Roof mounted synthetic turf assembly and method

Abstract

A synthetic turf assembly and method which can be securely installed on either new or existing flat roofs. The synthetic turf assembly and method incorporates a plurality of roof attachment mechanisms with a plurality of perimeter boards and a drainage mat to provide an installation base that is mechanically coupled to a desired aspect of a target flat roof and is suitable to provide a foundation for a turf layer. The turf layer, which includes one or more sections of synthetic turf forming, is then laid over and mechanically coupled to the installation base, with the turf layer and installation base forming the synthetic turf assembly that is securely fixed in place at the desired portion of the target flat roof.

Description

BACKGROUND OF THE INVENTIONField of the Invention

[0001] This invention relates generally to synthetic turf installations and, more particularly, to a synthetic turf assembly, and method of installing the same, which fastens to a flat roof without compromising any aspect of the integrity of the roof.Description of the Prior Art

[0002] Synthetic turf (or artificial turf) is well known as a synthetic fiber based surface that mimics the appearance of a natural grass surface. In modern times, the use of such synthetic turf as a substitute for, or supplement to, natural grass in sites where natural grass is traditionally used, such as sports arenas, residential lawns and commercial applications, is widespread. As such, systems and assemblies have been established to deploy synthetic turf in various indoor and outdoor spaces.

[0003] A problem which still exists, however, is that existing turf systems and assemblies are typically unable to be effectively deployed on a flat roof. For example, a common method for attaching a turf system to a roof involves using adhesives to secure perimeter boards that turf can be attached to. This method, however, is undesirable because it is typically not approved by roofing manufacturers and can even result in the voiding of a warranty on a roof. As such, it is often prohibited by builders. Consequently, many have resorted to employing a ballast based approach. A ballast based approach generally involves adding 3-4 pounds of sand per square foot on top of the turf to weigh it down. But such a ballast based approach can be ineffective against uplift forces and does not provide long-term reliability on a rooftop environment. Thus, a solution to prevent uplift in turf systems on roofs without employing an approach which risks voiding a roof warranty has remained elusive.

[0004] Accordingly, there remains a need for a synthetic turf assembly, and method of installation, which employs attachment mechanisms which would allow for secure attachment to a roof without compromising its warranty. It would be desirable for such a synthetic turf assembly and method to employ framing, drainage, and turf components in a complementary arrangement with the attachment mechanisms to provide a reliable and long-lasting installation that effectively resists uplift forces.SUMMARY OF THE INVENTION

[0005] The present disclosure provides for a synthetic turf assembly for a flat roof installation, comprising: an installation base having a top side, wherein the installation base includes a frame, at least one attachment mechanism, and at least one linking body; wherein the frame defines a perimeter structure of the installation base; a turf layer fixed to the top side of the installation base and sized to completely cover the top side of the installation base; wherein the at least one attachment mechanism includes at least one roof elongated mechanical fastener and a waterproof cover, and is adapted to attach to a target roof with the at least one roof elongated mechanical fastener being inserted into the target roof and the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener, completely covering the at least one roof elongated mechanical fastener; and wherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof at a location adjacent to the frame, the at least one linking body is operative to couple with the at least one attachment mechanism while holding the frame in place on the target roof.

[0006] Embodiments of the synthetic turf assembly may additionally include a drainage element positioned to define the entire area of the installation base under the turf layer and inside of the frame other than what is defined by the at least one attachment mechanism.

[0007] It is an object of the present disclosure to provide a synthetic turf assembly and method of installation which employs attachment mechanisms which allows for secure attachment to a roof without compromising its warranty. It is contemplated that this may be accomplished by utilizing mechanical fastening components that have been found in other contexts to be acceptable for use on roofs by roofing manufacturers

[0008] It is an additional object of the present disclosure to provide a synthetic turf assembly and method which employs framing, drainage, and turf aspects in a complementary arrangement with attachment mechanisms to provide a reliable and long-lasting installation that effectively resists uplift forces.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a partial perspective view of a synthetic turf assembly for a flat roof installation built in accordance with a first embodiment of the present disclosure, shown with a portion of a turf section removed.

[0010] FIG. 2 is a top plan view of a synthetic turf assembly for a flat roof installation built in accordance with a first embodiment of the present disclosure, shown with a portion of a turf section removed.

[0011] FIG. 3 is a flow chart showing a process for installing a synthetic turf assembly on a flat roof in accordance with the present disclosure.

[0012] FIG. 4 is a partial perspective view of a synthetic turf assembly for a flat roof installation built in accordance with a second embodiment of the present disclosure, shown with a portion of a turf section removed.

[0013] FIG. 5 is a partial side elevational view of a synthetic turf assembly for a flat roof installation built in accordance with a second embodiment of the present disclosure, shown with a portion of a turf section removed.DETAILED DESCRIPTION OF THE INVENTION

[0014] Described herein is a synthetic turf assembly and method which can be installed on either new or existing flat roofs. The synthetic turf assembly and method incorporates a plurality of roof attachment mechanisms with a plurality of framing members and a drainage element to provide an installation base that is mechanically coupled to a desired portion of a target flat roof and is suitable to provide a foundation for a turf layer that includes one or more sections of synthetic turf. Sections of synthetic turf may then be laid over and mechanically coupled to the installation base, with the turf layer and installation base forming the synthetic turf assembly that is securely fixed in place at the desired portion of the target flat roof.

