Abstract:
A mounting apparatus with self-sealing properties that is used for installing solar modules and other types of equipment and material by attaching it through roofing or other exterior or interior surfaces is disclosed. The mounting apparatus uses a bolt with a toggle to mount a body to the structural sheathing rather than bolting to a structural framing member. A nut is tightened on the bolt to secure the toggle on one side of the roofing or other exterior or interior surfaces while a plunger is simultaneously driven to dispose a sealant. Using the mounting apparatus eliminates the need for finding the centerline of a structural framing member and assures the quality and the integrity of the seal around the mounting apparatus.

Description:
This application is claims the benefit of priority to U.S. Provisional Application Ser. No. 61/993,923, filed May 15, 2014. All extrinsic materials identified herein are incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     The field of the invention is a self-sealing mounting apparatus for mounting equipment onto roofing or other exterior or interior surfaces. 
     BACKGROUND 
     The background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art. 
     All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply. 
     Mounting systems can be used in various circumstances to support equipment onto walls, roofs, and other surfaces. Many of these systems use mounting attachments that fasten onto the wall, roof or other surface in order to adequately support the weight of the equipment. While weight distribution is beneficial for the surface supporting the mounted equipment, the location of the mounting attachments can create other structural or regulatory problems. 
     For example, conventional roof mounting systems use mounting points of attachment called standoffs which are fastened with lag bolts through the structural framing members (e.g., truss, rafter, etc.) of the roof. To be installed properly, conventional roof mounted points of attachment require finding the centerline of the structural framing member through the roof sheathing with specialty tools or by trial and error drilling and patching. Consequently, this methodology weakens the structural integrity of the roof framing and can damage the roof rafters or roof trusses. 
     When used on tile roofing, conventional roof mounted points of attachment require that certain roof tiles be removed and cut or notched and then re-installed around the standoff. Alternatively, metal flashing may be used to replace the tile, but this is expensive and still requires removing the roof tile and locating the framing member through the roof sheathing. 
     Installation of conventional roof mounted points of attachment can be labor intensive. In addition, conventional roof mounted points of attachment can create regulatory concerns. For example, some jurisdictions require a special attic inspection because building inspectors are concerned about potential truss or rafter damage occurring when lag bolts are misaligned with the centerline of the framing member. In another example of a regulatory concern, some jurisdictions require that points of attachment be made by anchoring the lag bolts through new solid blocking instead of into the truss or rafter. 
     Furthermore, conventional roof mounted points of attachment follows the building structural framing member for layout purposes. This usually requires that the spacing between points of attachments be rounded down to the next available structural member (e.g., truss or rafter). Consequently, the number of standoffs needed for proper mounting often exceeds the number required. 
     Various approaches have been developed in the field of mounting and attachment equipment, such as U.S. Pat. Pub. No. 2012/0005983 to Stephan, U.S. Pat. No. 4,321,745 to Ford, U.S. Pat. Pub. No. 2013/0240466 to Sponseller, and U.S. Pat. No. 8,136,311 to Liu. While these references provide some benefit in overcoming a problem, there are numerous deficiencies that they fail to overcome. 
     Thus, there is still a need for a mounting apparatus that is easy to install for mounting equipment onto roofing or other exterior or interior surfaces. 
     SUMMARY OF THE INVENTION 
     The inventive subject matter provides apparatus, systems and methods in which a mounting device can be attached onto roofing or other exterior or interior surfaces. The mounting device has a body with a base that defines an opening and a first aperture. At least partially disposed within the body is a plunger that has a through hole aligned with the opening. A bolt having a first end and a toggle on a second end extends through the opening. The mounting device improves upon conventional mounting systems by using a toggle based fastener to allow the body to be mounted onto structural sheathing rather than the structural framing member (e.g., truss, rafter) as used by conventional attachments using lag bolts. Thus, conventional steps of finding the centerline of the structural framing member, removing multiple roof tiles to find the structural framing member, and any potential misalignment of the anchoring fastener are eliminated. 
     The body also comprises a sealant located between the plunger and the opening. By having the sealant located between the plunger and the opening, movement of the plunger disposes the sealant through at least one of the first aperture and the opening to produce self-sealing properties. Thus, the quality and the integrity of the seal surrounding the mounting device are consistent among various mounting devices. 
     To prevent accidental movement of the plunger, the mounting device can further include a set pin. The set pin engages a set hole that extends through the body and the plunger to prevent the plunger from moving within the body to dispose the sealant. The set pin is removed when installation is desired to allow the plunger to dispose the sealant. 
     The mounting device can have various suitable sealants and sealant housings for producing self-sealing properties. For example, the sealant can comprise sealant beads. It should be appreciated that housing the sealant in beads prevents the sealant from prematurely drying within the body of the mounting device. When the plunger moves to dispose the sealant, the beads are crushed and mixed to produce the seal. To improve mixing and crushing, the plunger can further include teeth. 
     In another example of a sealant housing, the sealant can be housed in a doughnut shaped breakable sealant bag. As used herein, doughnut shaped is defined as a ring-shaped object, such as a torus. Similar to the sealant beads discussed above, housing the sealant in a doughnut shaped breakable sealant bag prevents the sealant from prematurely drying within the body of the mounting device. When the plunger moves to dispose the sealant, the doughnut shaped breakable sealant bag is ruptured to expose the sealant. 
     While a housing can be used to prevent premature drying as discussed above, an airtight sticker and a plastic disk can be used within the body to prevent drying. The airtight sticker covers the first aperture and the plastic disk is disposed within the body between the plunger and the sealant. As used herein, airtight is defined as substantially impermeable to air by preventing at least 90% penetration of air, more preferably 95% penetration of air, and most preferably 99% penetration of air. 
     In another aspect of the inventive subject matter, the inventors have discovered a self-sealing mounting apparatus for a surface. The mounting apparatus comprises a body having a base that defines an opening and a first aperture. A plunger having a through hole aligns with the opening of the body. A bolt extends through the opening having a first end and a toggle on a second end. At the first end of the threaded bolt is a nut that is used to provide movement to the plunger. A sealant is disposed within the body between the plunger and the opening, such that a driving force created by the nut and the toggle moves the plunger to dispose the sealant through at least one of the first aperture and the opening to form a seal on the surface. 
     In this aspect, various suitable sealant configurations (e.g., airtight sticker and plastic disk, beads, doughnut shaped breakable bag) can be used to prevent premature drying of the sealant within the body. In addition, a set pin can be used that engages a set hole extending through the body and the plunger to prevent accidental movement of the plunger. 
     Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  is a cross sectional view of an example of a mounting apparatus before installation onto a surface. 
         FIG. 2  is a cross section view of the mounting apparatus of  FIG. 1  during installation. 
         FIG. 3  is a cross sectional view of the mounting apparatus of  FIG. 1  after installation. 
         FIG. 4  is a perspective view of the mounting apparatus of  FIG. 1  after installation having a mounting bracket and solar panel beam. 
         FIG. 5A  is a bottom view of the body of the mounting apparatus of  FIG. 1 . 
         FIG. 5B  is a cross sectional view of the body of  FIG. 5A  taken along the line A-A. 
         FIG. 6A  is a bottom view of the plunger of the mounting apparatus of  FIG. 1 . 
         FIG. 6B  is a cross sectional view of the plunger of  FIG. 6A  taken along the line B-B. 
         FIG. 7  is a side view of the bolt of the mounting apparatus of  FIG. 1 . 
         FIG. 8  is a cross sectional view of an example of a mounting apparatus having a sealant housed in a doughnut shaped breakable sealant bag. 
         FIG. 9  is a cross sectional view of an example of a mounting apparatus having sealant beads. 
         FIG. 10A  is a bottom view of the plunger of the mounting apparatus of  FIG. 9 . 
         FIG. 10B  is a cross sectional view of the plunger of  FIG. 10A  taken along the line C-C. 
         FIG. 11  is a cross sectional view of an example of a mounting apparatus having a spring and spring core. 
     
