Flat roof mounting device

A mounting device for covering a roof penetration in a roof includes a base having a central hub, an outer perimeter structure, a top which is open, a bottom which is open, and ribs extending from the hub outward to the perimeter structure. A continuous internal reservoir extends between the hub and the perimeter structure, for holding a sealant against and in cooperation with the roof. The reservoir unsevered by the ribs. A cap is moveable onto the base for forming, in cooperation with the perimeter structure, an environmental seal over the roof penetration.

FIELD

The present specification relates generally to construction, and more particularly to roofing construction brackets and mounts.

BACKGROUND

Solar panels, electrical conduit, HVAC units, and other similar equipment are often mounted on the roof of a structure. Frequently, it is necessary to penetrate the roof to secure the equipment to the structure. Generally, a mount is used to connect the equipment—or a rack or framework for the equipment—to the roof at a roof penetration. A mount is placed on the roof, and a fastener or fasteners are driven through the mount and into the roof to secure the mount to the roof. The equipment (or rack therefor) is then secured to the mount, which is uniquely designed to accept the equipment (or rack therefor).

While a secure method for attaching roof-mounted equipment, this has drawbacks. The mounts can be awkward to install. The penetrations must be sealed from the weather. While some mounts use flashing to seal the penetrations, some use sealant (alone or in addition) to flashing. However, most mounts relying on sealant create a mess which is difficult to clean and can become unsightly. Further, if the sealant is not applied correctly, the penetration may not be sealed; some mounts hide the penetration, making it difficult for the installer to determine whether the penetration has been sealed.

An improved mount is needed.

SUMMARY

A mounting device for covering a roof penetration in a roof includes a base having a central hub, an outer perimeter structure, a top which is open, a bottom which is open, and ribs extending from the hub outward to the perimeter structure. A continuous internal reservoir extends between the hub and the perimeter structure, for holding a sealant against and in cooperation with the roof. The reservoir unsevered by the ribs. A cap is moveable onto the base for forming, in cooperation with the perimeter structure, an environmental seal over the roof penetration.

The above provides the reader with a very brief summary of some embodiments described below. Simplifications and omissions are made, and the summary is not intended to limit or define in any way the disclosure. Rather, this brief summary merely introduces the reader to some aspects of some embodiments in preparation for the detailed description that follows.

DETAILED DESCRIPTION

Reference now is made to the drawings, in which the same reference characters are used throughout the different figures to designate the same elements. Briefly, the embodiments presented herein are preferred exemplary embodiments and are not intended to limit the scope, applicability, or configuration of all possible embodiments, but rather to provide an enabling description for all possible embodiments within the scope and spirit of the specification. Description of these preferred embodiments is generally made with the use of verbs such as “is” and “are” rather than “may,” “could,” “includes,” “comprises,” and the like, because the description is made with reference to the drawings presented. One having ordinary skill in the art will understand that changes may be made in the structure, arrangement, number, and function of elements and features without departing from the scope and spirit of the specification. Further, the description may omit certain information which is readily known to one having ordinary skill in the art to prevent crowding the description with detail which is not necessary for enablement. Indeed, the diction used herein is meant to be readable and informational rather than to delineate and limit the specification; therefore, the scope and spirit of the specification should not be limited by the following description and its language choices.

FIG. 1illustrates a flat roof mounting device10(hereinafter “the device10”) for covering a roof penetration with a mount, the device10including a base11and a cap12moveable onto the base11for forming an environmental seal around the roof penetration. The device10is a mount for a rack, framework, or other apparatus carrying equipment such as a solar panel array (hereinafter identified as a “rack”).

The base11is wide, round, and has a low profile. The base11includes a central hub20and an outer perimeter structure21coaxially encircling the central hub20. The hub20and perimeter structure21are connected, or coupled, to each other by a plurality of ribs22extending radially outward from the hub20to the perimeter structure21. Each rib22is formed with a bore23through which a fastener13is passed and secured into the roof, so as to securely fix the base11to the roof. The hub20, perimeter structure21, and ribs22are preferably formed integrally and monolithically, from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base11is applied over the roof penetration and the fasteners13are passed through the bores23such that their heads are seated against the ribs22, the base11is securely mounted to the roof at the roof penetration. With the base11securely mounted to the roof, the base11is a stable, secure, and strong mount for the rack. The base has a top24and an opposed bottom25; the bottom25is mounted on the roof and the top24is directed away from the roof. Both the top24and bottom25are open, that is to say, openings are formed at both the top24and bottom25. It is noted briefly here that, while the description may refer to “a roof penetration,” the embodiment ofFIGS. 1A-1Factually has several roof penetrations—one for each of eight fasteners13. However, in some cases, only a single penetration may be made or used (and so only a single fastener13may be used), while in other cases only two or three penetrations through the roof may be made or used. The phrase “roof penetration” is therefore meant to include single and multiple penetrations through a roof in a local area, such as under the footprint of one device10.

Referring now primarily toFIGS. 1A and 1B, like the base11, the perimeter structure21is wide, round, and has a low profile. The perimeter structure21has an outer edge30and an opposed inner edge31, both of which are circular in the embodiment shown inFIGS. 1A-1F. The outer edge30is a radially-directed annular edge, while the inner edge31is an upstanding flat edge or wall. The perimeter structure21also has an upper face32and an opposed lower face33. The upper and lower faces32and33meet at the outer and inner edges30and31. The perimeter structure21includes a flat annulus34or ring extending inwardly from the outer edge30and along a plane at the bottom25of the base11. The annulus34terminates at an upstanding ridge35; the ridge35rises obliquely from the annulus34toward the top24of the base11at the inner edge31. The upper face32, along the ridge35, has several differently-angled pitches, and proximate the top24, the ridge35is formed with an inset seat36. The seat36is an annular depression extending into the ridge35from the upper face32thereof the seat36is sized and shaped to snugly receive the cap12when applied to the base11. The seat36terminates radially inwardly at the top24and at the inner edge31. The inner edge31extends vertically downward toward, but not entirely to, the bottom25of the base, generally perpendicular to the plane at the bottom25.

Referring primarily toFIG. 1B, where the underside of the base11is illustrated well, the base11is partially hollow. The lower face33of the base11is contoured. At the annulus34, proximate the outer edge30, the lower face33is flat. Just slightly inboard, however, the flat lower face33is interrupted by a coaxial channel37extending upward into the base11. The channel37has a generally rectangular cross-section (though other shapes may be suitable) for receiving an o-ring, foam ring, adhesive sealant, or other form of gasket or sealing member to be compressed between the base11and the roof. The lower face33extends from the channel37, along the plane at the bottom25, to the underside of the upstanding ridge35, at which point the lower face33rises upward toward the top24of the base11. The lower face33then drops back down toward the bottom25along the inner edge31. The inner edge31extends from the top24of the base11toward the bottom25of the base11, but it stops above the bottom25. The inner edge31projects downwardly from the top24approximately two-thirds of the distance between the top24and the bottom25.

The upper and lower faces32and33cooperate to bound a hold of the base11. The hold40is an inner space of the base11. The hold40is hereinafter identified as a reservoir40with respect to this embodiment because, when the device10is applied to a roof structure, the hold40cooperates with the roof structure to define a reservoir40configured to receive, hold, and contain a flowable sealant applied thereto. As such, the hold40is the reservoir40. Indeed, in all embodiments presented herein, the hold is a reservoir and will be referred to as such. The reservoir40is open to both the top24and the bottom25of the base11, and it extends between the hub20and the perimeter structure21and is unsevered by the ribs22. In operation, as discussed below, the reservoir40is filled with the flowable sealant to ensure an environmental seal against the roof and around the roof penetration. The inner edge31defines a gap41below the ridge35at the inner edge31; this gap41is best seen inFIG. 1D. The presence of the gap41prevents the inner edge31from separating the reservoir40into an outer ring (under the ridge35) and an inner ring (between the ridge35and the hub20). This gap41allows sealant to flow radially throughout the reservoir40.

The perimeter structure21is formed integrally and monolithically to each of the ribs22. Turning now primarily toFIG. 1C, five ribs22are visible. The device10preferably has eight ribs22, as shown in these drawings, but may suitably have a fewer or greater number of ribs22depending on the needs of the application. Moreover, the ribs22are identical in every respect, and so discussion of the various structural elements and features of the ribs22will be made without reference to one rib22in particular, and the reader should understand that the discussion applies to all the ribs22equally.

The rib22has an inner end50proximate the hub20and an outer end51proximate the perimeter structure21. The rib22has an arm52projecting outward from the inner end50toward the outer end51. The arm52is tall and narrow. It has a top53, a bottom54, and opposed sides55. The side55are flat, parallel, and tall between the top53and bottom54. The bottom54is generally flat, parallel to the plane at the bottom25of the base11but elevated above it. The top53is highest proximate the inner end50and tapers down slightly toward the bottom54. The arm52extends about two-thirds of the distance between the inner end50and the outer end51. The arm52terminates at its outer end at a seat56.

The seat56is a flat extension of the arm52. It has a flat top60, a flat bottom61, and short sides62. The tall sides55of the arm52transition to the short sides62of the seat56, and the narrow top53and bottom54of the arm52transition to the wider, flat top60and bottom61of the seat56. Formed centrally and entirely through the seat56from the top60to the bottom61is the bore23mentioned above. The bore23is preferably a cylindrical, unthreaded hole formed transversely through the seat56. The seat56terminates at its outer end at the outer end51of the rib22, which is formed continuously to the inner edge31of the perimeter structure21. Thus, the rib22, extending from the inner end50, to the arm52, to the seat56, and finally to the outer end51, is a single form, connected integrally and monolithically to both the hub20and the perimeter structure21.

Referring now toFIG. 1D, the top53of the rib22is below the top24of the base11and is below the top of the hub20. The seat56is also below the top24and below the top of the hub20. Since the top53of the rib22descends from proximate the hub20to the seat56, the entirety of the rib22is below the open top24of the base11. With the rib22disposed apart from the open top24, a cavity63is defined above the rib22. The bottom54of the arm52is contiguous with and coplanar to the bottom61of the seat56, such that the arm52has a single, straight, planar bottom extending entirely from the inner end50to the outer end51. This bottom—formed by the bottoms54and61—is elevated above the bottom25of the base11. With the rib22disposed apart from the bottom25of the base11, a cavity64is defined below the rib22and above the plane including the bottom25of the base11. Both cavities63and64above and below the rib22form part of the reservoir40. In this way, the rib22does not sever the reservoir40, because the rib22does not separate the reservoir40into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir40despite the ribs22, because the ribs22do not sever the reservoir40.

Referring again toFIGS. 1A-1C, the ribs22all extend radially outward from the central hub20. The hub20is located centrally, arranged coaxially with respect to the perimeter structure21. The hub20is a cylindrical block, having a top70, an opposed bottom71, and an outer cylindrical sidewall72extending between the top70and bottom71. The inner end50of each rib22is formed to the outer sidewall72. The sidewall72has a slight taper to it, so that the sidewall72is slightly reduced in outer diameter proximate the top70compared to proximate the bottom71. The top70of the hub20is coplanar with the top of the upstanding ridge35, and these two tops are coplanar with the open top24of the base11.

As shown best inFIG. 1B, the hub20has a central solid body73. The solid body73is separated from the sidewall72by an annular void74. A plurality of short ribs75extend from the solid body73to the sidewall72and are registered in alignment with the ribs22. Both the sidewall72and the solid body73extend downward entirely to the bottom71, while the bottoms of the ribs75are raised slightly with respect to the bottom71. However, when the base11is applied to the roof, the sidewall72is preferably in continuous contact with the roof and isolates the void74from the reservoir40. The void74extends up to the top70.

The top70is flat, circular, smooth, and planar. A threaded bore76is formed in the geometric center of the top70. The bore76extends into the solid body73of the hub20from the top70, normal to the flat top70, and terminates before the bottom71, such that the bore76is blind. When the cap12is placed over the base11, the bore76is registered with a hole in the cap12.

