FIG. 3A ), to prevent protective cover 200 from crossing further onto mount 101. Protective cover 200 may have a geometry such that one or more stop tabs 204 prevent all or a portion of mesh 207 from contacting sealant 103. Similarly, the thickness of the sealant 103, as measured as the distance away from the lower surface 111, may have a height such that when the stop tabs 204 abut against the lower surface 111, typically in the assembled state 151, the sealant 103 does not extend below the bottom outer edge 205, or contact the mesh 207, or exceed one or more flanges, feet, or similar features on the protective cover 200.

[0011]

[0059] The one or more stop tabs 204 may be flexible, resilient members that substantially reform to their original state after the mount 101 passes through the protective cover 200 until it contacts the installation surface 1001. In another exemplary embodiment, the stop tabs 204 may break, snap, yield, disengage, or permanently bend after the mount 101 passes through the protective cover 200 until it contacts the installation surface 1001. The stop tabs 204 may have sufficient strength to prevent the protective cover 200 from bending upward or over the mount 101 so that the sealant 103 conforms to the mesh 207 while the one or more roof mounting fixtures 100 are being transported to their final installation location. In other words, the stop tabs 204 may have sufficient tensile strength or sufficient elongation characteristics to withstand not only the weight of the mount 101, but also the weight of several roof mounting fixtures 100 that may be stacked on top of each other, for example, when packaged and shipped to their final installation location. The stop tabs 204 may have a maximum yield strength or tensile strength, or sufficient elongation characteristics, such that they bend, break, sag, or otherwise allow the mount 101 to pass through the protective cover 200 after one or more roof fasteners 104 engage the installation surface 1001 and press the mount 101 onto the installation surface 1001.

[0012]

[0060] 2B is a side cross-sectional view of protective cover 200 representing an exemplary embodiment of the present invention. As shown, mesh 207 may have all or a portion of its bottom surface offset from bottom outer edge 205. This offset distance may be sufficient to allow sealant 103 to pass across installation surface 1001 and underneath mesh 207 when roof mounting fixture 100 transitions to installed state 153. Exterior wall 209 may have a variable thickness cross section 211 in which the outer and inner surfaces are not parallel to one another. In other words, the thickness of exterior wall 209 may be thinner near the distal end compared to the thickness at the mid-height, as shown, or compared to the distal end opposite cross section 211. Exterior wall 209 may have a thickness thinner than the diameter of a typical pilot hole for roof fastener 104.

[0013]

[0061] FIG. 2C shows a top-down view of protective cover 200 representing an exemplary embodiment of the present invention. As shown, mesh perimeter 210 may substantially conform to the shape of exterior wall 209 and be connected to exterior wall 209 by one or more ribs 208. Mesh 207 may be disposed across mesh perimeter 210. One or more cover fastener openings 206 may be disposed throughout mesh 207 in locations that are substantially concentric with mount fastener openings 114 (illustrated in FIG. 3A ) when roof mount 100 is in assembled state 151. Mesh 207 may be configured to cooperate with mount feet 112 or any protrusions on lower surface 111 such that mesh 207 nests partially or completely within the protrusions when roof mount 100 is in installed state 153.

[0014]

[0062] Protective cover 200 may be made from polymer, EPDM rubber, silicone, other rubber, injection molded plastic, cast metal such as aluminum, carbon or stainless steel, foam, or other suitable material. Protective cover 200 may have no additional coating or may have a coating such as paint.

[0015]

[0063] 3A-3C depict mount 101 in isometric, side, and bottom views representing one embodiment of the present invention. FIG. 3A shows an isometric view of exemplary mount 101, which includes base 117, vertical flange 118, one or more flange ribs 119, one or more mount fastener openings 114, flange opening 121, front recess 126, rear recess 122 (illustrated in FIG. 3B), and multiple notches 123 around the periphery of the lower edge of mount 101. On the underside around the periphery of mount 101, one or more notches 123 may form one or more peripheral feet 124 that substantially follow the outline of mount 101, as seen in FIG. 3C. The notches 123 that form peripheral feet 124 may have the same cross-sectional width as viewed in FIG. 3B, or may have variable widths. When viewed from the side, one or more of the notches 123 may have a tapered geometry, where the width of the notch narrows toward the lower surface 111. A plurality of protruding mount feet 112 may be disposed inside the peripheral foot 124. The mount feet 112 may extend from the lower surface 111 to substantially coincide with the bottom surface of the peripheral foot 124, or they may extend downward from the lower surface 111 a distance shorter than the distance the peripheral foot 124 may extend downward from the lower surface 111. The peripheral foot 124 may have an additional, shorter step 133 adjacent toward the interior of the mount 101, as shown in FIG. 3C .

[0016]

[0064] At the top edge of the base 117, one or more locking features 115 may be formed to cooperate with the locking tabs 202. The locking features 115 may be chamfered corners on one or more portions of the base 117 or around the entire perimeter of the base 117. Alternatively, the locking features 115 may be radii, steps, lips, grooves, flanges, recesses, or other geometric shapes designed to cooperate with one or more locking tabs 202. When the peripheral foot 124 rests on a flat plane, such as the mounting surface 1001, the first flange surface 125 and the rear recess 122 may be perpendicular to the plane. The top surface 116 may form a non-perpendicular angle with the plane and therefore a non-perpendicular angle with the first flange surface 125. As can be seen in FIG. 3A , the flange sides 127 can have parting lines along their lengths such that a first portion of the flange side 127 forms an acute angle with the first flange surface 125 and a second portion of the side forms an acute angle with the second flange surface 128 (illustrated in FIG. 3B ). As shown in FIG. 3A , one or more flange ribs 119 can extend from the vertical flange 118 in the Y direction, the X direction, or both, in a straight or curved configuration. The flange ribs 119 can be solid or hollow. In exemplary embodiments in which the flange ribs 119 extend toward the mount fastener opening 114, such flange ribs 119 can have a truncated height that meets or is lower than the bottom point of the flange opening 121. In this manner, the rail 1102 (illustrated in FIG. 8E ) can be positioned to abut the first flange surface 125 without interfering with the flange ribs 119 when the connection mechanism 105 is in its lowest position within the flange opening 121.