[0015] A primary market for such a synthetic turf assembly may include high-end construction projects where a mechanically attached turf system is desirable for aesthetic, functional, and warranty-preserving purposes.

[0016] Referring now to the drawings and, in particular, FIGS. 1 and 2, a first embodiment of a synthetic turf assembly 100 for a flat roof installation is shown having framing members 110, roof attachment mechanisms 120, a drainage element 130, cover plates 140, and a turf layer 150. Each of the framing members 110 may be defined as rigid, rectangular boards having a pair of opposing longitudinal ends. The framing members 110 may be arranged to lie flat on the top surface of a target flat roof R, end to end sequentially such that a proximal longitudinal end of a first framing member 110 is placed against a distal longitudinal end of a second framing member 110 and a proximal longitudinal end of the third framing member 110 is placed against a distal longitudinal end of a third framing member 110. The framing members may then continue with such sequential end to end position around a perimeter of a desired section of a roof to be covered with the synthetic turf assembly 100. In this regard, the framing members 110 together may define a perimeter of an installation base for the synthetic turf assembly 100 and serve as a finishing edge which provides connection points for securing sections of synthetic turf.

[0017] It is contemplated that the desired section of a roof to be covered with the synthetic turf assembly 100 may define the flat roof in its entirety or one or more discrete sections thereof.

[0018] While the framing members 110 may be shown as forming a perimeter of the installation base for the synthetic turf assembly 100, in some embodiments, the framing members 110 may alternatively be arranged in a grid pattern.

[0019] Each of the roof attachment mechanisms 120 may include an elongated mechanical fastener 121, such as a screw, a flange 122, and a waterproof membrane 123 as mechanical fastening components. The flange 122 may be constructed of a rigid material, such as aluminum or another metal, and may generally include a body portion as well as an aperture which passes through the body portion, with the aperture being sized to allow the fastener 121 to pass through it. In this regard, the flange 122 may be embodied as the Flat Roof Attachment product made by IronRidge®. The fastener 121 may include a threaded portion and a head, with the threaded portion sized to pass through the flange 122 and be sufficiently inserted into the surface of a flat roof so as to attach securely thereto. The fastener 121 and the flange 122 are each shaped such that when the threaded portion of the fastener 121 is passed through the flange 122 and into the surface of a roof, the head may secure the flange 122 against the surface of the roof.

[0020] The membrane 123 may be constructed of a waterproof material that is suitable to be heat welded, such as polyvinyl chloride or thermoplastic polyolefin or other suitable roofing materials, and is sized such that when placed over a flange 122 that has been is secured against the surface of a roof, it extends beyond the perimeter edges and can contact the surface of the roof, completely encloses the flange 122 between the membrane 123 and the surface of the roof. In this regard, the membrane 123 may be embodied as the Flat Roof Attachment Membrane product made by IronRidge®. When a roof attachment mechanism 120 is in use, the portions of the membrane 123 which can contact the surface of the roof may be heat welded to the surface of the roof so as to form a watertight seal over the flange 122 and fastener 121.

[0021] It is contemplated that embodiments of the roof attachment mechanism may be embodied with just a flange and a membrane, with the flange being attached to a roof surface through an adhesive and / or the flange being held against a roof surface by the secured membrane.

[0022] It is additionally contemplated that embodiments of the roof attachment mechanism may be embodied with just a fastener and a membrane, with the membrane being secured to a roof over the fastener.

[0023] The drainage element 130 is operative to allow water to flow under and out from the synthetic turf assembly 100. In this regard, it may be positioned across the entire portion of a target flat roof R where the synthetic turf assembly 100 is to be installed except for the portions wherein framing members 110 and roof attachment mechanisms 120 are already positioned. In embodiments wherein the framing members 110 form a perimeter of this portion of a target flat roof R, the drainage element 130 may extend across the area enclosed by such a perimeter, except where the roof attachment mechanisms 120 are disposed. The drainage element 130 may be formed by a plurality of tiles which may be constructed of rubber or plastic, or a mat which may be constructed of rubber or plastic.

[0024] It is appreciated that the framing members 110 may include one or more transverse grooves on their bottom side in order to allow water flowing through the drainage element 130 to flow out from under the synthetic turf assembly 100.

[0025] Each of the cover plates 140 may be defined as a planar body that is sized to be placed on top of one of the roof attachment mechanisms 120, covering it completely, while also extending outwardly beyond the perimeter of the roof attachment mechanism 120 in all directions. Once positioned in this manner, the cover plate 140 may be fastened to the roof attachment mechanism 120 it is positioned over with a fastener such as a bolt 141, and fastened to adjacent framing members 110 with fasteners such as screws. The cover plates 140 may be constructed of a material which is impermeable and rigid, such as aluminum or another metal.