Referring now toFIGS. 1A and 1B, the cap12is wide, round, and has a very low-profile dome shape. The cap12has a top80and an opposed bottom81, and opposed upper and lower surfaces82and83. The cap12is thin between the upper and lower surfaces82and83, defining a shell. The upper surface82is convex, and the lower surface83is concave, because the cap12curves downward from the flat top80to an annular, downwardly-projecting lip84at the bottom81. The lip84also defines the outer edge of the cap12at its outer dimension. The lip84includes an inner first pitch85and an outer second pitch86(as best seen inFIG. 1F); the second pitch86is steeper than the first pitch85.

At the top80of the cap12is a hole87. The hole87is formed entirely through the cap12from the upper surface82to the lower surface83. The hole87is located centrally on the top80and on the cap12, such that when the cap12is moved onto the base11, the hole87is registered with the threaded bore76in the hub20. This allows a rugged bolt88to be passed through the hole87in the cap12and be threadably applied to the bore76in the hub20when the device10is used.

Turning now toFIGS. 1D-1F, in operation, the device10is useful for providing a mount for a rack on a roof14and for sealing roof penetration15made through the roof14, which are necessary to securely attach the device10to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base11is placed atop the roof, as inFIG. 1D. The base11is aligned so that each bore23in a rib22is registered with a respective roof penetration15. The fasteners13are then applied to the bores23. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base11is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13has a head90and a long shank91. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat56of the rib22and the shank91passes below the seat56, penetrating the roof14and forming into the roof penetration15. The head90is seated in flush and direct contact with the top60of the seat56, and an unthreaded portion of the shank91just below the head90fills the bore23snugly. When all fasteners13are engaged in this manner, the base11is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket or sealing member is applied to the channel37on the underside of the base11before the base11is secured according to the above. This gasket creates a first seal between the base11and the roof14, just inboard from the outer edge30. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus34. Use of a gasket is optional, however, and not necessary to ensure an environmental seal between the base11and the roof14.

Turning now toFIG. 1E, once the base11is securely fixed to the roof14, a flowable sealant92is applied to the reservoir40. The sealant92is slowly applied to the reservoir40until the sealant92nearly reaches the top24of the base11. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base11, surrounding the roof penetrations15. Because the roof penetrations15are under the bores23in the ribs22, the roof penetrations15are under the ribs22. However, the cavities64defined below the ribs22are in fluid communication with, and indeed, form part of, the reservoir40, and so sealant92moves into the cavities64and surrounds the fasteners13and the roof penetrations15. The sealant92entirely fills the bottom of the reservoir40, flowing through the cavities63and64and through the gaps41. This forms an environmental seal between the base11and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top24, the heads90of the fasteners13are covered. Because the seats56are disposed below the top24of the base11, the seats56and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir40is adequately filled.

The above defines an installed condition of the device10. This installed condition is sufficient to form an environmental seal over the roof penetrations15. Some installers may choose to apply the bolt88to the central hub20and then immediately begin installing racks. However, an additional step may also be completed.FIG. 1Fillustrates the cap12applied to the base11. The installer registers the cap12with the base11, so that the lip84is registered with the seat36at the top of the ridge35of the base11, and then moves the cap12downward onto the base11so that the lip84is snugly received in the seat36. When so placed, the lower surface83of the top80of the cap12is received in direct and continuous contact with the flat top70of the hub20, and the hole87and the bore76are aligned. The bolt88is then passed through the hole87and is threadably engaged with the bore76. When the bolt88is tightened in the bore76, the cap12is compressed onto the base11, and the lip84and seat36form an environmental seal preventing moisture and other ingress into the device10. The cap12also serves to deflect rain, snow, and other moisture onto the ridge35and annulus34, from which it will flow onto the roof14. In these ways, when the cap12is moved onto the base11, the cap12and the perimeter structure21of the base11cooperate to form an environmental seal around the roof penetrations15.

Embodiment of FIGS.2A-2D

FIG. 2Aillustrates a flat roof mounting device110(hereinafter “the device110”) for covering a roof penetration with a mount, the device110including a base111and a cap112moveable onto the base111for forming an environmental seal around the roof penetration. The device110is a mount for a rack.

The base111is wide, round, and has a low profile. The base111includes a central hub120and an outer perimeter structure121encircling the central hub120. The hub120and perimeter structure121are connected, or coupled, to each other by a plurality of ribs122extending radially outward from the hub120to the perimeter structure121. Each rib122is formed with a bore123through which a fastener13is passed and secured into the roof, so as to securely fix the base111to the roof. The hub120, perimeter structure121, and ribs122are preferably formed integrally and monolithically, from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base111is applied over the roof penetration and the fasteners13are passed through the bores123such that their heads are seated against the ribs122, the base111is securely mounted to the roof at the roof penetration. With the base111securely mounted to the roof, the base111is a stable, secure, and strong mount for the rack. The base has a top124and an opposed bottom125; the bottom125is mounted on the roof and the top124is directed away from the roof. Both the top124and bottom125are open, that is to say, openings into the base111are formed at both the top124and bottom125.

It is noted briefly here that, while the description may refer to “a roof penetration,” the embodiment ofFIGS. 2A-2Dactually has several roof penetrations—one for each of six fasteners13. However, in some cases, only a single penetration may be made or used (and so only a single fastener13may be used), while in other cases only two or three penetrations through the roof may be made or used. The phrase “roof penetration” is therefore meant to include single and multiple penetrations through a roof in a local area, such as under the footprint of one device110.

Referring now primarily toFIGS. 2A and 2B, like the base111, the perimeter structure121is wide, round, and has a low profile. The perimeter structure121has a circular outer edge130and a star-shaped opposed inner edge131. The outer edge130is a low edge, while the inner edge131is an upstanding flat edge. The perimeter structure121also has an upper face132and an opposed lower face133. The upper and lower faces132and133meet at the outer and inner edges130and131. The perimeter structure121includes a flat annulus134or ring extending inwardly from the outer edge130and along a plane at the bottom125of the base111. The annulus134terminates at a star-shaped, upstanding ridge135; the ridge135rises obliquely from the annulus134toward the top124of the base111at the inner edge131. The upper face132, along the ridge135, has several differently-angled pitches, and proximate the top124, the ridge135is formed with an inset seat136. The seat136is an annular depression extending around and into the ridge135from the upper face132thereof; the seat136is sized and shaped to snugly receive the cap112when applied to the base111. The seat136terminates inwardly at the top124and at the inner edge131. The inner edge131extends vertically downward toward, but not entirely to, the bottom125of the base, generally perpendicular to the plane at the bottom125.

Referring primarily toFIG. 2B, where the underside of the base111is illustrated well, the base111is partially hollow. The lower face133of the base111is contoured. At the annulus134, proximate the outer edge130, the lower face133is flat. Just slightly inboard, however, the flat lower face133is interrupted by a coaxial channel137extending upward into the base111. The channel137has a generally rectangular cross-section (though other shapes may be suitable) for receiving an o-ring, foam ring, adhesive sealant, or other form of gasket or sealing member to be compressed between the base111and the roof. The lower face133extends from the channel137, along the plane at the bottom125, to the underside of the upstanding ridge135, at which point the lower face133rises upward toward the top124of the base111. The lower face133then drops back down toward the bottom125along the inner edge131.

The upstanding ridge135and the inner edge131wrap around the central hub120in a star pattern with six legs. The ridge135and edge131project radially outward around each bore123, forming a long leg of the star around the rib122and its bore123. Then, between adjacent ribs122, the ridge135and edge131cut inward toward the hub120, thereby decreasing the volume of an internal reservoir140of the base111. The annulus134extends inward in these places to form wedge-shaped dome portions138. These dome portions138curve slightly upwardly toward the top124but stop short thereof. At the inner ends of the dome portions138, the inner edge131projects downwardly from the top124approximately two-thirds of the distance between the top124and the bottom125. In other words, in those areas, the inner edge131extends from the top124of the base111toward the bottom125of the base111, but it stops above the bottom125.

The upper and lower faces132and133cooperate to bound the continuous internal reservoir140of the base111. The reservoir140is open to both the top124and the bottom125of the base111, and it extends between the hub120and the perimeter structure121. The reservoir140is unsevered by the ribs122because, as will be explained, there are gaps above and below the ribs122. Further, there are gaps below the dome portions138, so that the reservoir140is continuous. The reservoir140is an inner space or hold, which, when the device110is applied to a roof structure, cooperates with the roof structure to receive, hold, and contain the flowable sealant applied to the reservoir40. In operation, as discussed below, the reservoir140is filled with the flowable sealant to ensure an environmental seal against the roof and around the roof penetration. As seen inFIGS. 2B and 2B, the inner edge131defines a gap141below the ridge135at the inner edge131. The presence of the gap141prevents the inner edge131from separating the reservoir140into an outer ring (under the ridge135) and an inner ring (between the ridge135and the hub120). This gap141allows sealant to flow radially throughout the reservoir140.

The perimeter structure121is formed integrally and monolithically to each of the ribs122. Turning now primarily toFIG. 2C, four ribs122are visible. The device110preferably has six ribs122, as shown in these drawings, but may suitably have a fewer or greater number of ribs122depending on the needs of the application. Moreover, the ribs122are identical in every respect, and so discussion of the various structural elements and features of the ribs122will be made without reference to one rib122in particular, and the reader should understand that the discussion applies to all the ribs122equally.

The rib122has an inner end150proximate the hub120and an outer end151proximate the perimeter structure121. The rib122has an arm152projecting outward from the inner end150toward the outer end151. The arm152is tall and narrow. It has a top153, a bottom154, and opposed sides155. The side155are flat, parallel, and tall between the top153and bottom154. The bottom154is generally flat, parallel to the plane at the bottom125of the base111but elevated above it. The top153is highest proximate the inner end150and tapers down slightly toward the bottom154. The arm152extends about two-thirds of the distance between the inner end150and the outer end151. The arm152terminates at its outer end at a seat156.

The seat156is a flat extension of the arm152. It has a flat top160, a flat bottom161, and short sides162. The tall sides155of the arm152transition to the short sides162of the seat156, and the narrow top153and bottom154of the arm152transition to the wider, flat top160and bottom161of the seat156. The seat156is tall; the bottom161projects downwardly entirely to the plane of the bottom125of the base111, such that it contacts the top of the roof. Formed centrally and entirely through the seat156from the top160to the bottom161is the bore123mentioned above. The bore123is preferably a cylindrical, unthreaded hole formed transversely through the seat156. The seat156terminates at its outer end at the outer end151of the rib122, which is formed continuously to the inner edge131of the perimeter structure121. Thus, the rib122, extending from the inner end150, to the arm152, to the seat156, and finally to the outer end151, is a single form, connected integrally and monolithically to both the hub120and the perimeter structure121.

The seat156is coupled the inner edge131at three places. Each of the sides162of the seat156extends laterally outward as an extension formed to the inner edge131proximate the dome portions138. Further, the distal or outer end of the seat156extends radially outward as an extension formed to the inner edge131at the distal end of one of the legs of the inner edge131.

Referring still toFIG. 2C, the top153of the rib122is below the top124of the base111and is below the top of the hub120. The seat156is also below the top124and below the top of the hub120. Since the top153of the rib122descends from proximate the hub120to the seat156, the entirety of the rib122is below the open top124of the base111. With the rib122disposed apart from the open top124, a cavity163is defined above the rib122. The bottom154of the arm152is above the bottom161of the seat156. The arm152has a single, straight, planar bottom154extending entirely from the inner end150to the seat156, which has a lower bottom161, and the bottom154of the arm152then rises slightly back up at the outer end151. This bottom154is elevated above the bottom125of the base111. With the rib122disposed apart from the bottom125of the base111, a cavity164is defined below the rib122and above the plane including the bottom125of the base111. Both cavities163and164above and below the rib122form part of the reservoir140. In this way, the rib122does not sever the reservoir140, because the rib122does not separate the reservoir140into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir140despite the ribs122, because the ribs122do not sever the reservoir140.