[0017]

[0065] The base 117 may have one or more mount fastener openings 114 configured to receive one or more roof fasteners 104. The mount fastener openings 114 may be circular or slot-shaped. The mount fastener openings 114 may have vertical walls or tapered walls, where the first and second ends of the mount fastener openings 114 have different widths or diameters. The one or more mount fastener openings 114 may be formed by a ridge 129 projecting upward from the top surface 116, where the top surface of the ridge 129 may be parallel to or at an angle with respect to the top surface 116. The ridge 129 may have substantially the same contour shape as the one or more mount fastener openings 114, e.g., a circular contour, or may extend tapered toward the vertical flange 118 as shown in FIG. 3A . In some exemplary embodiments, a thin web of material may be disposed across one or more mount fastener openings 114. The tips of roof fasteners 104 may be configured to pierce, cut, or penetrate the thin web to pass through mount fastener openings 114 and reach the installation surface. The thin web may be formed from the same material as mount 101, such as die-cast aluminum, formed when mount 101 is manufactured, or may be a different material, such as rubber or plastic, that is installed after mount 101 is manufactured.

[0018]

[0066] In FIG. 3A , parting line plane 131 may be formed along the Y and Z axes within the illustrated coordinate plane 130. Parting line plane 131 may be positioned along the X axis to bisect vertical flange 118 either at its midpoint or at a location offset to one side of vertical flange 118. In one embodiment of the invention, substantially all flat planes above base 117 may be either parallel or at an obtuse angle to parting line plane 131 to aid in manufacturability of mold-based parts, such as in castings. In another embodiment of the invention, parting line plane 131 may be defined by the Y axis and an angle relative to the YZ axis plane (e.g., the plane is rotated about the Y axis) such that top surface 116 may form an obtuse angle with parting line plane 131 while also being parallel to lower surface 111. In FIG. 3B , sliding plane 132 may be defined by the X and Y axes and may be located along the Z axis with a portion of sliding plane 132 coinciding with lower surface 111. Surfaces in the negative Z direction from the sliding plane 132 may form an obtuse angle with the sliding plane 132, such as the side surfaces of the mount foot 112 and the peripheral foot 124, or may be substantially parallel to the sliding plane 132, such as the bottom surface of the mount foot 112.

[0019]

[0067] 4A-4D show an alternative embodiment of mount 101 representing another example of the present invention. In this exemplary embodiment, vertical flange 118 may have a curved shape when viewed from above in FIG. 4A . One or more protrusions from vertical flange 118 on either side of flange opening 121 (illustrated in FIG. 4C ) may provide flat connection surfaces 401 to mount 101 of connection mechanism 105. Parting line plane 131 may be formed along a tangent to the outer curve of vertical flange 118, or parting line plane 131 may be curved to substantially follow the curvature of vertical flange 118. Alternatively, parting line plane 131 may be parallel to top surface 116 of base 117 or at a slight angle relative to base 117, such that the wall surfaces of vertical flange 118 form an obtuse angle with parting line plane 131. The parting line plane 131 may be slightly angled relative to the top surface 116 of the base 117 to allow the flat connecting surface 401 to be substantially perpendicular to the bottom of the mount 101 so that the flat connecting surface 401 is perpendicular to the installation surface 1001 after installation.

[0020]

[0068] The base 117 may have a larger dimension in the Y direction compared to the X direction. The base 117 may have an oval shape, as shown, or may have a rectangular shape, a polygonal shape, or a complex shape. As seen from above, the mount 101 may have one or more base flanges 402 that extend beyond the perimeter of the oval shape to form a complex shape and provide additional structural support.

[0021]

[0069] Flange opening 121 may be formed through vertical flange 118 and may be a circular hole, a slot closed on both ends, or a slot with one end open to the top of vertical flange 118, as shown in FIG. 4C . Vertical flange 118 may be configured to receive connection mechanism 105 for securing rail 1102 or solar panel to roof mount 100. In FIG. 4D , flange opening 121 may have a rear recess 122, where the recessed surface forms peripheral lip 403. Rear recess 122 may be configured to allow the flange of a nut on connection mechanism 105 to remain within rear recess 122, such that the flange of the nut may abut peripheral lip 403 and prevent the nut from easily sliding out of flange opening 121 in the positive Z direction. The rear recess 122 may have sawtooth 404 disposed on its surface that cooperate to prevent the connection mechanism 105 from easily disengaging from the roof mounting fixture 100. In some embodiments, sawtooth 404 may also be present on the front recess 126.

[0022]

[0070] One or more fastener openings 114 may have a tapered cross section, where the diameter of the fastener openings 114 on the top side of the base 117 is different from the diameter of the fastener openings 114 on the lower surface 111 .

[0023]

[0071] Mount 101 may be manufactured from a variety of techniques using a variety of materials, such as high pressure die casting, investment casting, vacuum die casting, injection molding, extrusion, machining, turning, forging, additive manufacturing, or other suitable techniques. Mount 101 may be manufactured from aluminum, steel, stainless steel, polymer, plastic, resin, fiberglass reinforced resin, carbon fiber reinforced resin, or other suitable materials.