[0026] In some embodiments, the flanges 122 may be positioned so as to be adjacent to the meeting point of two end to end framing members 110. In this regard, a single cover plate 140 that is fastened to the roof attachment mechanism 120 of that flange 122 may extend over both of the end to end framing members 110 so as to hold each end in place on a roof. In some embodiments, the flanges 122 may be spaced a set distance apart, such as 10 feet, with the framing members 110 sized accordingly.

[0027] It is appreciated that in addition to allowing for necessary and proper drainage of water (or other fluid), the drainage element 130 also may provide enhanced bottom support for areas of the synthetic turf assembly 100 where there is no framing member 110 or cover plate 140 beneath sections of turf 150.

[0028] The turf layer 150 may be defined as one or more sections of synthetic turf which are together sized to extend across the entire portion of a target flat roof R where the synthetic turf assembly 100 is to be installed. In embodiments wherein, the framing members 110 form a perimeter of this portion of a target flat roof R, the drainage element 130 may extend across the framing members 110 in their entirety as well as the entire area enclosed by such a perimeter. The turf layer 150 may be secured in place by being fastened to the framing members 110 with fasteners such as screws.

[0029] Referring now to FIG. 3, the installation process for a synthetic turf assembly on a flat roof in accordance with a first embodiment of the present disclosure wherein the framing members are used to form the perimeter of an aspect of the roof desired to be covered with the synthetic turf assembly is shown. This process may begin with positioning the framing members at step 300. Positioning the framing members (or perimeter boards) may entail laying the framing members flat on the top surface of a target flat roof, end to end, around the perimeter of the desired section of the roof.

[0030] It is appreciated, however, that it may be desired or necessary to ensure the roof is free of debris or surface obstructions prior to performing the step of positioning of framing members.

[0031] Following this, the roof attachment mechanisms may be installed at step 310. Installing the roof attachment mechanisms may entail placing the flange of each roof attachment mechanism directly on the roof, positioned inside of the perimeter boards at the seams (where two boards meet). Each flange may then be fastened to the roof, by inserting the screw of the roof attachment mechanisms through the flange into the roof until the head of the screw secures the flange against the surface of the roof. Then, the waterproof membrane of the roof attachment mechanism is placed over each secured flange and heat welded to the roof surface.

[0032] Next, the drainage element is positioned on the desired section of the roof at step 320. In embodiments where the drainage element defines a drainage mat, positioning the drainage element may involve laying a drainage mat sized and shaped to completely fill the open section on the flat roof inside the perimeter created by the framing elements but cut around the roof attachment mechanisms on the surface of the roof at the desired section of the roof.

[0033] Once the drainage element is positioned, cover plates are installed at step 330. Installing the cover plates may include positioning a separate cover plate over each roof attachment mechanism so that extends outwardly beyond said roof attachment mechanism laterally in all directions, fastening the cover plate to the roof attachment mechanism using a bolt (or other elongated mechanical fastener), and then fastening each cover plate to each of the framing members that it extends over top of due to its positioning and orientation relative to its associated roof attachment mechanism. Through this positioning and orientation, it is appreciated that the cover plates may operate to hold the framing boards and the drainage element down against the surface of the roof.

[0034] Following this, the turf layer, which may be provided in one or more turf sections, is laid over the entire desired area at step 340, including the framing elements forming perimeter boards and area container therein. Through this arrangement, the turf layer extends all the way to the outer edge of the perimeter boards. Next, the turf layer is fastened to the framing elements with elongated mechanical fasteners, such as screws, at step 350. It is contemplated that in some embodiments, the fasteners attaching the turf layer to the framing elements may be desirably positioned halfway between the outer edge and inner edge of the framing elements, while in other embodiments they may be desirably positioned closer to the outer edge of the framing elements, while in other embodiments, they may halfway between the outer edge and inner edge of the framing elements on one hand, and closer to the outer edge of the framing elements on the other.

[0035] Referring now to FIGS. 4 and 5, a second embodiment of a synthetic turf assembly 200 for a flat roof installation is shown having framing members 210, roof attachment mechanisms, a drainage element 230, cover plates 240, and a turf layer 250. In this embodiment, the framing members 210 may be structured in the same manner as the framing elements of the first embodiment, but may be arranged with the roof attachment mechanisms positioned between discrete framing members 210. In this regard, the roof attachment mechanisms may include a rigid, rectangular member 222 sized to be positioned between framing members 210 and a waterproof membrane 223 sized to be placed over the rectangular member 222 and extend beyond its perimeter edges so as to be able to contact the surface of the roof and completely enclose the rectangular member 222 between the membrane 223 and the surface of the roof. When the roof attachment mechanism is in use, the portions of the membrane 223 which can contact the surface of the roof may be heat welded to the surface of the roof so as to form a watertight seal over the rectangular member 222 (the membrane 223 may also extend over portions of the framing members 210). In such an embodiment, the rectangular member 222 may be adhered to the surface of the roof or may be held in place by operation of the welding of the membrane 223 to the roof.

[0036] In this second embodiment, the cover plates 240 are structured and operate as the cover plates in the first embodiment, including the use of a fastener such as a bolt 141 to attach it to the rectangular member 222, but with the exception that they do not extend over the drainage element 230, while the structure and operation of the drainage element 230 and a turf layer 250 is the same as in the first embodiment.