Referring again toFIGS. 2A-2C, the ribs122all extend radially outward from the central hub120. The hub120is located centrally, arranged coaxially with respect to the perimeter structure121. The hub120is a cylindrical block, having a top170, an opposed bottom171, and an outer cylindrical sidewall172extending between the top170and bottom171. The inner end150of each rib122is formed to the outer sidewall172. The sidewall172has a slight taper to it, so that the sidewall172is slightly reduced in outer diameter proximate the top170compared to proximate the bottom171. The top170of the hub120is coplanar with the top of the upstanding ridge135, and these two tops are coplanar with the open top124of the base111.

As shown best inFIG. 2C, the hub120has a central solid body173. The top170of the hub120is flat, circular, smooth, and planar. A threaded bore176is formed in the geometric center of the top170. The bore176extends into the solid body173of the hub120from the top170, normal to the flat top170, and terminates before the bottom171, such that the bore176is blind. When the cap112is placed over the base111, the bore176is registered coaxially with a hole in the cap112. Indeed, when the cap112is placed over the base11, the entire hub120is registered with the hole in the cap112, as will be explained.

Referring now toFIGS. 2A and 2B, the cap112is wide and has a very low-profile, domed, star shape with six legs. The cap112has a top180and an opposed bottom181, and opposed upper and lower surfaces182and183. The cap112is thin between the upper and lower surfaces182and183, defining a shell. The upper surface182is convex, and the lower surface183is concave, because the cap112curves downward from the flat top180to an downwardly-projecting star-shaped lip184at the bottom181. The lip184also defines the outer edge of the cap112. The lip184includes an inner first pitch185and an outer second pitch186; the second pitch186is steeper than the first pitch185.

At the top180of the cap112is a hole187, surrounded by an downwardly-projecting lip189. The hole187is formed entirely through the cap112from the upper surface182to the lower surface183. The hole187is wide and is located centrally on the top180and on the cap112, such that when the cap112is moved onto the base111, the hole187receives the top170of the hub120. The lip189snugly receives the sidewall172of the hub120proximate the top180, and the bottom of the lip189is in contact with the tops153of the ribs122. A rugged bolt, similar to the bolt88used with the device10, can then be threadably applied to the bore176in the hub120when the device110is used.

Turning now toFIGS. 2C and 2D, in operation, the device110is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device110to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base111is placed atop the roof14, as inFIG. 2C. The base111is aligned so that each bore123in a rib122is registered with a respective roof penetration15. The fasteners13are then applied to the bores123. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base111is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13has a head90and a long shank91. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat156of the rib122and the shank91passes below the seat156into the roof penetration15. The head90is seated in flush and direct contact with the top160of the seat156, and an unthreaded portion of the shank91just below the head90fills the bore123snugly. When all fasteners13are engaged in this manner, the base111is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket of sealing member is applied to the channel137on the underside of the base111before the base111is secured according to the above. This gasket creates a first seal between the base111and the roof14, just inboard from the outer edge130. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus134. Use of a gasket is optional, however, and not necessary to ensure an environmental seal between the base111and the roof14.

Turning now toFIG. 2D, once the base111is securely fixed to the roof14, a flowable sealant92is applied to the reservoir140. The sealant92is slowly applied to the reservoir140until the sealant92nearly reaches the top124of the base111. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base111, surrounding the roof penetrations15. The cavities64defined below the ribs122are in fluid communication with, and indeed, form part of, the reservoir140, and so sealant92moves into the cavities64and surrounds the seat156and the fasteners13in the roof penetrations15. The sealant92entirely fills the bottom of the reservoir140, flowing through the cavities163and164and through the gaps141. This forms an environmental seal between the base111and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top124, the heads90of the fasteners13are covered. Because the seats156are disposed below the top124of the base111, the seats156and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir140is adequately filled.

The above defines an installed condition of the device110. This installed condition is sufficient to form an environmental seal over the roof penetrations15. Some installers may choose to apply the bolt to the central hub120and then immediately begin installing racks. However, an additional step may also be completed.FIG. 2Dillustrates the cap112applied to the base111. The installer registers the cap112with the base111, so that the lip184is registered with the seat136at the top of the ridge135of the base111and the lip189around the hole187is registered with the sidewall172of the hub120, and then moves the cap112downward onto the base111so that the lip184is snugly received in the seat136. When so placed, the bottom of the lip189is received in direct contact with the tops153of the ribs122, and the hole187is coaxially aligned around the bore176. A bolt can then be passed through the hole187and threadably engaged with the bore176. The cap112serves to deflect rain, snow, and other moisture onto the ridge135, annulus134, and dome portions138, from which it will flow onto the roof14. In these ways, when the cap112is moved onto the base111, the cap112and the perimeter structure121of the base111cooperate to form an environmental seal around the roof penetrations15.

Embodiment of FIGS.3A-3D

FIG. 3Aillustrates a flat roof mounting device210(hereinafter “the device210”) for covering a roof penetration with a mount, the device210including a base211for forming an environmental seal around the roof penetration. The device210is a mount for a rack, framework, or other apparatus carrying equipment such as a solar panel array (hereinafter identified as a “rack”). A key211is inserted into the base211to close a wide opening or keyway213in a central hub220at the top of the base211.

The base211is wide, round, and has a low profile. The base211includes the hub220and an outer perimeter structure221encircling the hub220. The hub220and perimeter structure221are connected, or coupled, to each other by a monolithic, integral, one-piece sheet214of material molded into the form of the base211, which sheet214includes the hub220, the perimeter structure221, and the various structures therebetween. The sheet214is preferably constructed from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base211is applied over the roof penetration and fasteners13are passed through the base211and into the roof, the base211is securely mounted to the roof at the roof penetration. With the base211securely mounted to the roof, the base211is a stable, secure, and strong mount for the rack.

The base211has a top224and a bottom225. Both the top224and bottom225are open, that is to say, openings into the base211are formed at both the top224and bottom225. A continuous internal reservoir230is defined between the top224and bottom225. The reservoir230is an inner space or hold, which, when the base211is applied to the roof, cooperates with the roof to receive, hold, and contain a flowable sealant. The key212is applied to the keyway213to enclose the reservoir230and seal the roof penetration.

The central hub220depends from the open top224. The hub220is a generally round cylindrical structure depending into the reservoir230. The hub220includes a smooth, vertical sidewall or inner edge231bounding the open keyway213. The inner edge231also defines a radially-inward termination of the sheet214about the keyway213. Formed on the inner edge231below the top224are two separated, opposed inward flanges232. The flanges232are spaced apart by two circumferential voids and extend inwardly below the top224. The flanges232are engaged by complemental flanges on the key212when the key212is applied to the keyway213, as is explained later.

From the top224, the sheet214extends downwardly into a star-shaped dome233. The dome233includes a plurality of spaced-apart legs234, each extending from the central hub220radially outward to the perimeter structure221and also downward from the top224. Together, the legs234form the dome233.

Each leg234is identical, and the discussion here will be made without reference to one leg234in particular, and the reader should understand that the discussion applies to all the legs234equally. Referring primarily toFIG. 3C, the leg234has an inner end235and an opposed outer end236. The leg234has a top237which is nearly flat, depending downwardly from the inner end235slightly to the outer end236. The leg234has two opposed sides238extending from the inner end235to the outer end236, and a sidewall239extends downward from the top237around the sides238and the sidewall239. The sidewall239is nearly vertical.

The leg234has an underside, seen best inFIG. 3B. As an integrally-molded piece of the sheet214, the leg234is generally hollow at its underside, between the sides238. Partially filling that hollow, however, is a rib240which extends from the outer end236to the inner end235of the leg234. The rib240has an inner end241terminating at the inner edge231and an opposed outer end242terminating on the underside or inner surface of the leg234at its outer end236. The rib240is narrow and tall, depending from the underside of the leg234. The rib240structurally supports the leg234and resists flexion and deflection of the leg234.

Formed in the leg234, approximately one-third of the distance from the outer end236to the inner end235of the leg234, is a seat243. The seat243has a flat top which is exposed on top of the base211and is parallel to the open bottom225of the base211. Below the top237of the leg234, the seat243includes a rugged, cylindrical protrusion in the rib240. This protrusion extends outward from the rib240and is formed around a bore244. The bore244extends entirely vertically through this protrusion to the seat243, such that is a through-bore. The bore244is preferably a cylindrical, unthreaded hole formed transversely through the seat243and perpendicular to the bottom225of the base211. The bore244closely receives a fastener13.

The leg234and the rib240depend from the top224of the base211and do not extend entirely to the bottom225. Instead, they terminate just above, so as to define a bifurcated cavity245below the leg234. The cavity245is bifurcated but not severed by the rib240; the cavity245is large and occupies nearly the entire volume under the leg234, but the rib240extending through the middle of the leg234bifurcates the cavity245into left and rights sides, though those sides are not entirely separated and do nonetheless remain in fluid communication with each other. The cavity245forms part of the reservoir230, and indeed, the cavities245of all legs234are coupled in fluid communication.

The internal reservoir230occupies the volume under the dome233, including the keyway213and the volume under the keyway213. The reservoir230terminates radially at the perimeter structure221. Referring toFIG. 3A-3C, the perimeter structure221is wide, round, and has a low profile. The perimeter structure221has a circular outer edge250and a star-shaped inner edge251. The outer edge250is a low edge, while the inner edge251is an upstanding edge which transitions into the sidewalls239of the legs234of the dome233. The perimeter structure221includes a flat annulus252or ring extending inwardly from the outer edge250and along a plane at the bottom of the base211. The annulus252terminates just inboard of the outer ends236of the legs234; the dome233overlaps the annulus252slightly. The annulus252is integrally formed to the dome233, and between the legs234, the annulus252is integrally formed to wedge-shaped dome portions253. These dome portions253curve slightly upwardly toward the top224but stop well short thereof. Each dome portion253terminates at the union of two adjacent legs234, just outside the central hub220.

The key212is applicable to the base211. Referring now primarily toFIGS. 3A and 3B, the key212is a generally round, cylindrical plug. It has a top260and an opposed bottom261. The top260of the key212is flat and includes an outer annulus262, an inner, inset nut263, and a depressed annular channel264therebetween. The annulus262is a wide, flat, annular structure at the outer edge of the key212. It terminates radially inwardly at the channel264, which extends downward into the key212. The nut263then rises back up, such that its top is coplanar with the flat top of the annulus262. The annulus262and the nut263are both formed integrally and monolithically to the key212, which is preferably a single, solid piece of material.

The annulus252terminates radially outward at a lip265, which is formed with an inwardly-directed channel266suitable for holding an o-ring, gasket, or the like. Below the lip265, a coaxial core267extends downwardly to the bottom261of the key212. The core267is conical, having a taper such that its top is wider than its bottom. Flanking the core267are two opposed flanges268, circumferentially spaced-apart by two circumferential voids269. Each flange268includes an outwardly-projecting lug270and an inwardly-directed channel271just above the lug270, which channel271is just below the lip265of the key212.

In operation, the key212is applied to the base211to close the open top224of the base211, enclose the reservoir230, and cooperate with the perimeter structure221to form an environmental seal around the roof penetration. Turning now toFIGS. 3C and 3D, in operation, the device210is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device210to the roof14. Roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base211is placed atop the roof14, as inFIG. 3C. The base211is aligned so that each bore244in a leg234is registered with a respective roof penetration15. The fasteners13are then applied to the bores244. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base211is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13has a head90and a long shank91. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat243and the shank91passes below the seat243into the roof penetration15. The head90is seated in flush and direct contact with the seat243, and an unthreaded portion of the shank91just below the head90fills the bore244snugly. When all fasteners13are engaged in this manner, the base211is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket of sealing member is applied to a channel272on the underside of the base211before the base211is secured according to the above. This gasket creates a first seal between the base211and the roof14, just inboard from the outer edge250. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus252. Use of a gasket is optional, however, and not necessary to ensure an environmental seal between the base211and the roof14.