[0024]

[0072] 5A-5B illustrate one embodiment of the present invention, in which sealant 103 is disposed on lower surface 111 of mount 101 and protective cover 200 is aligned with mount 101. Sealant 103 may be preformed into a shape, such as an oval, as shown, or may be disposed on lower surface 111 in a desired shape, such as when injected from a nozzle. In an exemplary assembly process, roof fixture 100 may begin in an unassembled state 150, where mount 101, protective cover 200, sealant 103, and one or more roof fasteners 104 are loose, unassembled, and unassociated components. In some embodiments, these components may be obtained from a variety of different manufacturing suppliers or sources. To transform roof fixture 100 from unassembled state 150 to assembled state 151, mount 101 may be placed in a fixture, for example, a stationary or robotic assembly line-type fixture. The mount 101 may be positioned upside down, with the underside of the mount 101 facing substantially upward, as in FIG. 5B . The sealant 103 may then be disposed on the lower surface 111 in one or more circles, ovals, squares, polygons, lines, dots, drops, or other similar shapes or patterns. The sealant 103 may have a predetermined volume disposed on the lower surface 111 and may be controlled, for example, by an electronic dispenser. In another application process, the sealant 103 may be disposed using a manual process, such as using a caulking tube or syringe. The sealant 103 may be disposed to form a substantially desired or programmed shape, thickness, width, or curvature to achieve a desired volume. In an alternative process, the sealant 103 may be disposed within the protective cover 200, such as on the mesh 207, in one or more circles, ovals, squares, polygons, lines, dots, drops, or other similar shapes or patterns.

[0025]

[0073] In a potential next step, protective cover 200 may be aligned to the underside of mount 101. Alternatively, protective cover 200 may be in a fixed position, and mount 101 with sealant 103 applied may be positioned to align over protective cover 200. Protective cover 200 may then be pressed onto mount 101 such that one or more locking tabs 202 engage and / or cooperate with a lip, groove, flange, chamfer, radius, or similar engagement feature 110 on mount 101 to prevent protective cover 200 from easily separating in the reverse direction from mount 101 after engagement.

[0026]

[0074] FIG. 6 shows a side cutaway view of roof mounting fixture 100 in an assembled state 151. In assembled state 151, sealant 103 has been applied to the underside of mount 101, and protective cover 200 has been installed on mount 101 such that locking tabs 202 engage one or more engagement features 110 and stop tabs 204 have or nearly abutment with mount 101. As an example, an intentional tolerance may be allowed such that a gap remains between mount 101 and stop tabs 204 when locking tabs 202 engage, or an intentional interference fit may occur between stop tabs 204 and mount 101 when locking tabs 202 engage one or more engagement features 110. As shown in FIG. 6, sealant 103 is in an initial (uncompressed) state and may form a dome-like shape when viewed in cross section here. In this uncompressed state, the sealant 103 may have a tapered shape, with a thinner cross-section near its lower edge (e.g., furthest from the lower surface 111) and a wider cross-section near the lower surface 111. The cross-sectional shape of the sealant 103 may be a substantially regular sideways "D" shape, a trapezoid, a pyramid, an oval, a circle, a semi-oval, a semi-circle, or a similar shape. The sealant 103 may have an initial shape or width in the pre-installed state 152 such that, after the mount 101 is pressed against the installation surface 1001, sufficient pressure is induced on the sealant 103 to allow the sealant 103 to flow over substantially the entire projected area of ​​the foot, and in some embodiments, over the exterior wall 209 of the protective cover 200, when the roof attachment 100 transitions to the installed state 153 (e.g., having a different shape corresponding to the volume of space filled by the compressed sealant 103). In other embodiments, a reservoir space may be defined within the protective cover, wherein excess sealant 103 is directed into the reservoir space as roof fixture 100 transitions to installed state 153 .

[0027]

[0075] The sealant 103 is comprised of a substance intended to prevent water from entering a roof penetration, where the roof fasteners 104 are positioned to secure the roof attachment 100 to the installation surface 1001. Additionally, the sealant 103 may have properties to fill voids or cracks on the underlying installation surface 1001, such as gaps between asphalt shingles, or to fill open holes in the roof, such as unused pilot holes. The sealant 103 may have properties that make it waterproof, water-resistant, weather-resistant, or water-repellent. In an exemplary embodiment of the invention, the sealant 103 may be an isobutylene compound, a butyl-based rubber sealant, a wax, a non-skinning or minimally skinning sealant, a non-sag or minimally-sag sealant, or a combination thereof.

[0028]

[0076] The sealant 103 may have a viscosity or ingress protection rating that prevents the sealant 103 from easily flowing past the protective cover 200 when the roof mounting fixture 100 is in any orientation (face up, upside down, on its side, or in a bulk packaging) at high temperatures, such as 140 degrees Fahrenheit, while also having a viscosity that still allows the sealant 103 to deform from its initial shape and move under pressure to different configurations or positions to fill differently shaped spaces (e.g., around the roof fasteners 104, or through the mesh 207, or within a roof void) when installed in colder weather, such as when installed on a sub-freezing roof.

[0029]

[0077] In some embodiments, the sealant 103 may have properties such as being permanently or semi-permanently flexible or flowable, maintaining permanent or semi-permanent adhesion, being self-healing, or a combination thereof. In another exemplary embodiment of the present invention, the sealant 103 may be formulated to maintain a desired flexibility or flowability, maintain adhesion, be self-healing, or a combination thereof for a desired period of time, such as six months, one year, etc. The sealant 103 may maintain its flexibility or flowability at low temperatures and may be designed to function in its intended application, transitioning from the pre-installed state 152 to the installed state 153 (e.g., different shapes and positions within the roof fixture 101) within a temperature range of 0 to 180 degrees Fahrenheit.