[0037] For the second embodiment, the installation process for a synthetic turf assembly on a flat roof installation may be similar but include modifications with respect to the order of steps. For example, the process may begin with the roof attachment mechanisms and then move to positioning the framing members. Such an order would allow for the rectangular member and membranes to be secured in place before the framing members are placed around them.

[0038] Similarly, with the second embodiment, the cover plates may be installed before the drainage element is positioned. Such an order would allow for the framing members to be secured in place before the drainage element is added.

[0039] It is appreciated that certain components defined herein, such as the fasteners, attachments, and drainage mat, can be modified without altering the core function of the system. Such alternative designs could be employed to address different priorities as far as usability, manufacturing efficiency, or performance in specific applications.

[0040] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.

Examples

first embodiment

[0016]Referring now to the drawings and, in particular, FIGS. 1 and 2, a synthetic turf assembly 100 for a flat roof installation is shown having framing members 110, roof attachment mechanisms 120, a drainage element 130, cover plates 140, and a turf layer 150. Each of the framing members 110 may be defined as rigid, rectangular boards having a pair of opposing longitudinal ends. The framing members 110 may be arranged to lie flat on the top surface of a target flat roof R, end to end sequentially such that a proximal longitudinal end of a first framing member 110 is placed against a distal longitudinal end of a second framing member 110 and a proximal longitudinal end of the third framing member 110 is placed against a distal longitudinal end of a third framing member 110. The framing members may then continue with such sequential end to end position around a perimeter of a desired section of a roof to be covered with the synthetic turf assembly 100. In this regard, the framing me...

second embodiment

[0037]For the second embodiment, the installation process for a synthetic turf assembly on a flat roof installation may be similar but include modifications with respect to the order of steps. For example, the process may begin with the roof attachment mechanisms and then move to positioning the framing members. Such an order would allow for the rectangular member and membranes to be secured in place before the framing members are placed around them.

[0038]Similarly, with the second embodiment, the cover plates may be installed before the drainage element is positioned. Such an order would allow for the framing members to be secured in place before the drainage element is added.

[0039]It is appreciated that certain components defined herein, such as the fasteners, attachments, and drainage mat, can be modified without altering the core function of the system. Such alternative designs could be employed to address different priorities as far as usability, manufacturing efficiency, or pe...

BACKGROUND OF THE INVENTIONField of the Invention

[0001] This invention relates generally to synthetic turf installations and, more particularly, to a synthetic turf assembly, and method of installing the same, which fastens to a flat roof without compromising any aspect of the integrity of the roof.Description of the Prior Art

[0002] Synthetic turf (or artificial turf) is well known as a synthetic fiber based surface that mimics the appearance of a natural grass surface. In modern times, the use of such synthetic turf as a substitute for, or supplement to, natural grass in sites where natural grass is traditionally used, such as sports arenas, residential lawns and commercial applications, is widespread. As such, systems and assemblies have been established to deploy synthetic turf in various indoor and outdoor spaces.

[0003] A problem which still exists, however, is that existing turf systems and assemblies are typically unable to be effectively deployed on a flat roof. For example, a common method for attaching a turf system to a roof involves using adhesives to secure perimeter boards that turf can be attached to. This method, however, is undesirable because it is typically not approved by roofing manufacturers and can even result in the voiding of a warranty on a roof. As such, it is often prohibited by builders. Consequently, many have resorted to employing a ballast based approach. A ballast based approach generally involves adding 3-4 pounds of sand per square foot on top of the turf to weigh it down. But such a ballast based approach can be ineffective against uplift forces and does not provide long-term reliability on a rooftop environment. Thus, a solution to prevent uplift in turf systems on roofs without employing an approach which risks voiding a roof warranty has remained elusive.

[0004] Accordingly, there remains a need for a synthetic turf assembly, and method of installation, which employs attachment mechanisms which would allow for secure attachment to a roof without compromising its warranty. It would be desirable for such a synthetic turf assembly and method to employ framing, drainage, and turf components in a complementary arrangement with the attachment mechanisms to provide a reliable and long-lasting installation that effectively resists uplift forces.SUMMARY OF THE INVENTION

[0005] The present disclosure provides for a synthetic turf assembly for a flat roof installation, comprising: an installation base having a top side, wherein the installation base includes a frame, at least one attachment mechanism, and at least one linking body; wherein the frame defines a perimeter structure of the installation base; a turf layer fixed to the top side of the installation base and sized to completely cover the top side of the installation base; wherein the at least one attachment mechanism includes at least one roof elongated mechanical fastener and a waterproof cover, and is adapted to attach to a target roof with the at least one roof elongated mechanical fastener being inserted into the target roof and the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener, completely covering the at least one roof elongated mechanical fastener; and wherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof at a location adjacent to the frame, the at least one linking body is operative to couple with the at least one attachment mechanism while holding the frame in place on the target roof.

[0006] Embodiments of the synthetic turf assembly may additionally include a drainage element positioned to define the entire area of the installation base under the turf layer and inside of the frame other than what is defined by the at least one attachment mechanism.