Turning now toFIG. 3D, once the base211is securely fixed to the roof14, a flowable sealant92is applied to the reservoir230. The sealant92is slowly applied to the reservoir230until the sealant92nearly reaches the top224of the base211. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base211, surrounding the roof penetrations15. The cavities245defined below the ribs122are in fluid communication with, and indeed, form part of, the reservoir230, and so sealant92moves into the cavities245and surrounds the fasteners13in the roof penetrations15. The sealant92entirely fills the bottom of the reservoir230. This forms an environmental seal between the base211and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top224, the shanks91of the fasteners13inside the reservoir230are covered, the roof penetrations15are covered, and the bores244are covered from below. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until nearly the top224of the base211, the installer performing the work receives visual confirmation.

Once sealant92is applied to the base211in the manner above, the key212is applied to the base211. The key212is taken up, such as by hand, and registered with the keyway213in the hub220, with the bottom261directed toward the keyway213. The installer ensures that the circumferential voids269on the key212are registered with the flanges232on the inner edge231of the hub220, so that the key212can be directly inserted into the keyway213. The key212is then moved downward into the keyway213. The conical core267pushes sealant away from the advancing key212. Some sealant92may spill out of the keyway213and out onto the top237; that sealant92will need to be cleaned up before installation is complete. The key212is pushed into the keyway213until the tops of the inward flanges232are against the underside of the lip265of the key212. This prevents further downward movement of the key212into the keyway213, and also arranges the top260of the key212flush with the top224of the base211. The key212now needs to be rotated to lock the key212in the base211.

The nut263formed in the key212is suitable to be grasped a turned with a wrench. In the embodiments shown inFIGS. 3A-3D, the nut263is a hex nut, but it has other shapes in other embodiments. The channel264surrounding the nut263allows the nut263to be gripped by a wrench, socket driver, or similar tool. The installer takes up such a tool, fits it to the nut263, and rotates the tool and nut263by ninety degrees. Doing so causes the lugs270on the key212to slip under the flanges232on the hub220and the channels271on the key212to snugly receive the flanges232. This engagement prevents inadvertent removal of the key212from the base211. As the sealant92cures, the adhesive engagement between the sealant92and the key212will also operate to prevent inadvertent removal of the key212. The above defines an installed condition of the device210, which is sufficient to form an environmental seal over the roof penetrations15.

The key212has a threaded bore276formed in the geometric center of the top260of the key212. The bore276extends into the solid body of the key212, normal to the flat top260, and terminates above the bottom261, such that the bore276is blind. When the key212is secured in the keyway213as described above, bore276is centered coaxially with respect to the perimeter structure221. A rugged bolt, similar to the bolt88used with the device10, can then be threadably applied to the bore276to provide a mount for a rack.

Embodiment of FIGS.4A-4C

FIG. 4Aillustrates a flat roof mounting device310(hereinafter “the device310”) for covering a roof penetration with a mount, the device310including a base311and a cap312moveable onto the base311for forming an environmental seal around the roof penetration. The device310is a mount for a rack.

The base311is wide, round, and has a low profile. The base311includes a central depressed socket320and an outer perimeter structure321encircling the socket320. The socket320and perimeter structure321are connected, or coupled, to each other by a monolithic, integral, one-piece sheet314of material molded into the form of the base311, which sheet314includes the socket320, the perimeter structure321, and the various structures therebetween. The sheet314is preferably constructed from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base311is applied over the roof penetration and a fastener13is passed through the base311and into the roof, the base311is securely mounted to the roof at the roof penetration. With the base311securely mounted to the roof, the base311is a stable, secure, and strong mount for the rack.

The base311has a top324and a bottom325. Both the top324and bottom325are open, that is to say, openings into the base311are formed at both the top324and bottom325. A continuous internal reservoir330is defined between the top324and bottom325. The reservoir330is an inner space or hold, which, when the base311is applied to the roof, cooperates with the roof structure to receive, hold, and contain a flowable sealant; the cap312is then applied over the open top324to enclose the reservoir330and cooperate with the base311to seal the roof penetration.

The central socket320depends from the open top324. The socket320is a truncated, generally conical structure depending into the reservoir330, such that the socket320is wider near the top324than at its bottom. The socket320includes two opposed arcuate sidewalls331circumferentially spaced apart by two openings332. The sidewalls331are angled to define the conical shape of the socket320. They extend downwardly and inwardly toward each other in a converging fashion, terminating at a flat bottom333of the socket320. The bottom333extends from one sidewall331to the other and is formed at its center with a bore334suitable for receiving the fastener13. The bore334is preferably cylindrical and unthreaded, and it extends transversely through the bottom333. The bottom333does encircle the bore334with a circular structure, defining a seat338in which the bore334is formed.

The socket320includes engagement structure for engaging with and holding the cap312. The engagement structure overhangs the openings332. At the top324, the base311has a flat rim335, characterized as a thin annulus surrounding the socket320. The rim335has a larger width, extending radially inward slightly to form an overhanging lip336above each opening332. This lip336terminates, in a clockwise-direction (when the base311is viewed from above), with a leading edge337that extends downward to the bottom333. The leading edge337is formed on and parallels the sidewall331, and extends radially inward therefrom. Thus, the engagement structure overhanging each opening332is the lip336, which defines a catch for corresponding structure on the cap312, and the edge337, which defines a stop for corresponding structure on the cap312.

Like the base311, the perimeter structure321is wide, round, and has a low profile. The perimeter structure321has an outer edge340, and opposed to the outer edge340is the rim335, both of which are circular in the embodiment shown inFIGS. 4A-4C. The outer edge340is a low, flat edge. The perimeter structure321includes a flat annulus341or ring extending inwardly from the outer edge340and along a plane at the bottom of the base311. The annulus341terminates at an upstanding ridge342; the ridge342rises obliquely from the annulus341to the rim335at the top324of the base311. The ridge342has several differently-angled pitches, and proximate the top324, the ridge342is formed with an inset seat343. The seat343is an annular depression extending into the ridge342; the seat343is sized and shaped to snugly receive the cap312when applied to the base311. The seat343terminates radially inwardly at the top324and at the rim335.

Attention is now directed primarily toFIG. 4B, where the underside of the base311is illustrated well. The underside of the annulus341is flat. The underside of the upstanding ridge342rises upward from the annulus341toward the top324of the base311until it meets the rim335, at which point the underside of the socket320drops down to the bottom333. The bottom333of the socket320is disposed above the bottom325of the base311.

The underside of the socket320is formed integrally with a plurality of ribs344, each extending from an inner end345to an outer end346. There are preferably six ribs344, as shown in these drawings, but other embodiments of the device310have a fewer or greater number of ribs344depending on the needs of the application. The ribs344are identical in every respect, and so discussion of the various structural elements and features of the ribs344will be made without reference to one rib344in particular, and the reader shoulder understand that the discussion applies to all of the ribs344equally.

The inner end345of the rib344terminates at a ring347formed on the underside of the bottom333, surrounding the bore334. The ring347is a low wall, projecting downward from the bottom333and continuously encircling the bore334such that it lengthens the depth of the bore334and thus also reinforces the bore334. The inner end345of the rib344is formed integrally and monolithically to the ring347. The rib343is formed on and parallels the bottom333and the sidewall331and extends downward therefrom. Thus, the rib344is a single form, connected integrally and monolithically to the sheet314, the socket320, and the perimeter structure321.

The rib344has an arm348projecting radially outward from the inner end345toward the outer end346. The arm has a bottom350and opposed sides; the sides are flat and parallel between the underside of the socket320and the bottom350. The bottom350is smooth and undulates with the curvature of the base311. The arm348extends approximately two-thirds of the distance between the bore334at the center of the base311and the outer edge340of the perimeter structure321. The arm348terminates outwardly at its outer end346on the underside of the upstanding ridge342.

The bottom333of the socket320, and the bottom350of each rib344, is disposed between the open top324and the open bottom325of the base311. Moreover, the bottom333of the socket320, and the bottom350of each rib344, is disposed below the open top324and also above the open bottom325of the base311, such that they are vertically spaced apart from the top324and bottom325. The sidewalls331and bottom333of the socket320therefore define an upper cavity351above the socket320, and the socket320, rim335, and ridge342define a lower cavity352opposed from the upper cavity351. The upper cavity351extends upward from the socket320to the open top324; the lower cavity352extends downward to the open bottom325. The upper and lower cavities351and352are formed in communication with each other through the openings332in the socket320and through the bore334, and they cooperate to define the internal reservoir330of the base311. Moreover, because the bottom333and bottoms350of the ribs344are above the bottom325of the base311, when the base311is mounted on a roof, sealant applied to the base311flows vertically, radially, and circumferentially in the upper and lower cavities351and352without interruption or blockage. In this way, the socket320does not sever the reservoir330, because the socket320does not separate the reservoir330into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir330despite the socket320, because the socket320does not sever the reservoir330. Referring now toFIGS. 4A and 4B, the cap312is wide, round, and has a very low-profile dome shape. The cap312has a top360and an opposed bottom361, and it opposed upper and lower surfaces362and363. The cap312is thin between the upper and lower surfaces362and363, defining a shell. The upper surface362is convex, and the lower surface363is concave, because the cap312curves downward from the flat top360to an annular, downwardly-projecting lip364at the bottom361. The lip364also defines the outer edge of the cap312at its outer dimension.

At the top360of the cap312is a hole365. The hole365is formed entirely through the cap312from the upper surface362to the lower surface363. The underside of the cap312is reinforced, and has a greater thickness around the hole365than do other parts of the cap312. The hole365is located centrally on the top360of the cap312.

Turning now toFIG. 4C, in operation, the device310is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device310to the roof14. The roof penetration15is formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). Once the roof penetration15is formed, the base311is placed atop the roof. The base311is aligned so that its bore334is registered with the roof penetration15. Preferably, an o-ring, foam ring, adhesive sealant, or other form of gasket or sealing member366is compressed between the base11and the roof14; the sealing member366is placed just under the annulus341. This sealing member366creates a first seal between the base311and the roof14, just inboard from the outer edge340. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus341. Use of a sealing member366is optional, however, and not necessary to ensure an environmental seal between the base311and the roof14.

The fastener13is applied to the bore334. In other embodiments, the fastener13is a self-tapping or self-drilling fastener, and it is not necessary to drill a hole through the roof14; rather, the base311is placed over a desired location on the roof14and then the fastener13is applied through the base311and into the roof14. The fastener13is threadably engaged with the roof14until the head90is seated in the seat338surrounding the bore334and the shank91passes below the seat338into the roof penetration15. The head90is seated in flush and direct contact with the top of the seat338, and an unthreaded portion of the shank91just below the head90fills the bore334snugly. When the fastener13is engaged in this manner, the base311is securely fixed to the roof14.

Once the base311is securely fixed to the roof14, a flowable sealant92is applied to the reservoir330. With a tool such as a caulking gun, the sealant92is slowly applied through the open top324to the reservoir330until the sealant92nearly reaches the top324of the base311. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base311, surrounding the roof penetration15. Because the roof penetration15is under the bore334, the roof penetrations15is under the bottom333of the socket320and under the ring347at the inner ends345of the ribs344. However, the lower cavity352defined below the ribs344is in fluid communication with, and indeed, forms part of, the reservoir330, and so sealant92moves into the lower cavity352and surrounds the fastener13and the roof penetration15. The sealant92entirely fills the lower cavity352of the reservoir330, flowing through under each of the ribs344. Then, the sealant92fills from the lower cavity352, through the openings332in the socket320, and into the upper cavity351. This forms an environmental seal between the base311and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top324, the head90of the fastener13is covered. Because the bore334and seat338are disposed below the top324of the base311, the bore334, the seat338, and the head90and shank91of the fastener13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the head90is covered, the installer performing the work receives visual confirmation: when the head90is no longer visible, the installer can be sure the reservoir330is adequately filled.

Next, the installer applies a rugged bolt370through the hole365in the cap312. The bolt370is inverted, such that its head371is below the cap312and its shank372passes upward through it, exposing a portion of the shank372above the top360of the cap312. A nut373is threaded tightly onto the shank372until the head371and the nut373are drawn snugly toward each other on either side of the cap312.