[0030]

[0078] The sealant 103 may have a particular color, such as off-white, dark gray, blue, etc., to visually blend in with the average hue and color of the installation surface 1001 or to visually contrast with the average hue and / or color of the installation surface 1001 or protective cover 200. Alternatively, the sealant 103 may intentionally have a color that contrasts with the color of the protective cover 200 and / or installation surface 1001 to facilitate visual confirmation of the mount 101 transitioning from the pre-installed state 152 to the installed state 153 when the sealant 103 spills outside the perimeter, edge, or surface of the protective cover 200 or mount 101 or into a reservoir, thereby making a portion of the sealant 103 visible to a person installing the roof mounting fixture 100.

[0031]

[0079] The sealant 103 may be non-hardening, defined as maintaining a liquid or semi-liquid state for an extended period of time, such as six months, one year, ten years, or indefinitely. The sealant 103 may have a low viscosity or a cure time of more than one year, five years, or ten years. The sealant 103 may have a silent cure time, where it hardens over time but never fully hardens or cures. In other words, the sealant 103 may increase in viscosity, become less flexible, less tacky, less adhesive, or change state over time, or a combination thereof. The sealant 103 maintains its tack for an extended period of time, such as ten or thirty years, thereby maintaining a water-resistant barrier with the installation surface 1001. Some formulations of sealant 103 may or may not maintain elasticity after compression and therefore may not be able to transition from the installed state 153 to an uninstalled state (e.g., the unassembled state 150) and back.

[0032]

[0080] The sealant 103 may have a chemical composition that is compatible with various roofing materials, such as asphalt, composite asphalt, composite shingles, tar paper, roofing paper, tar roofing, thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), Hypalon, Kynar, painted metal, fiberglass, stone-grained steel, clay, ceramic, glass, concrete, cement, and other common roofing materials. The sealant 103 may have a viscosity that decreases at temperatures above room temperature, in part to allow a bead of sealant 103 to more easily distribute on the underside of the mount 101 during assembly, such as when transitioning the roof fixture 100 from the unassembled state 150 to the assembled state 151. The sealant 103 may have a viscosity over a standard installation temperature range, such as from 0 to 170 degrees Fahrenheit, that allows the sealant 103 to flow and wet substantially the entire surface of the installation surface below the mount 101 when the roof fixture 100 is in the installed state 153. The mounting surface 1001 may be one or more asphalt shingle tabs, where the tabs abut with a small gap between them. The viscosity of the sealant 103 may allow the sealant 103 to wet all surfaces below the mount 101 in the small gap formed between the two shingle tabs.

[0033]

[0081] 7A-7B show an isometric vertical cutaway view of the roof mount 100 in an assembled state 151, with the sealant 103 omitted to illustrate an unobstructed view of the interior of the roof mount 100. As shown, a first locking tab 202 is engaged with an engagement feature 110. One or more locking tabs 202 may be shaped with a recessed, angled, chamfered, or radiused surface to easily slide over the lateral outer surface of the mount 101 and then "click" into a locked position onto the engagement feature 110 on the mount 101. One or more locking tabs 202 may have one or more adjacent cutout openings 212 in the outer wall 209 to increase the length of the locking tab 202 for increased flexibility. The locking tab 202 may have a tapered cross-section. The one or more locking tabs 202 may be evenly positioned around the perimeter of the mount 101 or offset near one side of the perimeter of the mount 101.

[0034]

[0082] 8A through 8E are various views showing the roof mount 100 being installed on an installation surface 1001, illustrating an exemplary installation method. FIGS. 8A-8E also show the roof mount 100 transitioning from a pre-installation state 152 to an installed state 153, with the rails being installed. In FIG. 8A , the roof mount 100 may be placed on the installation surface 1001 in the pre-installation state 152. In this state, the protective cover 200 supports the mount 101 and sealant 103 above the installation surface 1001 so that the sealant 103 does not contact the installation surface 1001. One or more pilot holes or openings may be drilled in the installation surface 1001, or no pilot holes may be drilled in the installation surface 1001. Because the sealant 103 is not in contact with the installation surface 1001, the roof mount 100 may be easily slid, moved, dragged, rotated, or otherwise positioned to a desired location. For example, mount fastener openings 114 and cover fastener openings 206 may be positioned to substantially align with pilot holes in the roof, if such pilot holes are present.

[0035]

[0083] 8B shows first roof fastener 104 positioned through fastener opening 114 and cover fastener opening 206. Roof fastener 104 may have a hexagonal head shape, a star shape, or a hexagonal internal cavity and may have no flange or a flanged head. In the exemplary embodiment, roof fastener 104 also has a metal and rubber adhesive washer positioned under the hexagonal head.

[0036]

[0084] 8C shows roof attachment 100 in installed state 153 after the threads of roof fasteners 104 engage mounting surface 1001 and overcome the strength of stop tabs 204, applying a downward force on mount 101, thereby pushing mount 101 through the body of protective cover 200 until mount 101 is flush with mounting surface 1001 or, in some embodiments, the top side of mesh 207. In some exemplary embodiments, roof fasteners 104 engage openings in mounting surface 1001, such as pilot holes, while in other embodiments, roof fasteners 104 bite into mounting surface 1001 and then threadably engage. As mount 101 passes through the body of protective cover 200, the volumetric area defined by the space between mesh 207, lower surface 111, and exterior wall 209 decreases. The sealant 103 is thus pressed between the mount 101, the installation surface 1001, and the protective cover 200 and is forced to flow onto the installation surface 1001, around the one or more roof fasteners 104, and through the mesh 207, if present. As previously mentioned, the mesh 207 may be offset from the bottom edge of the exterior wall 209 to allow the sealant 103 to flow over, around, and under the mesh 207. In this manner, a portion or all of the mesh 207 may not contact the installation surface 1001. In some exemplary embodiments, the sealant 103 may drain beyond the exterior wall 209 of the protective cover 200, as shown in FIG. 8C , or the excess sealant 103 may flow into one or more overflow reservoirs.