[0007] It is an object of the present disclosure to provide a synthetic turf assembly and method of installation which employs attachment mechanisms which allows for secure attachment to a roof without compromising its warranty. It is contemplated that this may be accomplished by utilizing mechanical fastening components that have been found in other contexts to be acceptable for use on roofs by roofing manufacturers

[0008] It is an additional object of the present disclosure to provide a synthetic turf assembly and method which employs framing, drainage, and turf aspects in a complementary arrangement with attachment mechanisms to provide a reliable and long-lasting installation that effectively resists uplift forces.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] FIG. 1 is a partial perspective view of a synthetic turf assembly for a flat roof installation built in accordance with a first embodiment of the present disclosure, shown with a portion of a turf section removed.

[0010] FIG. 2 is a top plan view of a synthetic turf assembly for a flat roof installation built in accordance with a first embodiment of the present disclosure, shown with a portion of a turf section removed.

[0011] FIG. 3 is a flow chart showing a process for installing a synthetic turf assembly on a flat roof in accordance with the present disclosure.

[0012] FIG. 4 is a partial perspective view of a synthetic turf assembly for a flat roof installation built in accordance with a second embodiment of the present disclosure, shown with a portion of a turf section removed.

[0013] FIG. 5 is a partial side elevational view of a synthetic turf assembly for a flat roof installation built in accordance with a second embodiment of the present disclosure, shown with a portion of a turf section removed.DETAILED DESCRIPTION OF THE INVENTION

[0014] Described herein is a synthetic turf assembly and method which can be installed on either new or existing flat roofs. The synthetic turf assembly and method incorporates a plurality of roof attachment mechanisms with a plurality of framing members and a drainage element to provide an installation base that is mechanically coupled to a desired portion of a target flat roof and is suitable to provide a foundation for a turf layer that includes one or more sections of synthetic turf. Sections of synthetic turf may then be laid over and mechanically coupled to the installation base, with the turf layer and installation base forming the synthetic turf assembly that is securely fixed in place at the desired portion of the target flat roof.

[0015] A primary market for such a synthetic turf assembly may include high-end construction projects where a mechanically attached turf system is desirable for aesthetic, functional, and warranty-preserving purposes.

[0016] Referring now to the drawings and, in particular, FIGS. 1 and 2, a first embodiment of a synthetic turf assembly 100 for a flat roof installation is shown having framing members 110, roof attachment mechanisms 120, a drainage element 130, cover plates 140, and a turf layer 150. Each of the framing members 110 may be defined as rigid, rectangular boards having a pair of opposing longitudinal ends. The framing members 110 may be arranged to lie flat on the top surface of a target flat roof R, end to end sequentially such that a proximal longitudinal end of a first framing member 110 is placed against a distal longitudinal end of a second framing member 110 and a proximal longitudinal end of the third framing member 110 is placed against a distal longitudinal end of a third framing member 110. The framing members may then continue with such sequential end to end position around a perimeter of a desired section of a roof to be covered with the synthetic turf assembly 100. In this regard, the framing members 110 together may define a perimeter of an installation base for the synthetic turf assembly 100 and serve as a finishing edge which provides connection points for securing sections of synthetic turf.

[0017] It is contemplated that the desired section of a roof to be covered with the synthetic turf assembly 100 may define the flat roof in its entirety or one or more discrete sections thereof.

[0018] While the framing members 110 may be shown as forming a perimeter of the installation base for the synthetic turf assembly 100, in some embodiments, the framing members 110 may alternatively be arranged in a grid pattern.

[0019] Each of the roof attachment mechanisms 120 may include an elongated mechanical fastener 121, such as a screw, a flange 122, and a waterproof membrane 123 as mechanical fastening components. The flange 122 may be constructed of a rigid material, such as aluminum or another metal, and may generally include a body portion as well as an aperture which passes through the body portion, with the aperture being sized to allow the fastener 121 to pass through it. In this regard, the flange 122 may be embodied as the Flat Roof Attachment product made by IronRidge®. The fastener 121 may include a threaded portion and a head, with the threaded portion sized to pass through the flange 122 and be sufficiently inserted into the surface of a flat roof so as to attach securely thereto. The fastener 121 and the flange 122 are each shaped such that when the threaded portion of the fastener 121 is passed through the flange 122 and into the surface of a roof, the head may secure the flange 122 against the surface of the roof.

[0020] The membrane 123 may be constructed of a waterproof material that is suitable to be heat welded, such as polyvinyl chloride or thermoplastic polyolefin or other suitable roofing materials, and is sized such that when placed over a flange 122 that has been is secured against the surface of a roof, it extends beyond the perimeter edges and can contact the surface of the roof, completely encloses the flange 122 between the membrane 123 and the surface of the roof. In this regard, the membrane 123 may be embodied as the Flat Roof Attachment Membrane product made by IronRidge®. When a roof attachment mechanism 120 is in use, the portions of the membrane 123 which can contact the surface of the roof may be heat welded to the surface of the roof so as to form a watertight seal over the flange 122 and fastener 121.