The cap312is then registered with the base311, so that the lip364is registered with the seat343at the top of the ridge342of the base311, and the installer then moves the cap312downward onto the base311so that the lip364is snugly received in the seat343. When so placed, the lower surface363at the top360of the cap312is above the socket320, and a gap may be formed between the top of filled sealant92and the lower surface363of the cap312. Otherwise, if the sealant92has been filled to the top324of the base311, excess sealant92may spill out of the base311when the cap312is applied. This should be cleaned up by the installer.

In this manner, the lip364and the seat343form an environmental seal preventing moisture and other ingress into the device310. The cap312also serves to deflect rain, snow, and other moisture onto the ridge342and annulus341, where it will flow onto the roof14. In these ways, when the cap312is moved onto the base311, the cap312and the perimeter21of the base311cooperate to form an environmental seal over and around the roof penetrations15. Further, the shank370of the bolt370is available for the installer to apply the rack.

Embodiment of FIGS.5A-5C

FIGS. 5A-5Cillustrates a flat roof mounting device410(hereinafter “the device410”) for covering a roof penetration15with a mount. The device410includes a base411and a cap412moveable onto the base411for forming an environmental seal around the roof penetration15, so that a rack can be mounted on the device410.

The base411is wide, round, and has a low profile. The base411includes a central hub420and an outer perimeter structure421coaxially encircling the central hub420. The hub420and perimeter structure421are connected, or coupled, to each other by a plurality of ribs422extending radially outward from the hub420to the perimeter structure421. Each rib422is formed with a bore423through which a fastener13is passed and secured into the roof14, so as to securely fix the base411to the roof14. The hub420, perimeter structure421, and ribs422are preferably formed integrally and monolithically, from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base411is applied over the roof penetration and the fasteners13are passed through the bores423such that their heads are seated against the ribs422, the base411is securely mounted to the roof14at the roof penetration15. With the base411securely mounted to the roof, the base411is a stable, secure, and strong mount for the rack.

The base411has a top424and an opposed bottom425; the bottom425is mounted on the roof and the top424is directed away from the roof. Both the top424and bottom425are open, that is to say, openings into the base411are formed at both the top424and bottom425. It is noted briefly here that, while the description of this embodiment refers to “a roof penetration,” the embodiment ofFIGS. 5A-5Cactually has several roof penetrations—one for each of four fasteners13. However, in some cases, only a single penetration may be made or used (and so only a single fastener13may be used), while in other cases only two or three penetrations through the roof may be made or used. The phrase “roof penetration” is therefore meant to include single and multiple penetrations through a roof14in a local area, such as under the footprint of one device410.

Referring now primarily toFIGS. 5A and 5B, like the base411, the perimeter structure421is wide, round, and has a low profile. The perimeter structure421has an outer edge430and an opposed inner edge431, both of which are circular in the embodiment shown inFIGS. 5A-5C. The outer edge430is a low edge, while the inner edge431is an upstanding flat edge. The perimeter structure421also has an outer or upper face432and an opposed inner or lower face433. The upper and lower faces432and433meet at the outer and inner edges430and431. The perimeter structure421includes a flat annulus434or ring extending inwardly from the outer edge430and along a plane at the bottom425of the base411. The annulus434terminates at an upstanding wall435; the wall435rises vertically from the annulus434toward the top424of the base411, and the inner face of the wall435is the inner edge431. The inner edge431extends vertically downward from the top424toward, but not entirely to, the bottom425of the base411, generally perpendicular to the plane at the bottom425. The inner edge431extends from the top424of the base411toward the bottom425of the base411, but it stops above the bottom425. The inner edge431projects downwardly from the top424approximately two-thirds of the distance between the top424and the bottom425. The upper face432, along the wall435, is formed with outwardly-directed threads for engaging with the cap412.

Referring primarily toFIG. 5B, where the underside of the base411is illustrated well, the base411is partially hollow. At the annulus434, proximate the outer edge430, the lower face433of the base411is flat. At the inner edge of the annulus434, the lower face433turns upwardly with two sets of annular shoulders, each of decreasing inner diameter, until the lower face433meets the inner edge431. The inner edge431rises upwardly to the top424, bounding and defining an internal reservoir440of the base411in cooperation with the lower face433. The reservoir440is an inner space or hold, which, when the device410is applied to a roof structure, cooperates with the roof structure to receive, hold, and contain a flowable sealant applied to the reservoir440. The reservoir440is open to both the top424and the bottom425of the base411, and it extends between the hub420and the perimeter structure421and is unsevered by the ribs422. In operation, as discussed below, the reservoir440is filled with the flowable sealant to ensure an environmental seal against the roof14and around the roof penetration15.

The perimeter structure421is formed integrally and monolithically to each of the ribs422. With continuing reference toFIGS. 5A and 5B, four ribs422are visible. The device410preferably has four ribs422, as shown in these drawings, but may suitably have a fewer or greater number of ribs422depending on the needs of the application. Moreover, the ribs422are identical in every respect, and so discussion of the various structural elements and features of the ribs422will be made without reference to one rib422in particular, and the reader should understand that the discussion applies to all the ribs422equally.

The rib422has an inner end450proximate the hub420and an outer end451proximate the perimeter structure421. The rib422has an arm452projecting outward from the inner end450toward the outer end451. The arm452is wide, straight, flat, extending laterally from the inner end450toward the outer end451without rising or dropping. It has a top453, a bottom454, and opposed sides. The bottom454is flat, parallel to the plane at the bottom425of the base411, but elevated above it. The arm452extends about two-thirds of the distance between the inner end450and the outer end451. The arm452terminates at its outer end at a seat456.

The seat456is a flat extension of the arm452. It therefore shares the top453and bottom454of the arm452. The seat546also opposed sides which bulge outwardly from the sides of the arm452to encircle the seat456. Formed centrally and entirely through the seat456from the top453to the bottom454is the bore423. The bore423is preferably a cylindrical, unthreaded hole formed transversely through the seat456. The seat456terminates at its outer end at the outer end451of the rib422, which is formed continuously to the inner edge431of the perimeter structure421. Thus, the rib422, extending from the inner end450, to the arm452, to the seat456, and finally to the outer end451, is a single form, connected integrally and monolithically to both the hub420and the perimeter structure421.

The top453of the rib422is below both the top424of the base411and the top of the hub420. The seat456is thus also below the top424and below the top of the hub420. Since the rib422is flat, the entirety of the rib422is below the open top424of the base411. With the rib422disposed apart from the open top424, an upper cavity463is defined above the rib422. The bottom454of the arm452is contiguous with and coplanar to the bottom of the seat456, such that the arm452has a single, straight, planar bottom extending entirely from the inner end450to the outer end451. This bottom454is elevated above the bottom425of the base411. With the rib422disposed apart from the bottom425of the base411, a lower cavity464is defined below the rib422and above the plane including the bottom25of the base11. The upper and lower cavities463and464extend entirely around the hub420and separated by the ribs422, but are nonetheless in fluid communication with each other and together, above and below the rib422, form part of the reservoir440. In this way, the rib422does not sever the reservoir440, because the rib422does not separate the reservoir440into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir440despite the ribs422, because the ribs422do not sever the reservoir440.

Referring still toFIGS. 5A and 5B, the ribs422all extend radially outward from the central hub420. The hub420is located centrally, arranged coaxially with respect to the perimeter structure421. The hub420is a cylindrical block, having a top470, an opposed bottom471, and an outer cylindrical sidewall472extending between the top470and bottom471. The inner end450of each rib422is formed to the outer sidewall472. Above the ribs422, the sidewall472is vertical, but below the ribs422, the sidewall is semi-spherical. The top470of the hub420projects just slightly above the top of the upstanding wall435of the perimeter structure421.

As shown best inFIG. 5C, the hub420has a central solid body473. The top470is flat, circular, smooth, and planar, but a threaded bore476is formed in the geometric center of the top470, extending into the solid body473of the hub420from the top470, normal to the flat top470, and terminates before the bottom471, such that the bore476is blind. When the cap412is placed over the base411, the hub420is registered with a hole in the cap412, exposing this bore476.

Referring back toFIGS. 5A and 5B, the cap412is wide, round, and has a very low-profile disc shape. The cap412has a top480and an opposed bottom481, as well as opposed upper and lower surfaces. The cap412is thin between the upper and lower surfaces, defining a shell. The flat top480of the cap412extends outward to an annular, downwardly-projecting lip484which extends down to the bottom481. The inner surface of the lip484is formed with inwardly-directed threads485which correspond to and are complemental with the threads436on the wall435of the base411.

At the top480of the cap412is a large hole487. The hole487is formed entirely through the cap412from the upper surface to the lower surface. The hole487is located centrally on the top480and on the cap412, such that when the cap412is moved onto the base411, the hole487is registered with the hub420. This allows a rugged bolt to be passed through the hole487in the cap412and be threadably applied to the bore476in the hub420when the device410is used.

Turning now primarily to justFIG. 5C, in operation, the device410is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device410to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base411is placed atop the roof. The base411is aligned so that each bore423in a rib422is registered with a respective roof penetration15. The fasteners13are then applied to the bores423. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base411is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat456of the rib422and the shank91passes below the seat456into the roof penetration15. The head90is seated in flush and direct contact with the top453of the seat456, and an unthreaded portion of the shank91just below the head90fills the bore423snugly. When all fasteners13are engaged in this manner, the base411is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket488or sealing member is applied to the lower face433of the annulus434before the base411is secured according to the above. This gasket488creates a first seal between the base411and the roof14, just inboard from the outer edge430. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus434. Use of a gasket488is optional, however, and not necessary to ensure an environmental seal between the base411and the roof14.

Once the base411is securely fixed to the roof14, a flowable sealant92is applied to the reservoir440. The sealant92is slowly applied to the reservoir440until the sealant92nearly reaches the top424of the base411. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base411, surrounding the roof penetrations15. Because the roof penetrations15are under the bores423in the ribs422, the roof penetrations15are under the ribs422. However, the lower cavity464defined below the ribs422is in fluid communication with, and indeed, forms part of, the reservoir440, and so sealant92moves into the lower cavity464and surrounds the fasteners13and the roof penetrations15. The sealant92entirely fills the bottom of the reservoir440, flowing upward from the lower cavity464to the upper cavity463. This forms an environmental seal between the base411and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top424, the heads90of the fasteners13are covered. Because the seats456are disposed below the top424of the base411, the seats456and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir440is adequately filled.

The above defines an installed condition of the device410. This installed condition is sufficient to form an environmental seal over the roof penetrations15. Some installers may choose to apply a rugged bolt to the bore476in the central hub420and then immediately begin installing racks. However, an additional step may also be completed.FIG. 1Fillustrates the cap412applied to the base411. The installer registers the cap412with the base411, so that the lip484is registered with the wall435of the base411, and then moves the cap412downward onto the base411, rotating the cap412so as to threadably engage the threads485on the lip484with the threads436on the base411. The cap412is rotated completely. When so engaged, the hub420extends through the hole487in the cap412and is snugly received therein, and the top470of the hub420is flush with the top480of cap412.

A rugged bolt, similar to the bolt88inFIGS. 1D-1F, is then threadably engaged with the bore476. The cap412serves to deflect rain, snow, and other moisture onto the wall435and annulus434, from which it will flow onto the roof14. In these ways, when the cap412is moved onto the base411, the cap412and the perimeter structure421of the base411cooperate to form an environmental seal around the roof penetrations15.