[0037]

[0085] The volume and shape of sealant 103 disposed on mount 101 during the assembly process (e.g., transitioning from pre-assembly state 150 to assembled state 151) can change to match the volume of the space between mesh 207, lower surface 111, and exterior wall 209 in installed state 153. For example, roof fixture 100 can be configured to have a volume of sealant 103 in installed state 153 that is greater than the volume of the space below mount 101, intentionally resulting in sealant 103 draining beyond exterior wall 209 of protective cover 200. FIGS. 8D-8E show isometric and cutaway views, respectively, of an installed roof fixture with rails 1102 already installed.

[0038]

[0086] 9A-9G show various views of an alternative embodiment of a roof fixture 100 including a mount 101 and protective cover 200 having a plurality of roof fasteners 104, mount fastener openings 114, and cover fastener openings 206. FIG. 9A shows an isometric view of the roof fixture 100 in an assembled state 151. A first roof fastener 104 is positioned through the first mount fastener opening 114. FIG. 9B shows a cutaway view of FIG. 9A depicting a sealant 103 disposed on the lower surface 111. The sealant 103 is shaped like a sideways "D" and is offset from the mesh 207. The plurality of cover fastener openings 206 are coincidentally positioned relative to the similar plurality of mount fastener openings 114. 9C and 9D show the roof mounting fixture 100 in the installed state 153 after the first roof fastener 104 has been engaged with the mounting surface 1001 (e.g., a roof surface) to push the mount 101 through the body portion of the protective cover 200 until the mount 101 contacts the mounting surface 1001 (not shown to show the fastener 104 in the engaged position). As shown in the cutaway view of FIG. 9D, the sealant 103 is pressed against the lower surface 111 and perimeter wall 209, threaded through the mesh 207, and applied onto the roof surface 1001. FIGS. 9E and 9F show the roof mounting fixture 100 in the installed state 153, where an additional roof fastener 104 has been installed on the mounting surface 1001 through the additional mount fastener opening 114. FIG. 9G shows an isometric view of the roof mounting fixture 100 in the installed state 153, with the connection mechanism 105 engaged with the mount 101. In this exemplary embodiment, connection mechanism 105 is a nut and bolt fastener that secures rail 1102 to mount 101. Rail 1102 may be used to support one or more solar panels. Rail 1102 may be an aluminum extrusion, a steel bar, a bracket, or another suitable configuration.Although illustrated and described herein as being used to mount rails 1102, roof mounting fixture 100 may also be used to mount one or more other types of fixtures to an installation surface, such as solar panels themselves, clamps for solar panels, HVAC units, electrical conduits, piping, bulkheads (e.g., in building structures), stairs, pads, generators, battery enclosures, electrical equipment enclosures, satellite dishes, and related equipment.

[0039]

[0087] In the illustrated exemplary embodiment of mount 101, vertical flange 118 is present. However, in other exemplary embodiments not shown, mount 101 may not have such vertical flange 118. In other exemplary embodiments of mount 101 not shown, mount 101 may have one or more threaded bosses configured to engage one or more fasteners for attaching various brackets (e.g., some examples are depicted in FIGS. 11A-11D, 12A-12C, and 17A-17B).

[0040]

[0088] FIG. 10A shows an isometric view of a roof fixture showing a mount 101 and protective cover 200 with multiple mount fastener openings 114. In the exemplary embodiment, one or more mount fastener openings 114 are located on one side of a vertical flange 118 and one or more mount fastener openings are located on the other side of the vertical flange 118, parallel to the shorter diameter of the base 117. In another embodiment not shown, the multiple mount fastener openings 114 may be arranged in a circular, oval, or similar pattern around the base 117 when viewed from above. FIG. 10B shows an isometric view of an alternative embodiment of the invention showing a mount 101 and protective cover 200 with multiple mount fastener openings 114, and according to an alternative configuration in which the vertical flange 118 is parallel to the longer diameter of the base 117.

[0041]

[0089] 11A-11D show various views of an alternative embodiment of the present invention, in which mount 101 does not have vertical flange 118. In this example, multiple mount fastener openings 114 may be disposed across mount 101, such as in an evenly spaced circular pattern as shown. Mount fastener openings 114 may have chamfers, radiuses, or beveled edges transitioning between top surface 116 and the interior of a given mount fastener opening 114. Mount 101 may be circular in shape, as shown, with one or more accessory openings 1301 that are threadably engaged with accessory openings 1302 (illustrated in FIG. 11D) disposed on top surface 116 for securing various accessory components, such as HVAC brackets, L-foots, solar mounting systems, or other equipment typically installed on building roofs. The top surface 116 may be substantially flat as shown, or may have one or more protrusions, bosses, flanges, platforms, or similar features in which one or more accessory openings 1302 may be disposed.

[0042]

[0090] The protective cover 200 may have a shape substantially similar to the mount 101, such as circular as shown. In this exemplary embodiment, the protective cover 200 also has an inner wall 1303 that defines a central cover opening 1304. The mesh 207 is disposed between the outer wall 209 and the inner wall 1303 and may not extend across the central cover opening 1304, as shown. One or more cover fastener openings 206 may be disposed throughout the mesh 207 and configured to substantially align with a respective one or more mount fastener openings 114. The protective cover 200 may not have the locking tabs 202 as shown. In other examples not shown, one or more locking tabs 202 and stop tabs 204 may be disposed along either or both the outer wall 209 or the inner wall 1303. The sealant 103 may be disposed on the mount 101 or within the protective cover 200 such that the sealant 103 is between the outer wall 209 and the inner wall 1303 .