[0021] It is contemplated that embodiments of the roof attachment mechanism may be embodied with just a flange and a membrane, with the flange being attached to a roof surface through an adhesive and / or the flange being held against a roof surface by the secured membrane.

[0022] It is additionally contemplated that embodiments of the roof attachment mechanism may be embodied with just a fastener and a membrane, with the membrane being secured to a roof over the fastener.

[0023] The drainage element 130 is operative to allow water to flow under and out from the synthetic turf assembly 100. In this regard, it may be positioned across the entire portion of a target flat roof R where the synthetic turf assembly 100 is to be installed except for the portions wherein framing members 110 and roof attachment mechanisms 120 are already positioned. In embodiments wherein the framing members 110 form a perimeter of this portion of a target flat roof R, the drainage element 130 may extend across the area enclosed by such a perimeter, except where the roof attachment mechanisms 120 are disposed. The drainage element 130 may be formed by a plurality of tiles which may be constructed of rubber or plastic, or a mat which may be constructed of rubber or plastic.

[0024] It is appreciated that the framing members 110 may include one or more transverse grooves on their bottom side in order to allow water flowing through the drainage element 130 to flow out from under the synthetic turf assembly 100.

[0025] Each of the cover plates 140 may be defined as a planar body that is sized to be placed on top of one of the roof attachment mechanisms 120, covering it completely, while also extending outwardly beyond the perimeter of the roof attachment mechanism 120 in all directions. Once positioned in this manner, the cover plate 140 may be fastened to the roof attachment mechanism 120 it is positioned over with a fastener such as a bolt 141, and fastened to adjacent framing members 110 with fasteners such as screws. The cover plates 140 may be constructed of a material which is impermeable and rigid, such as aluminum or another metal.

[0026] In some embodiments, the flanges 122 may be positioned so as to be adjacent to the meeting point of two end to end framing members 110. In this regard, a single cover plate 140 that is fastened to the roof attachment mechanism 120 of that flange 122 may extend over both of the end to end framing members 110 so as to hold each end in place on a roof. In some embodiments, the flanges 122 may be spaced a set distance apart, such as 10 feet, with the framing members 110 sized accordingly.

[0027] It is appreciated that in addition to allowing for necessary and proper drainage of water (or other fluid), the drainage element 130 also may provide enhanced bottom support for areas of the synthetic turf assembly 100 where there is no framing member 110 or cover plate 140 beneath sections of turf 150.

[0028] The turf layer 150 may be defined as one or more sections of synthetic turf which are together sized to extend across the entire portion of a target flat roof R where the synthetic turf assembly 100 is to be installed. In embodiments wherein, the framing members 110 form a perimeter of this portion of a target flat roof R, the drainage element 130 may extend across the framing members 110 in their entirety as well as the entire area enclosed by such a perimeter. The turf layer 150 may be secured in place by being fastened to the framing members 110 with fasteners such as screws.

[0029] Referring now to FIG. 3, the installation process for a synthetic turf assembly on a flat roof in accordance with a first embodiment of the present disclosure wherein the framing members are used to form the perimeter of an aspect of the roof desired to be covered with the synthetic turf assembly is shown. This process may begin with positioning the framing members at step 300. Positioning the framing members (or perimeter boards) may entail laying the framing members flat on the top surface of a target flat roof, end to end, around the perimeter of the desired section of the roof.

[0030] It is appreciated, however, that it may be desired or necessary to ensure the roof is free of debris or surface obstructions prior to performing the step of positioning of framing members.

[0031] Following this, the roof attachment mechanisms may be installed at step 310. Installing the roof attachment mechanisms may entail placing the flange of each roof attachment mechanism directly on the roof, positioned inside of the perimeter boards at the seams (where two boards meet). Each flange may then be fastened to the roof, by inserting the screw of the roof attachment mechanisms through the flange into the roof until the head of the screw secures the flange against the surface of the roof. Then, the waterproof membrane of the roof attachment mechanism is placed over each secured flange and heat welded to the roof surface.

[0032] Next, the drainage element is positioned on the desired section of the roof at step 320. In embodiments where the drainage element defines a drainage mat, positioning the drainage element may involve laying a drainage mat sized and shaped to completely fill the open section on the flat roof inside the perimeter created by the framing elements but cut around the roof attachment mechanisms on the surface of the roof at the desired section of the roof.

[0033] Once the drainage element is positioned, cover plates are installed at step 330. Installing the cover plates may include positioning a separate cover plate over each roof attachment mechanism so that extends outwardly beyond said roof attachment mechanism laterally in all directions, fastening the cover plate to the roof attachment mechanism using a bolt (or other elongated mechanical fastener), and then fastening each cover plate to each of the framing members that it extends over top of due to its positioning and orientation relative to its associated roof attachment mechanism. Through this positioning and orientation, it is appreciated that the cover plates may operate to hold the framing boards and the drainage element down against the surface of the roof.