Embodiment of FIGS.6A-6C

FIGS. 6A-6Cillustrate a flat roof mounting device490(hereinafter “the device490”) for covering a roof penetration15with a mount. The device490is nearly identical to the device410, and many of the structural elements and features are common to both devices410and490. As such, for structural elements and features of the device490which are identical to those of the device410, the discussion herein adopts the same reference characters, and full description of such elements and features may not be made. The reader will understand the structure and function of such elements and features, a discussion of them having already been presented with respect to the device410. For clarity, the reference characters of the device490which are identical will be marked with a prime (“′”) symbol to distinguish them from those of the device410, andFIGS. 6A-6Cwill not be marked with all of the identical reference characters. For example, the device490includes a base491and a cap492moveable onto the base491for forming an environmental seal around the roof penetration15, so that a rack can be mounted on the device490. The base491and cap492are nearly identical to their counterpart base411and cap412of the device410, but are slightly different and so have a different reference character. However, the base491includes an outer perimeter structure421′ which is identical to the outer perimeter structure421′ of the device410, and so that same reference character—marked with a prime symbol—is used. The base491also includes a central hub493which is coaxially encircled by the perimeter structure421′.

A plurality of ribs422′ extends radially outward from the hub493to the perimeter structure421′, each with a bore423′ for a fastener13. The hub493, perimeter structure421′, and ribs422′ are preferably formed integrally and monolithically, from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base491is applied over the roof penetration and the fasteners13are passed through the bores423′ such that their heads are seated against the ribs422′, the base491is securely mounted to the roof14at the roof penetration15. With the base491securely mounted to the roof, the base491is a stable, secure, and strong mount for the rack.

Like the base411of the device410, the base491has an top424′ and an opposed open bottom425′. The perimeter structure421′ has an outer edge430′, an opposed inner edge431′, an outer or upper face432′, an opposed inner or lower face433′, a flat annulus434′, an upstanding wall435′, threads436′ on the wall435′, and an internal reservoir440′. The ribs422′ are identical, and each has an inner end450′, an outer end451′, an arm452′, a top453′, a bottom454′, opposed sides, and a seat456′. The base491further includes an upper cavity463′ and a lower cavity464′, which extend entirely around the hub493, are separated by the ribs422′, and are in fluid communication with each other. Together, above and below the rib422′, the upper and lower cavities463′ and464′ form part of the reservoir440′. The rib422′ does not sever the reservoir440′, because the rib422′ does not separate the reservoir440′ into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir440′ despite the ribs422′, because the ribs422′ do not sever the reservoir440′.

The hub493is located centrally, arranged coaxially with respect to the perimeter structure421′. Rather than being a large cylindrical block like the hub420, the hub493has a flat top which is coplanar with the tops453′ of the arms452′ of the ribs422′ and a flat bottom which is coplanar with the bottoms454′ as well. Indeed, the inner ends450′ of the four ribs422′ contiguously transition extend to the hub493, which lies in the same plane as those ribs422′. As such, the top of the hub493is well below the top424′ of the base491, and the bottom of the hub493is well above the bottom425′. A large hole494is formed centrally in the hub493; when the cap492is placed over the base491, the hole494receives a depression or protrusion on the underside of the cap492.

Referring still toFIGS. 6A and 6B, the cap492is wide, round, and has a very low-profile disc shape. The cap492has a top480′, an opposed bottom481′, opposed upper and lower surfaces, and a downwardly-projecting lip484′, the inner surface of which is formed with inwardly-directed threads485′ which correspond to and are complemental with the threads436′ on the wall435′ of the base491.

At the top480′ of the cap492is a bore495extending downward into the cap492and into a protrusion496depending from the lower surface of the cap492. The protrusion496is a solid, truncated, conical block having a diameter which is wider at its top proximate to the lower surface of the cap492than it is at its flat bottom497, away from the lower surface. The bore495extends into the solid body of the protrusion496, normal to the flat top480′, and terminates before the bottom497, such that the bore495is blind. The bore495is sized to receive a rugged bolt to be passed through the bore495to be threadably engaged therein when the device490is used.

Turning now primarily to justFIG. 6C, in operation, the device490is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device490to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base491is placed atop the roof. The base491is aligned so that each bore423′ in a rib422′ is registered with a respective roof penetration15. The fasteners13are then applied to the bores423′. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base491is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat456′ of the rib422′ and the shank91passes below the seat456′ into the roof penetration15. The head90is seated in flush and direct contact with the top453′ of the seat456′, and an unthreaded portion of the shank91just below the head90fills the bore423′ snugly. When all fasteners13are engaged in this manner, the base491is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket488′ or sealing member is applied to the lower face433′ of the annulus434′ before the base491is secured according to the above. This gasket488′ creates a first seal between the base491and the roof14, just inboard from the outer edge430′. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus434′. Use of a gasket488′ is optional, however, and not necessary to ensure an environmental seal between the base491and the roof14.

Once the base491is securely fixed to the roof14, a flowable sealant92is applied to the reservoir440′. The sealant92is slowly applied to the reservoir440′ until the sealant92nearly reaches the top424′ of the base491. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base491, surrounding the roof penetrations15. Because the roof penetrations15are under the bores423′ in the ribs422′, the roof penetrations15are under the ribs422′. However, the lower cavity464′ defined below the ribs422′ is in fluid communication with, and indeed, forms part of, the reservoir440′, and so sealant92moves into the lower cavity464′ and surrounds the fasteners13and the roof penetrations15. The sealant92entirely fills the bottom of the reservoir440′, flowing upward from the lower cavity464′ to the upper cavity463′. This forms an environmental seal between the base491and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top424′, the heads90of the fasteners13are covered. Because the seats456′ are disposed below the top424′ of the base491, the seats456′ and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir440′ is adequately filled.

The installer next registers the cap492with the base491, so that the lip484′ is registered with the wall435′ of the base491, and then moves the cap492downward onto the base491, rotating the cap492so as to threadably engage the threads485′ on the lip484′ with the threads436′ on the base491. The cap492is rotated completely. When so engaged, the protrusion496extends downward through the hole494in the hub493where it is snugly received. A rugged bolt, similar to the bolt88inFIGS. 1D-1F, is then threadably engaged with the bore495.

In these ways, when the cap492is moved onto the base491, the cap492and the perimeter structure421′ of the base491cooperate to form an environmental seal around the roof penetrations15. The above defines an installed condition of the device490. This installed condition is sufficient to form the environmental seal over the roof penetrations15. The cap492serves to deflect rain, snow, and other moisture onto the wall435′ and annulus434′, from which it will flow onto the roof14. Some installers may choose to apply a rugged bolt to the bore476.

Embodiment of FIGS.7A-7C

FIG. 7Aillustrates a flat roof mounting device510(hereinafter “the device510”) for covering a roof penetration with a mount, the device510including a base511and a cap512moveable onto the base511for forming an environmental seal around the roof penetration. The device510is a mount for a rack.

The base511is wide, round, and has a low profile. The base511includes a central depressed socket520and an outer perimeter structure521encircling the socket520. The socket520and perimeter structure521are connected, or coupled, to each other by a monolithic, integral, one-piece sheet514of material molded into the form of the base511, which sheet514includes the socket520, the perimeter structure521, and the various structures therebetween. The sheet514is preferably constructed from a single piece of material having strong, rugged, durable, and rigid material characteristics. When the low base511is applied over the roof penetration and a fastener13is passed through the base511and into the roof, the base511is securely mounted to the roof at the roof penetration. With the base511securely mounted to the roof, the base511is a stable, secure, and strong mount for the rack.

The base511has a top524and a bottom525, both of which are open, with openings into the base511formed at both the top524and bottom525. A continuous internal reservoir530is defined between the top524and bottom525. The reservoir530is an inner space or hold, which, when the base511is applied to the roof, cooperates with the roof to receive, hold, and contain a flowable sealant which is applied into the reservoir530. The cap512is applied over the open top524to enclose the reservoir530and cooperate with the base511to seal the roof penetration.

The central socket520depends from the open top524. The socket520is a truncated, narrow, generally conical structure depending into the reservoir530, such that the socket520is wider near the top524than at its bottom. The socket520includes four opposed arcuate sidewalls531circumferentially spaced apart by four openings or slots532. The sidewalls531are angled to define the conical shape of the socket520. They extend downwardly and inwardly toward each other in a converging fashion, terminating at a small, roughly circular flat bottom533of the socket520. The bottom533extends between the bottom of each of the four sidewalls531and is formed at its center with a bore534suitable for receiving the fastener13. The bore534is preferably cylindrical and unthreaded, and it extends transversely through the bottom533. The bottom533does encircle the bore534with a circular structure, defining a seat538in which the bore534is formed.

At its top524, the base511has a flat rim535, characterized as a wide annulus surrounding the socket520. The slots532cut into the rim535slightly from its inner diameter; the slots532also cut into the otherwise circular bottom533from its outer diameter. Formed through the rim535are four threaded holes536, each sized to threadably receive screws537which secure the cap512to the base511.

Like the base511, the perimeter structure521is wide, round, and has a low profile. The perimeter structure521has an outer edge540opposing the rim535; the outer edge540and rim535are both circular in the embodiment shown inFIGS. 7A-7C. The outer edge540is a low, flat edge. The perimeter structure521includes a flat annulus541or ring extending inwardly from the outer edge540and along a plane at the bottom of the base511. The annulus541terminates at an upstanding ridge542; the ridge542rises obliquely from the annulus541to the rim535at the top524of the base511. When the cap512is applied to the base511, the cap512overlies the rim535and most of the ridge542.

Attention is now directed primarily toFIG. 7B, where the underside of the base511is illustrated well. The underside of the annulus541is flat. The underside of the upstanding ridge542rises upward from the annulus541toward the top524of the base511until it meets the rim535, at which point the underside of the socket520drops down to the bottom525. The bottom525of the socket520is disposed above the bottom525of the base511, and the bottom533of the socket520is disposed below the open top524. In other words, the bottom533of the socket520is disposed between the open top524and the open bottom525of the base511; the top524and bottom525are vertically spaced apart from the top524and bottom525.

The sidewalls531and bottom533of the socket520therefore define an upper cavity551above the socket520, and the socket520, rim535, and ridge542define a lower cavity552opposed from the upper cavity551. The upper cavity551extends upward from the socket520to the open top524; the lower cavity552extends downward to the open bottom525. The upper and lower cavities551and552are formed in communication with each other through the slots532in the socket520and through the bore534, and they cooperate to define the internal reservoir530of the base511. Thus, when the base511is mounted on a roof, sealant applied to the base511flows vertically, radially, and circumferentially in the upper and lower cavities551and552without interruption or blockage.

Referring now toFIGS. 7A and 7B, the cap512is wide, round, and has a very low-profile dome shape. The cap512has a top560and an opposed bottom561, and it opposed upper and lower surfaces562and563. The cap512is thin between the upper and lower surfaces562and563, defining a shell. The upper surface562is convex, and the lower surface563is concave, because the cap512curves downward from the flat top560to an annular, downwardly-projecting lip564at the bottom561. The lip564also defines the outer edge of the cap512at its outer dimension.

At the top560of the cap512is a hole565formed in a central downward depression566. The hole565is formed entirely through the cap512from the upper surface562to the lower surface563. The underside of the cap512is reinforced, and has a greater thickness around the hole565than do other parts of the cap512. The hole565is located centrally on the top560of the cap512, and it is disposed below the top560; the depression566surrounding the hole565extends downwardly from the top560and the hole is formed in the depression566.

Holes567are formed through the cap512, between the depression566and the lip564. When the cap512is placed over the base511, the holes567are registered with the holes536in the base511, such that the screws537can be applied to both.

Turning now toFIG. 7C, in operation, the device510is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device510to the roof14. The roof penetration15is formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). Once the roof penetration15is formed, the base511is placed atop the roof. The base511is aligned so that its bore534is registered with the roof penetration15. Preferably, an o-ring, foam ring, adhesive sealant, or other form of gasket or sealing member568is compressed between the base11and the roof14; the sealing member568is placed just under the annulus541. This sealing member568creates a first seal between the base511and the roof14, just inboard from the outer edge540. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus541. Use of a sealing member568is optional, however, and not necessary to ensure an environmental seal between the base511and the roof14.