[0043]

[0091] The roof fastener 104 may have a hex head as shown, which may be configured to engage with a ½″ socket or a 13 mm socket. The roof fastener 104 may have a flange below the hex head, which may have serrations disposed on the underside. The roof fastener 104 may have a cutting tip 1305 configured to bite into the installation surface 1001 to avoid pre-drilling pilot holes. The accessory fastener 1301 may have a different head type, such as a socket hex head as shown, or may have the same hex head as the roof fastener 104 to allow for engagement of both the roof fastener 104 and the accessory fastener 1301 with the same tool.

[0044]

[0092] 11B shows the roof fixture 100 in an assembled state 151, including accessory fasteners 1301 partially installed on the mount 101. In other exemplary embodiments of this style of roof fixture 100 in the assembled state 151, the accessory fasteners 1301 may not be installed. FIG. 11C shows a view of the underside of the roof fixture 100 in the assembled state 151.

[0045]

[0093] 11D shows roof mount 100 in a cutaway view in assembled state 151 to better illustrate the internal features of the present invention. As shown, sealant 103 is disposed on lower surface 111 such that sealant 103 is between exterior wall 209 and interior wall 1303. Exterior wall 209 may align with exterior wall groove 1307, and interior wall 1303 may align with interior wall groove 1308 such that mount 101 may extend down and through the body portion of the protective cover until it contacts installation surface 1001. In other exemplary embodiments, exterior wall 209 may be positioned outside mount 101 (such as in FIG. 1 ), and interior wall 1303 may be positioned inside central mount cavity 1309. Threaded boss 1306 may penetrate into central mount cavity 1309 to make accessory opening 1302 deep enough for accessory fastener 1301 to fit fully onto top surface 116. The accessory opening 1302 may be surrounded, captured, or hidden on the ends so that the accessory opening 1302 extends to or opens into the central mounting cavity 1309.

[0046]

[0094] 12A-12C show various views of the present invention in which the mount 101 does not have the vertical flange 118. In this exemplary embodiment of the present invention, the base 117 has one or more mount fastener openings 114 configured on a mounting platform 1401 thereon. The mounting platform 1401 may be configured to support a variety of accessories, such as an L-bracket, a conduit support strap, a plumbing strap, a mounting bracket for an HVAC unit or pipe, or numerous other applications. One or more accessory openings 1402 are disposed on the mounting platform 1401 and may be configured to receive and engage threaded fasteners. The accessory openings 1402 are threaded and may or may not be cut through to the lower surface 111. In this exemplary configuration, the mount 101 may be formed from sheet metal, extruded metal, stamped metal, die-cast metal, injection-molded plastic, or similar processes and materials. In another exemplary embodiment not shown, a clasp, ratchet, strap, or similar retention feature may be formed from base 117 for securing one or more pipes or tubes, such as electrical conduit. Figure 12C shows an isometric view of the present invention with roof fixture 100 in the installed state 153 with roof fasteners 104 attached. In some exemplary embodiments not shown, mounting platform 1401 may be higher than the top of the protective cover when roof fixture 100 is in the installed state 153.

[0047]

[0095] 13A-13C are various views illustrating different exemplary embodiments of the present invention. In this exemplary embodiment, protective cover 200 comprises outer wall 209 with a single large opening 1501 (without rib 208 or mesh 207 across the bottom surface as shown in FIGS. 2A-2C). Protective cover 200 may have a groove 1502 around its interior upper portion configured to grip the outer periphery of base 117 to secure protective cover 200 in the assembled state 151 illustrated in FIG. 15B. In this exemplary embodiment, protective cover 200 may be made from a resilient, flexible material, such as rubber, silicone, foam, plastic, or other suitable material. When viewed in cross section in FIG. 13C, protective cover 200 may have a tapered shape such that the lower portion of outer wall 209 is farther from the central portion of roof mounting fixture 100 than the upper portion. In other words, the lower distal end of outer wall 209 has a larger circumference than the upper distal end. In an alternative embodiment not shown, the sealant 103 may have a substantially uniform thickness and cover a majority of the open underside of the mount 101 surrounded by the exterior wall 209. In this alternative embodiment, the sealant 103 may be butyl tape, butyl mastic, PVC, or other similar material.

[0048]

[0096] 14A-14D illustrate another alternative embodiment of the present invention. In this exemplary embodiment, mount 101 has a cross-section that is the same shape along its entire length along Y-direction 1601, except for one or more mount fastener openings 114 and / or one or more flange openings 121 disposed perpendicular to the cross-section. Mount 101 in this exemplary embodiment may be manufactured from extrusion, casting, machining, forging, roll-forming, bending, stamping, or other suitable processes, and may be made from aluminum, steel, stainless steel, plastic, synthetic polymer, or other suitable materials. A volume of sealant 103, which functions similarly to roof fixture 100 described previously, may be disposed on the underside of mount 101, and protective cover 200 may be secured to mount 101 by one or more locking tabs 202 and stop tabs 204, as previously described. The flange opening 121 in this exemplary embodiment of the mount 101 may be a closed slot, as shown, or may be an open slot with the top end of the slot open to the top of the mount 101 so that a fastener can pass down the slot from the top of the mount 101.