[0034] Following this, the turf layer, which may be provided in one or more turf sections, is laid over the entire desired area at step 340, including the framing elements forming perimeter boards and area container therein. Through this arrangement, the turf layer extends all the way to the outer edge of the perimeter boards. Next, the turf layer is fastened to the framing elements with elongated mechanical fasteners, such as screws, at step 350. It is contemplated that in some embodiments, the fasteners attaching the turf layer to the framing elements may be desirably positioned halfway between the outer edge and inner edge of the framing elements, while in other embodiments they may be desirably positioned closer to the outer edge of the framing elements, while in other embodiments, they may halfway between the outer edge and inner edge of the framing elements on one hand, and closer to the outer edge of the framing elements on the other.

[0035] Referring now to FIGS. 4 and 5, a second embodiment of a synthetic turf assembly 200 for a flat roof installation is shown having framing members 210, roof attachment mechanisms, a drainage element 230, cover plates 240, and a turf layer 250. In this embodiment, the framing members 210 may be structured in the same manner as the framing elements of the first embodiment, but may be arranged with the roof attachment mechanisms positioned between discrete framing members 210. In this regard, the roof attachment mechanisms may include a rigid, rectangular member 222 sized to be positioned between framing members 210 and a waterproof membrane 223 sized to be placed over the rectangular member 222 and extend beyond its perimeter edges so as to be able to contact the surface of the roof and completely enclose the rectangular member 222 between the membrane 223 and the surface of the roof. When the roof attachment mechanism is in use, the portions of the membrane 223 which can contact the surface of the roof may be heat welded to the surface of the roof so as to form a watertight seal over the rectangular member 222 (the membrane 223 may also extend over portions of the framing members 210). In such an embodiment, the rectangular member 222 may be adhered to the surface of the roof or may be held in place by operation of the welding of the membrane 223 to the roof.

[0036] In this second embodiment, the cover plates 240 are structured and operate as the cover plates in the first embodiment, including the use of a fastener such as a bolt 141 to attach it to the rectangular member 222, but with the exception that they do not extend over the drainage element 230, while the structure and operation of the drainage element 230 and a turf layer 250 is the same as in the first embodiment.

[0037] For the second embodiment, the installation process for a synthetic turf assembly on a flat roof installation may be similar but include modifications with respect to the order of steps. For example, the process may begin with the roof attachment mechanisms and then move to positioning the framing members. Such an order would allow for the rectangular member and membranes to be secured in place before the framing members are placed around them.

[0038] Similarly, with the second embodiment, the cover plates may be installed before the drainage element is positioned. Such an order would allow for the framing members to be secured in place before the drainage element is added.

[0039] It is appreciated that certain components defined herein, such as the fasteners, attachments, and drainage mat, can be modified without altering the core function of the system. Such alternative designs could be employed to address different priorities as far as usability, manufacturing efficiency, or performance in specific applications.

[0040] The instant invention has been shown and described herein in what is considered to be the most practical and preferred embodiment. It is recognized, however, that departures may be made therefrom within the scope of the invention and that obvious modifications will occur to a person skilled in the art.

Examples

first embodiment

[0016]Referring now to the drawings and, in particular, FIGS. 1 and 2, a synthetic turf assembly 100 for a flat roof installation is shown having framing members 110, roof attachment mechanisms 120, a drainage element 130, cover plates 140, and a turf layer 150. Each of the framing members 110 may be defined as rigid, rectangular boards having a pair of opposing longitudinal ends. The framing members 110 may be arranged to lie flat on the top surface of a target flat roof R, end to end sequentially such that a proximal longitudinal end of a first framing member 110 is placed against a distal longitudinal end of a second framing member 110 and a proximal longitudinal end of the third framing member 110 is placed against a distal longitudinal end of a third framing member 110. The framing members may then continue with such sequential end to end position around a perimeter of a desired section of a roof to be covered with the synthetic turf assembly 100. In this regard, the framing me...

second embodiment

[0037]For the second embodiment, the installation process for a synthetic turf assembly on a flat roof installation may be similar but include modifications with respect to the order of steps. For example, the process may begin with the roof attachment mechanisms and then move to positioning the framing members. Such an order would allow for the rectangular member and membranes to be secured in place before the framing members are placed around them.

[0038]Similarly, with the second embodiment, the cover plates may be installed before the drainage element is positioned. Such an order would allow for the framing members to be secured in place before the drainage element is added.

[0039]It is appreciated that certain components defined herein, such as the fasteners, attachments, and drainage mat, can be modified without altering the core function of the system. Such alternative designs could be employed to address different priorities as far as usability, manufacturing efficiency, or pe...

Claims

1. A synthetic turf assembly for installation on a flat roof, comprising:an installation base having a top side, wherein the installation base includes a frame, at least one attachment mechanism, and at least one linking body;a turf layer fixed to the top side of the installation base and sized to completely cover the top side of the installation base;wherein the at least one attachment mechanism includes at least one roof elongated mechanical fastener and a waterproof cover, and is adapted to attach to a target roof with the at least one roof elongated mechanical fastener being inserted into the target roof and the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener, completely covering the at least one roof elongated mechanical fastener; andwherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof, the at least one linking body is operative to couple with the at least one attachment mechanism while holding the frame in place on the target roof.

2. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the frame is defined by a plurality of discrete framing members which are adjacent to one another, positioned sequentially end to end.

3. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the turf layer is attached to the frame with at least one turf elongated mechanical fastener.

4. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the turf layer defined by at least one section of turf.

5. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the at least one linking body is defined by a plate sized extend outwardly over at least a portion of the frame when coupled to the at least one attachment mechanism.

6. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the at least one attachment mechanism additionally includes a flange and is adapted to attach to the target roof with the at least one roof elongated mechanical fastener being inserted through the flange and into the target roof, with the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener and the flange, completely covering the at least one roof elongated mechanical fastener and the flange.

7. The synthetic turf assembly for installation on a flat roof of claim 1, wherein the installation base additionally includes a drainage element positioned to form a portion of the installation base under the turf layer that is not defined by the frame or the at least one attachment mechanism.

8. A synthetic turf assembly for installation on a flat roof, comprising:an installation base having a top side, wherein the installation base includes a frame, at least one attachment mechanism, and at least one linking body;wherein the frame defines a perimeter structure of the installation base;a turf layer fixed to the top side of the installation base and sized to completely cover the top side of the installation base;wherein the at least one attachment mechanism includes at least one roof elongated mechanical fastener and a waterproof cover, and is adapted to attach to a target roof with the at least one roof elongated mechanical fastener being inserted into the target roof and the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener, completely covering the at least one roof elongated mechanical fastener; andwherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof at a location adjacent to the frame, the at least one linking body is operative to couple with the at least one attachment mechanism while holding the frame in place on the target roof.

9. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the frame is defined by a plurality of discrete framing members which are next to one another, positioned sequentially end to end.

10. The synthetic turf assembly for installation on a flat roof of claim 9, wherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof at an attachment location that is adjacent to the frame, the at least one linking body is operative to couple with the at least one attachment mechanism while extending over the top side of the frame at a linking portion of the frame so as to holding the frame in place on the target roof.

11. The synthetic turf assembly for installation on a flat roof of claim 10, wherein the linking portion of the frame is defined by a location where an end of a first frame member amongst the plurality of frame members and an end of a second frame member amongst the plurality of frame members are next to one another.

12. The synthetic turf assembly for installation on a flat roof of claim 8, wherein when the frame is in place on the target roof and the at least one attachment mechanism is attached to the target roof at an attachment location that is adjacent to the frame, the at least one linking body is operative to couple with the at least one attachment mechanism while extending over the frame at a linking portion of the frame so as to holding the frame in place on the target roof.

13. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the turf layer is attached to the frame with at least one turf elongated mechanical fastener.

14. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the turf layer is defined by at least one section of synthetic turf.

15. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the at least one linking body is defined by a plate sized extend outwardly over at least a portion of the frame when coupled to the at least one attachment mechanism.

16. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the at least one attachment mechanism additionally includes a flange and is adapted to attach to the target roof with the at least one roof elongated mechanical fastener being inserted through the flange and into the target roof, with the waterproof cover being sealed to the target roof all around the at least one roof elongated mechanical fastener and the flange, completely covering the at least one roof elongated mechanical fastener and the flange.

17. The synthetic turf assembly for installation on a flat roof of claim 8, wherein the installation base additionally includes a drainage element positioned to define the entire area of the installation base under the turf layer and inside of the frame other than what is defined by the at least one attachment mechanism.

18. A method for installing a synthetic turf assembly on a flat roof, comprising:positioning a frame on a target roof so as to define a perimeter structure, wherein the frame has a top side;installing at least one attachment mechanism at an attachment location that is adjacent to the frame, wherein the at least one attachment mechanism includes at least one roof elongated mechanical fastener and a waterproof cover and the step of installing at least one attachment mechanism includes inserting the at least one roof elongated mechanical fastener into the target roof and sealing the waterproof cover to the target roof all around the at least one roof elongated mechanical fastener, completely covering the at least one roof elongated mechanical fastener;positioning a drainage element such that it covers the entire area inside the perimeter structure formed by the frame other than what is defined by the at least one attachment mechanism;attaching at least one linking body to the at least one attachment mechanism, wherein the at least one linking body is sized and shaped to extend outwardly over at least a portion of the top side of the frame when coupled to the at least one attachment mechanism and thereby hold the frame in place on the target roof; andinstalling a turf layer, wherein the step of installing the turf layer includes positioning at least one section of turf on the frame such that the top side of the frame, the drainage element, the at least one attachment mechanism and the at least one linking body are completely covered thereby and attaching the at least one section of turf to the frame with at least one turf elongated mechanical fastener.

19. The method of claim 18, wherein the at least one attachment mechanism additionally includes a flange and the step of installing at least one attachment mechanism includes inserting the at least one roof elongated mechanical fastener through the flange into the target roof and sealing the waterproof cover to the target roof all around the at least one roof elongated mechanical fastener and the flange, completely covering the at least one roof elongated mechanical fastener and the flange.

20. The synthetic turf assembly for installation on a flat roof of claim 18, wherein the frame is defined by a plurality of discrete framing members, and the step of positioning a frame includes laying the plurality of discrete framing members next to one another end to end sequentially.

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