The fastener13is applied to the bore534. In other embodiments, the fastener13is a self-tapping or self-drilling fastener, and it is not necessary to drill a hole through the roof14; rather, the base511is placed over a desired location on the roof14and then the fastener13is applied through the base511and into the roof14, thus forming the roof penetration15as it is applied to the roof14. The fastener13is threadably engaged with the roof14until the head90is seated in the seat538surrounding the bore534and the shank91passes below the seat538into the roof penetration15. The head90is seated in flush and direct contact with the top of the seat538, and an unthreaded portion of the shank91just below the head90fills the bore534snugly. When the fastener13is engaged in this manner, the base511is securely fixed to the roof14.

Once the base511is securely fixed to the roof14, a flowable sealant92is applied to the reservoir530. With a tool such as a caulking gun, the sealant92is slowly applied through the open top524to the reservoir530until the sealant92reaches just below the top524of the base511. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base511, surrounding the roof penetration15. Because the roof penetration15is under the bore534, the roof penetration15is under the bottom533of the socket520. However, the lower cavity552defined below the socket520is in fluid communication with, and indeed, forms part of, the reservoir530. In this way, the socket520does not sever the reservoir530, because the socket520does not separate the reservoir530into separate portions or parts among which the sealant cannot flow. Rather, the sealant can flow through the entire reservoir530despite the socket520, because the socket520does not sever the reservoir530. As such, sealant92moves into the lower cavity552and surrounds the fastener13and the roof penetration15. The sealant92entirely fills the lower cavity552of the reservoir530, flowing through each of the slots532. Then, the sealant92fills the lower cavity552, the slots532in the socket520, and the upper cavity551. This forms an environmental seal between the base511and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to near the top524, the head90of the fastener13is covered. Because the bore534and seat538are disposed below the top524of the base511, the bore534, the seat538, and the head90and shank91of the fastener13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the head90is covered, the installer performing the work receives visual confirmation: when the head90is no longer visible, the installer can be sure the reservoir530is adequately filled.

Next, the installer applies a rugged bolt570through the hole565in the cap512. The bolt570is inverted, such that its head571is below the cap512and its shank572passes upward through it, exposing a portion of the shank572above the top560of the cap512.

The cap512is then registered with the base511, so that the lip564is registered with the ridge542of the base511, and the installer then moves the cap512downward onto the base511so that the lip564is snugly received on the ridge542. When so placed, the lower surface563at the top560of the cap512is above the socket520, and a gap may be formed between the top of sealant92filling the socket520and the lower surface563of the cap512. Otherwise, if the sealant92has been filled to the top524of the base511, excess sealant92may spill out of the base511when the cap512is applied. This should be cleaned up by the installer.

In this manner, the lip564and the ridge542form an environmental seal preventing moisture and other ingress into the device510. The cap512also serves to deflect rain, snow, and other moisture onto the ridge542and annulus541, where it will flow onto the roof14. In these ways, when the cap512is moved onto the base511, the cap512and the perimeter structure521of the base511cooperate to form an environmental seal over and around the roof penetrations15. Further, the shank572of the bolt570is available for the installer to apply the rack.

Embodiment of FIGS.8A-E

FIGS. 8A-8Eillustrate a flat roof mounting device610(hereinafter “the device610”) for covering a roof penetration with a mount for a rack, which mount forms an environmental seal around the roof penetration.

The device610includes a lower base611and an upper attachment arm612projecting upwardly from the base611. The base611is hollow and defines an internal reservoir620. The reservoir620is an inner space or hold, which, when the device610is applied to a roof, cooperates with the roof to receive, hold, and contain a flowable sealant applied to the reservoir620. The reservoir620is filled with the sealant during installation. A cap or plug613is snugly fit into an opening in the base611through which the sealant is applied; when the plug613is applied and the base611is properly fit on the roof14, the plug encloses the reservoir620, and sealant applied to the reservoir620seals the roof penetration.

The base611includes an oblong dome621, formed from a thin sidewall, which includes a top622and an opposed bottom623. At the bottom623, the base611terminates with a downwardly-directed channel624. The channel624surrounds a bottom opening625in communication with the reservoir620, and the channel624is snugly fit with an o-ring, foam ring, adhesive sealant, or other form of gasket626which forms a seal with the roof when the base611is applied thereto.

The base611has an inner surface630and an opposed outer surface631. The inner surface630extends upwardly inside the base611from the channel624and bounds the reservoir620. The outer surface631, in contrast, extends from the channel624entirely up to and along the arm612. The inner and outer surfaces630and631meet at the channel624, and also at an opening632in the base611. The opening632is formed proximate the top622of the base611, and it extends across the top622roughly parallel to the bottom623of the base611. The opening632provides access to a top of the reservoir620. The opening632is oblong, extending in its long dimension in the same direction that the dome621extends in its long dimension.

Below the opening, a hub633is disposed in the reservoir620. The hub633is a generally round, cylindrical structure suspended within the reservoir620. The hub633includes a smooth, vertical outer sidewall634extending between a top635and an opposed bottom636of the hub633. The top635and bottom636are flat and parallel to each other and to the bottom623. Indeed, the bottom636of the hub633is coplanar to the bottom623of the base611, while the top635of the hub633is spaced below the top622of the base611.

The hub633has a central solid body through which a bore640is formed. The bore640extends entirely through the hub633from the top635to the bottom636, normal to the bottom623of the base611. When the plug613is removed from the opening632, the bore640is visible and accessible in the reservoir620.

The hub633is suspended in the reservoir620by opposed ribs641and642. The rib641extends forwardly to a “front” of the device610, and so is considered a “forward rib”641. The rib642extends rearwardly to a “back” of the device610, and so is considered a “rearward rib”642.

The forward rib641extends forwardly from an inner end formed integrally and monolithically to the sidewall634of the hub633to an outer end formed integrally and monolithically to the inner surface630of the base611. The rib641is narrow, having opposed sides which are flat, parallel, and tall. The rib641has a top643which is contiguous with the top635of the hub633, and it also has a bottom644which is contiguous with the bottom636of the hub633. Similarly, the rearward rib642extends rearwardly from an inner end formed integrally and monolithically to the sidewall634of the hub633to an outer end formed integrally and monolithically to the inner surface630of the base611, opposite the location where the forward rib641is joined to the inner surface630. The rib642is narrow and tall, having opposed sides which are flat, parallel and tall, having a top645and opposed bottom646. Behind the hub630, as seen inFIG. 8C, the reservoir620rises upwardly slightly. The top645of the rib642rises as well, and is joined to the inner surface630at the top of the reservoir620and along the back of the inner surface630entirely down to the bottom623. Indeed, the bottom646of the rib642is contiguous with the bottom636of the base611.

The hub633and ribs641and642separate the reservoir620into two lobes. However, with the hub620disposed below the top622of the base611, a cavity647is formed between the hub620and the top622. This cavity647is part of the reservoir620, but also joins the lobes of the reservoir620in communication with each other, so that the reservoir620is not severed or entirely separated by the hub633and ribs641and642. Rather, the sealant can flow through the entire reservoir620despite the ribs641and642.

Above the base611, the arm612projects upwardly. The arm612is an upstanding projection, integrally and monolithically formed to the base611, and it is rigidly connected thereto. The arm612has a top650and an opposed bottom651which is formed to the top622of the base611. The arm612extends smoothly and continuously from the base611as an extension thereof from the bottom651to its top650. The arm612has a front652and an opposed back653, both of which are roughly flat and parallel to each other between the top650and bottom651. The arm612has a thickness between the front652and back653which is approximately one-quarter the width of both the front652and the back653. The arm612is solid and preferably not hollow.

The arm612has opposed sides654and655which are inboard of the dome621of the base611. The sides654and655converge toward each other slightly to form a taper from the bottom651to the top650. The top650of the arm612is flat, and rounded corners extend between each of the sides654and655and the top650.

An aperture or slot660extends through the arm612and is useful for mounting rack hardware. The slots660is elongate, extending between the top650and bottom651of the arm612. The slot660has a length and a width; its length is approximately two-thirds of the height of the arm612between the top650and the bottom651, and its width is approximately one-fourth its height. Moreover, the top of the slot660is offset below the top650of the arm612by approximately the width of the slot660. On the front652of the arm612, the outer surface631surrounding the slot660is beveled slightly inward into the slot660and is formed with ridges661. The ridges661extend radially outward from the slot660. Similarly, on the back653of the arm612, the outer surface631of the arm612is covered with ridges662which are arranged laterally between the opposed sides654and655. The ridges662cover the outer surface631on the back653from the top650to just below the bottom of the slot660. The slot660has an inner surface663with is smooth and formed without any ridges.

The plug613is wide and oval-shaped. The plug613fits into and seals the opening632in the base611. The plug613has a top670and a downwardly-projecting lip671formed continuously around the top670at a perimeter672of the plug613. The top670is slightly curved and corresponds to the gentle concave rise at the top622of the base611and the bottom651of the arm612. The outer surface of the top670is smooth, so that it presents a continuous and contiguous surface to the outer surface631of the base611, such that water and other environmental effects move from the arm612over the base611without interruption at the plug613. The lip671is a short lip, extending just slightly downward from the top670at the perimeter672. The plug613is constructed from a resilient, flexible material, such that when it is applied to the opening632, the lip671deforms slightly to snugly fit into the opening632and form an environmental seal with the opening632that prevents water from entering the reservoir620.

Turning now primarily toFIGS. 8C-8E, in operation, the device610is useful for providing a mount for a rack on a roof and for sealing a roof penetration which is made through the roof and which is necessary to securely attach the device610to the roof. None of theFIGS. 8A-8Eillustrate the roof or roof penetration, as the foregoing discussions should provide sufficient information for the reader to grasp the discussion without explicit illustration. The roof penetrations are formed, such as with a drill, through the roof and potentially other roof structures. Once the roof penetrations are formed, the device610is placed atop the roof, and the bore640is registered with the roof penetration. Preferably, the plug613is initially removed, so that the roof penetration can be sighted through the reservoir620below the bore640.

The fastener13is then applied through the bore640. In other embodiments, the fastener13is self-tapping or self-drilling, and it is not necessary to pre-drill a hole; rather, the base611is placed over a desired location on the roof14and then the fastener13is applied into the roof14. The fastener13is threadably engaged with the roof14until the head90is seated against the top635of the hub633and the shank91passes below the top635, through the bore640, and into the roof penetration. The head90is seated in flush and direct contact with the top635, and an unthreaded portion of the shank91just below the head90fills the bore640snugly. When the fastener13is engaged in this manner, the device610is securely fixed to the roof14.

As best seen inFIGS. 8D and 8E, in some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket626or sealing member is applied to the channel624on the bottom623of the base611. This gasket626creates a first seal between the base611and the roof. This first seal is effective at preventing water, moisture, and other environmental ingress into the base611. Use of a gasket is optional, however, and not necessary to ensure an environmental seal between the base611and the roof.

Once the base611is securely fixed to the roof, a flowable sealant is applied to the reservoir620. The sealant is slowly applied to the reservoir until the sealant covers the head90of the fastener13. By slowly filling the sealant, the sealant can flow across the portion of the roof covered by the base611, surrounding the hub633and flowing into both lobes of the reservoir620on either side of the hub633. The sealant entirely fills the bottom of the reservoir620, flowing up along the sides of the ribs641and642, up above the top635of the hub633, through the cavity647, and finally over the head90of the fattener13. This forms an environmental seal between the base11and the roof which prevents environmental ingress through the roof.

By filling the sealant to cover the head90of the fastener13, the installer can be sure that the reservoir620is entirely filled. Because the hub633, bore640, and roof penetration are below the head90of the fastener13, when the head90is no longer visible, the reservoir620is adequately filled.

The above defines an installed condition of the device610. This installed condition is sufficient to form an environmental seal over the roof penetration. The plug613is preferably applied to the base611, however, to form an additional environmental seal around the reservoir620. When the plug613is applied, some excess sealant in the reservoir620may be squeezed out; the installer need only clean it up and continue application of the plug613. The plug613is pressed into the opening625until its top670is contiguous to the top622of the dome621. In this way, the plug forms a snug fit in the opening625and an environmental seal therewith. Equipment can now be mounted to the arm612of the device610.