[0049]

[0097] 15A-15C show an alternative embodiment of the present invention in which protective cover 200 is replaced with one or more flexible, resilient feet 1701. Sealant 103 may be similar in shape and cross-section as described in the previous embodiment, or may be flat and of uniform thickness as shown. In the same installation method previously described, roof fixture 100 may be placed on installation surface 1001 such that one or more flexible, resilient feet 1701 support roof fixture 100 at a desired height above installation surface 1001 so that sealant 103 does not contact installation surface 1001 in pre-installation state 152. In other words, the flexible resilient feet 1701 may have a height below the bottom of the mount 101 that is greater than the thickness of the sealant 103 and may have a resilience greater than the weight of the roof mounting fixture 100 so as not to compress the sealant 103 and thereby maintain the sealant 103 at or below the bottom surface of the flexible resilient feet 1701 prior to installation on the installation surface 1001. After one or more roof fasteners 104 are installed through one or more mount fastener openings 114, the downward force created by the mount fasteners 104 engaging the installation surface 1001 compresses the one or more flexible resilient feet 1701 until the sealant 103 contacts the installation surface 1001 in the installed state 153, as shown in FIG. 15C . Additionally, the mount 101 may have one or more peripheral feet 124, not shown but similar to those described in FIGS. 3A-3C , that conform to the installation surface 1001 when the mount 101 is fully installed. In this manner, the roof fixture 100 has transitioned from the pre-installed state 152 to the installed state 153 .

[0050]

[0098] 16A-16C show various views of the present invention illustrating an alternative connection mechanism 105 for securing a rail 1102 to a mount 101 of a roof fixture 100. In this exemplary embodiment, the connection mechanism 105 may be comprised of one or more grip moldings 1801 and 1802 with grip fasteners 1803. The grip moldings 1801 and 1802 may be formed as a single piece or, as shown, may be two separate pieces. The one or more grip moldings 1801 and 1802 may have one or more grooves 1804 that secure onto a rail flange 1805. The grip fasteners 1803 may have a flanged hex head, a simple hex head, or a socket hex head. The grip fasteners 1803 may threadably engage and compress the one or more grip moldings 1801 and / or 1802 to the connection mechanism 105 to the rail 1102 and vertical flange 118. In an exemplary embodiment of the invention in which grip fastener 1803 has a flanged head, the flange may seat in rear recess 122. In the exemplary embodiment shown, rail 1102 may be secured to roof fixture 100 after roof fixture 100 is placed in installed state 153.

[0051]

[0099] 17A and 17B show isometric and isometric cutaway views of an alternative embodiment of the present invention, in which a flow channel 1901 is disposed along the length of mount 101. In this exemplary embodiment, flow channel 1901 is formed from two side walls 1902. Side protrusions 1903 may extend inward relative to flow channel 1901, as shown, or may extend toward the outside of the flow channel. In this exemplary embodiment, mount 101 may have a uniform cross-section along its entire length, except for one or more openings, such as mount fastener opening 114. The flow channel walls (e.g., side walls 1902) may be parallel to one another or may form obtuse or acute angles with respect to one another.

[0052]

[0100] 18A-18C show various views of an alternative embodiment of the present invention, in which mount 101 is configured as an enclosable container. In FIG. 18A, mount 101 has sidewalls 2001 extending upward from base 117, which may form a box-like configuration. Base 117 may be square, rectangular, or polygonal in shape, with sidewalls 2001 extending upward from all edges to form upper interior cavity 2003. Lid 2002 may be releasably connected to one of sidewalls 2001 via hinge 2004 and configured to be secured to the sidewall 2001 opposite or adjacent to hinge 2004. One or more roof fasteners 104 may be used to secure roof attachment 100 to installation surface 1001. One or more mount fastener openings 114 may be disposed on base 117. FIG. 18A shows an exploded view of the roof fixture 100 in an unassembled state 150, where the sealant 103 and protective cover 200 have not yet been assembled onto the mount 101.

[0053]

[0101] 18B shows a view of the underside of roof fixture 100 in assembled state 151, with sealant 103 disposed on the lower surface of mount 101 and protective cover 200 installed on mount 101 using one or more locking tabs 202 that engage one or more respective engaging features, not shown. One or more cover fastener openings 206 may be disposed within mesh 207 and substantially aligned with respective one or more mount fastener openings 114 when protective cover 200 is assembled on mount 101. Central cover opening 1304 may be configured to be large enough to allow one or more conduit openings (not shown) to be disposed through lower surface 111 and within central cover opening 1304. The one or more conduit openings may be formed after roof fixture 100 is in assembled state 151 or even after it is in installed state 153. Although not shown, one or more perimeter feet 124 and mounting feet 112 may be disposed across lower surface 111 .

[0054]

[0102] FIG. 18C shows a cutaway view of roof mount 100 in assembled state 151. In this exemplary embodiment, mount 101 may be made from a polymer, plastic, metal, or similar material. Side wall 2001 may be formed at an obtuse angle 2005 with respect to base 117. Outer wall 209 may be configured to slide within outer wall groove 1307, and inner wall 1303 may align with inner wall groove 1308 so that mount 101 may extend down and through the body portion of protective cover 200 until it contacts installation surface 1001. Although not shown, one or more bosses or protrusions may extend up from the bottom inner surface and be configured with notches or openings configured to receive screws for fastening electrical equipment, such as a DIN rail or terminal block.

[0055]

[0103] In an exemplary installation method, roof mount 100, in assembled state 151, may be placed on installation surface 1001. One or more roof fasteners 104 may be inserted through mount fastener openings 114 and cover fastener openings 206 and threadably engaged within installation surface 1001. After the heads of roof fasteners 104 engage installation surface 1001, mount 101 is pulled toward installation surface 1001 with sufficient force to overcome the strength of one or more stop tabs 204 (not shown). Mount 101 being pulled toward installation surface 1001 compresses sealant 103 through one or more openings in mesh 207 and forces it onto installation surface 1001. Additional roof fasteners 104 may be installed after the first fastener 104 is installed. One or more conduit openings may be formed in the base 117, for example, in the bottom surface of the upper internal cavity 2003 and through the mounting surface 1001, and may be configured to allow one or more electrical wires to pass therethrough.

[0056]

[0104] The foregoing detailed description of the technology has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the technology to the precise form disclosed. Numerous modifications and variations are possible in light of the above teachings. The described embodiments have been chosen to best explain the principles of the technology and its practical application, and will enable those skilled in the art to utilize the technology in various embodiments with various modifications as suited to the particular applications contemplated. It is intended that the scope of the technology be defined by the claims.

Claims

1. 1. A roof-mounted device comprising: Mount and a fastener configured to engage a mounting surface, wherein the fastener attaches the mount to the mounting surface when engaged with the mounting surface; a compressible sealant disposed between the bottom of the mount and the mounting surface when the mount is attached to the mounting surface, wherein the sealant is compressed upon engagement between the fastener and the mounting surface, and the compressed sealant flows to fill a volume of a space between the bottom of the mount and the mounting surface; A roof mounting device comprising:

2. 2. The device of claim 1, wherein the installation surface includes one or more openings, the fasteners engage with openings in the installation surface, and the volume of space filled by the sealant includes spaces associated with other openings in the installation surface.

3. 10. The apparatus of claim 1, further comprising a protective cover having one or more openings, wherein the compressed sealant flows through the one or more openings in the protective cover and onto the installation surface.

4. The device of claim 3 , wherein the protective cover further comprises one or more openings, and wherein the fastener passes through the openings in the protective cover.

5. The apparatus of claim 3 , wherein the protective cover is configured to prevent the sealant from contacting the mounting surface until the sealant is compressed.

6. The apparatus of claim 3 , wherein the protective cover includes one or more stop tabs configured to support the mount and prevent the mount from moving transversely relative to the protective cover based on the resilience of the stop tabs.

7. 7. The device of claim 6, wherein the fastener engages the mounting surface at different stages of engagement, and wherein at least one stage of engagement provides a force that overcomes the resilience of the stop tab.

8. The apparatus of claim 3 , wherein the front protective cover comprises one or more locking tabs configured to secure the protective cover to the mount.

9. 10. The apparatus of claim 1, wherein a force greater than the weight of the mount is required to compress the sealant into contact with the mounting surface.

10. The apparatus of claim 1 , wherein the sealant comprises a petroleum-based compound.

11. The apparatus of claim 10, wherein the petroleum-based compound is a butyl-based compound.

12. 10. The apparatus of claim 1, wherein the sealant maintains a liquid state associated with flowability for a period of time after being compressed between the mount and the installation surface.

13. 13. The apparatus of claim 12, wherein the period of time is at least 180 days.

14. The apparatus of claim 1 , wherein the mount comprises a vertical flange having an aperture disposed therethrough.

15. The apparatus of claim 1 , wherein the mount comprises a fastener opening disposed on a top surface thereof, the fastener opening configured to engage the fastener.

16. 1. A roof-mounted device comprising: Mount and a protective cover having a bottom surface with one or more openings formed therein; a quantity of sealant disposed between the mount and the protective cover, wherein the protective cover prevents the sealant from contacting a mounting surface until the sealant is compressed between the mount and the protective cover, and wherein when the sealant is compressed by a force greater than the weight of the mount, the sealant flows through the one or more openings in the bottom surface of the protective cover and onto the mounting surface to substantially fill a volume of a space between the bottom surface and the mounting surface; A roof mounting device comprising:

17. Rails and 17. The apparatus of claim 16, further comprising a connection mechanism that secures the rail to the mount.

18. 17. The apparatus of claim 16, wherein the mounting surface is an asphalt shingle roof.

19. 1. A method of installing a roof mount, comprising: placing a roof mount on a mounting surface, wherein the roof mount is positioned such that a sealant is disposed between a bottom surface of the roof mount and the mounting surface; installing fasteners that engage with a mounting surface, wherein the fasteners attach the roof mount to the mounting surface when engaged with the mounting surface; applying a force based on the engagement between the fastener and the installation surface, wherein the force compresses and presses the sealant onto the installation surface, and wherein the compressed sealant occupies a volume of space between the installation surface and the roof mounting fixture. A method for providing

20. 20. The method of claim 19, wherein the roof attachment comprises a mount, a protective cover, and one or more stop tabs that prevent the mount from passing over the protective cover before the force is applied, and wherein the force applied by the engagement further overcomes the strength of the stop tabs, resulting in the mount passing over the protective cover.

21. 20. The method of claim 19, further comprising attaching a rail to the roof mount using a connection mechanism.

22. 1. A method of assembling a roof mount, comprising: utilizing a robot to deposit a volume of sealant onto an undersurface of the mount; securing a protective cover onto the mount using one or more locking tabs, wherein the sealant does not protrude beyond an opening in the protective cover; A method for providing

23. 1. A roof-mounted device comprising: Mount and one or more resilient flexible members configured to support the mount above a mounting surface; a sealant disposed under the mount, wherein the resilient flexible member extends below a bottom surface of the sealant to prevent the sealant from touching the mounting surface under gravity, and wherein when a fastener is engaged with the mounting surface, the fastener provides a force that compresses the resilient flexible member until the sealant contacts the mounting surface. A roof mounting device comprising:

24. 24. The apparatus of claim 23, wherein the sealant comprises a butyl-based tape.

25. 1. A roof-mounted device comprising: a mount having a plurality of walls forming a box; A protective cover and a sealant disposed between the bottom of the mount and the installation surface, wherein the sealant is compressed upon engagement between the fastener and the installation surface, and the compressed sealant flows to fill a volume of the space between the bottom of the mount and the installation surface; A roof mounting device comprising:

26. 26. The device of claim 25, wherein one or more stop tabs disposed on the protective cover prevent the mount from passing over the protective cover before a force is applied, wherein the force applied by the engagement further overcomes the strength of the stop tabs, resulting in the mount passing over the protective cover.

Images