Embodiment of FIGS.9A-9C

FIGS. 9A-9Cillustrate a flat roof mounting device710(hereinafter “the device710”) for covering a roof penetration with a mount. The device710has a base491and a cap712; the base491is the same base491as in the device490. No additional description of the base491is made here, as the reader will already understand the base491from its previous description.

The cap712is wide, round, and has an upstanding shape. The cap712has a top720, an opposed bottom721, and a sidewall722extending therebetween. Proximate the bottom721, the sidewall722has a wider diameter than it does proximate the top720, and so the cap712has a stepped or dual-diameter shape similar to two concentric cylinders stacked atop one another.

From the top720, the sidewall722is cylindrical and extends downward to a midplane723. A round opening724is defined at the top720, thereby providing access into an interior725defined within the sidewall722. The interior725is open entirely down to the midplane723, and so the midplane723defines an endwall to the interior725. As such, the interior725is blind. Several bores726are formed laterally through the sidewall722; these receive set screws as is explained below. A drain hole727is also formed laterally through the sidewall722at the bottom of the interior725to allow water to drain out of the interior725.

The midplane723is a circular disc between the top720and the bottom721. The midplane723extends radially inward from the sidewall722to define an endwall to the interior725, as explained above, and also extends radially outward from the sidewall722to a perimeter730. However, the midplane723and sidewall722are integrally and monolithically formed to each other; the vertical sidewall722transitions into the horizontal midplane723continuously, without seam or sever. At the perimeter730, the sidewall722extends downward to form a lip731. The lip731extends downwardly to the bottom721where the lip731terminates to define a lower opening732. The lower opening732opens into the shallow lower interior733beneath the midplane723. The inner surface of the lip731is formed with inwardly-directed threads734, which correspond to and are complemental with the threads436′ on the wall435′ of the base491.

Turning now primarily to justFIG. 9C, in operation, the device710is useful for providing a mount for a rack on a roof14and for sealing a roof penetration15which is made through the roof14and which is necessary to securely attach the device710to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base491is placed atop the roof. The base491is aligned so that each bore423′ in a rib422′ is registered with a respective roof penetration15. The fasteners13are then applied to the bores423′. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base491is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat456′ of the rib422′ and the shank91passes below the seat456′ into the roof penetration15. The head90is seated in flush and direct contact with the top453′ of the seat456′, and an unthreaded portion of the shank91just below the head90fills the bore423′ snugly. When all fasteners13are engaged in this manner, the base491is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket488′ or sealing member is applied to the lower face433′ of the annulus434′ before the base491is secured according to the above. This gasket488′ creates a first seal between the base491and the roof14, just inboard from the outer edge430′. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus434′. Use of a gasket488′ is optional, however, and not necessary to ensure an environmental seal between the base491and the roof14.

Once the base491is securely fixed to the roof14, a flowable sealant92is applied to the reservoir440′. The sealant92is slowly applied to the reservoir440′ until the sealant92nearly reaches the top424′ of the base491. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base491, surrounding the roof penetrations15. Because the roof penetrations15are under the bores423′ in the ribs422′, the roof penetrations15are under the ribs422′. However, the lower cavity464′ defined below the ribs422′ is in fluid communication with, and indeed, forms part of, the reservoir440′, and so sealant92moves into the lower cavity464′ and surrounds the fasteners13and the roof penetrations15. The sealant92entirely fills the bottom of the reservoir440′, flowing upward from the lower cavity464′ to the upper cavity463′. This forms an environmental seal between the base491and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top424′, the heads90of the fasteners13are covered. Because the seats456′ are disposed below the top424′ of the base491, the seats456′ and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir440′ is adequately filled.

The installer next registers the cap712with the base491, so that the lip731is registered with the wall435′ of the base491, and then moves the cap712downward onto the base491, rotating the cap712so as to threadably engage the threads734on the lip731with the threads436′ on the base491. The cap712is rotated completely. When the cap712is moved onto the base491, the cap712and the perimeter421′ of the base491cooperate to form an environmental seal around the roof penetrations15. The above defines an installed condition of the device710. This installed condition is sufficient to form the environmental seal over the roof penetrations15. The cap712serves to deflect rain, snow, and other moisture onto the wall435′ and annulus434′, from which it will flow onto the roof14.

With the cap712so positioned, the sidewall722is directed normal with respect to the roof14, and the interior725is directed upwardly with the opening724accessible above the roof14. The installer can then apply hardware into the interior725, fitting it snugly and then securing such hardware in the interior725with set screws applied through any or all of the bores726. Although the embodiment shown inFIGS. 9A-9Cillustrates a cylindrical sidewall722of the cap712defining a cylindrical interior725to preferably accept a cylindrical piece of hardware, one having ordinary skill in the art will understand that the sidewall722has other shapes and configurations—such as square, rectangular, hexagonal, irregular, etc. —in other embodiments to accept differently-shaped and -sized hardware, and the disclosure is not limited to this cylindrical sidewall722embodiment.

Embodiment of FIGS.10A-10C

FIGS. 10A-10Cillustrate a flat roof mounting device810(hereinafter “the device810”) for covering a roof penetration with a mount. The device810has a base491and a cap812; the base491is the same base491as in the device490. No additional description of the base491is made here, as the reader will already understand the base491from its previous description.

The cap812is wide and round, structured to accept an embodiment of a mounting hardware. In other embodiments, the cap812may have other shapes to accommodate other hardware; such other embodiments are within the scope of this disclosure. The cap812has a top820, an opposed bottom821, and a sidewall822extending therebetween. Proximate the bottom821, the cap812generally has a disc shape. Extending upward from the bottom821, the sidewall822forms an annular lip823. The lip823defines a lower opening824into an interior825of the cap812. The inner surface of the lip823is formed with inwardly-directed threads826, which correspond to and are complemental with the threads436′ on the wall435′ of the base491.

The lip823projects upwardly from the bottom821to a dome830. The dome830extends radially inwardly and upwardly from the lip823. The dome830is part of the sidewall822, and as such, is formed integrally and monolithically to the lip823. The dome830includes two raised ridges831and832and a valley833therebetween. The outer surface of the dome830has a concave shape between the lip823and the ridges831and832, such that the outer surface curves smoothly between the lip823and each of the ridges831and832. The ridges831and832are identical, and as such, only the ridge831will be described here with the understanding that the description applies equally to the other ridge832.

The ridge832has a flat top834that extends across the top820of the cap812, parallel to the top820and bottom821. The ridge831has an inner edge835, which is straight, and an opposed outer edge836, which is arcuate and bows outwardly away from the inner edge835. The outer surface of the dome830is continuous with the ridge831, of course, and as such, the ridge831has an outer surface which, below the inner edge835, is straight, and which, below the outer edge836, is arcuate and bows outwardly from the inner edge835. The inner and outer edges835and836meet and front and rear ends837and838, and extending downward from these, the outer surface defines a forward curved edge840and a rearward curved edge841, respectively. Both of the forward and rearward curved edges840slope downward from the ridge831toward the lip823of the cap812, and then, arcuately, slope back upward to the opposite ridge832. The forward and rearward curved edges840and841mark inflections in the outer surface of the cap812. Indeed, between the forward and rearward curved edges840and841, the valley833extends parallel to the ridges831and832. The valley833is a smooth concave depression in the cap812between the two ridges831and832and is sized and shaped to receive mounting hardware for a rack. In other embodiments, the valley833has a profile other than a smooth concave depression, such as a rectangular or square channel, to accept different mounting hardware.

Turning toFIG. 10C, blind sockets842are formed in the cap812. These sockets842depend inwardly in a transverse direction from the tops834of the ridges831and832to bottoms. The bottoms of the sockets842are co-planar to the bottom of the valley833, all of which are elevated above the top of the lip823.

Turning now primarily to justFIG. 10C, in operation, the device810is useful for providing a mount for a rack on a roof14and for sealing roof penetrations15which are made through the roof14and which are necessary to securely attach the device810to the roof14. The roof penetrations15are formed, such as with a drill, through the roof14and potentially other roof structures (shingles, underlayment, wood decking, moisture barriers, rafters, and other structures are collectively simplified here as the roof14). If there are several roof penetrations15, a pattern is used to ensure each is located properly with respect to the other. Once the roof penetrations15are formed, the base491is placed atop the roof. The base491is aligned so that each bore423′ in a rib422′ is registered with a respective roof penetration15. The fasteners13are then applied to the bores423′. In other embodiments, the fasteners13are self-tapping or self-drilling fasteners, and it is not necessary to drill holes; rather, the base491is placed over a desired location on the roof14and then the fasteners13are applied into the roof14. Each fastener13is threadably engaged with the roof14until the head90is seated in the seat456′ of the rib422′ and the shank91passes below the seat456′ into the roof penetration15. The head90is seated in flush and direct contact with the top453′ of the seat456′, and an unthreaded portion of the shank91just below the head90fills the bore423′ snugly. When all fasteners13are engaged in this manner, the base491is securely fixed to the roof14.

In some embodiments, an o-ring, foam ring, adhesive sealant, or other form of gasket488′ or sealing member is applied to the lower face433′ of the annulus434′ before the base491is secured according to the above. This gasket488′ creates a first seal between the base491and the roof14, just inboard from the outer edge430′. This first seal is effective at preventing water, moisture, and other environmental ingress at the annulus434′. Use of a gasket488′ is optional, however, and not necessary to ensure an environmental seal between the base491and the roof14.

Once the base491is securely fixed to the roof14, a flowable sealant92is applied to the reservoir440′. The sealant92is slowly applied to the reservoir440′ until the sealant92nearly reaches the top424′ of the base491. By slowly filling the sealant92, the sealant92can flow across the portion of the roof14covered by the base491, surrounding the roof penetrations15. Because the roof penetrations15are under the bores423′ in the ribs422′, the roof penetrations15are under the ribs422′. However, the lower cavity464′ defined below the ribs422′ is in fluid communication with, and indeed, forms part of, the reservoir440′, and so sealant92moves into the lower cavity464′ and surrounds the fasteners13and the roof penetrations15. The sealant92entirely fills the bottom of the reservoir440′, flowing upward from the lower cavity464′ to the upper cavity463′. This forms an environmental seal between the base491and the roof14which prevents environmental ingress through the roof14.

By filling the sealant92to just below the top424′, the heads90of the fasteners13are covered. Because the seats456′ are disposed below the top424′ of the base491, the seats456′ and the heads90and shanks91of the fasteners13received in them are covered. This increases the surety of the environmental seal. Further, by filling the reservoir with sealant92until the heads90are covered, the installer performing the work receives visual confirmation: when the heads90are no longer visible, the installer can be sure the reservoir440′ is adequately filled.

The installer next registers the cap812with the base491, so that the lip823is registered with the wall435′ of the base491, and then moves the cap812downward onto the base491, rotating the cap812so as to threadably engage the threads826on the lip823with the threads436′ on the base491. The cap812is rotated completely. When the cap812is moved onto the base491, the cap812and the perimeter421′ of the base491cooperate to form an environmental seal around the roof penetrations15. The above defines an installed condition of the device810. This installed condition is sufficient to form the environmental seal over the roof penetrations15. The cap812serves to deflect rain, snow, and other moisture onto the wall435′ and annulus434′, from which it will flow onto the roof14.

With the cap812so positioned, the valley833is oriented parallel to the roof14, with the ridges831and832flanking the valley833. The valley833is available to received rack mounting hardware which can be placed into the valley833and then secured with fasteners applied to the sockets842in each of the ridges831and832. The ridges831and832flank the hardware placed into the valley833and prevent movement of such hardware in the valley833.

Preferred embodiments are fully and clearly described above so as to enable one having skill in the art to understand, make, and use the same. Those skilled in the art will recognize that modifications may be made to the description above without departing from the scope and spirit of the specification, and that some embodiments include only those elements and features described, or a subset thereof. To the extent that modifications do not depart from the scope and spirit of the specification, they are intended to be included within the scope and spirit thereof.