    
    
     DETAILED DESCRIPTION 
     The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed. 
     A mounting apparatus has been discovered that can attach to roofing and other surfaces without using structural members (e.g., rafter, truss, beam).  FIG. 1  shows an embodiment of a mounting apparatus  100  having a body  101 , a plunger  103 , a sealant  105 , and a bolt  107  that cooperate to provide a self-sealing mount. Body  101  has a base  109  that defines an opening  111  and a first aperture  113 . Plunger  103  is disposed within body  101  and has a through hole  115  that aligns with opening  111 . Bolt  107  extends through opening  111  and has a first end  117  and a toggle  119  on a second end  121 . Sealant  105  is located within body  101  between plunger  103  and opening  111 . In this location, plunger  103  can dispose sealant  105  through at least one of first aperture  113  and opening  111  whereby the disposed sealant  105  forms a seal. 
       FIG. 1  shows mounting apparatus  100  in a pre-installation configuration. During pre-installation, sealant  105  remains in body  101 . Sealant  105  can be protected from prematurely drying within body  101 . For example, as shown in  FIG. 1 , an airtight sticker  123  can be used to cover first aperture  113  to prevent sealant  105  from drying. In addition, a plastic disk  125  can be disposed within body  101  between plunger  103  and sealant  105  to prevent the sealant from drying onto plunger  103 . 
     In order to prevent accidental movement of plunger  103 , a set pin  127  engages a set hole  129  that extends through body  101  and plunger  103 . Since set pin  127  extends through body  101  and plunger  103 , plunger  103  is prevented from moving within body  101  to dispose sealant  105 . Thus, set pin  127  is removed prior to disposing sealant  105  in the process. 
     As shown in  FIG. 1  mounting apparatus includes a nut  131  that is sized and dimensioned to engage first end  117  of bolt  107 . Nut  131  moves down bolt  107  as it is tightened and drives plunger  103  towards base  109  of body  101  to dispose sealant  105 . 
     To better understand how the different components described above interact, an example of using mounting apparatus  100  on roof sheathing  133  is provided.  FIG. 1  shows mounting apparatus  100  in a pre-installation configuration having set pin  127  in place and sealant  105  within body  101 . A portion of mounting apparatus  100  is guided through a hole in roof sheathing  133 , such that toggle  119  is slid through the hole in roof sheathing  133 . The hole in roof sheathing  133  can be created by using a drill through a roof tile, if any, and the roof deck and creating two concentric holes through roof tile/foam and the sheathing below. The tile/foam hole is typically larger, but both holes are preferably on the same centerline. 
       FIG. 2  shows mounting apparatus  100  in a set configuration. Toggle  119  is slid through the hole in roof sheathing  133  to the underside of roof sheathing  133 . Once on the other side, toggle  119  has wings that expand, which are used to spread weight applied to mounting apparatus  100  over a larger area. Body  101  also has a ridge  135  that extends from base  109 . Ridge  135  engages the hole in roof sheathing  133  as shown in  FIG. 2 , which stabilizes body  101  against lateral forces. A user can pull on bolt  107  back so that toggle  119  rests on the back side of roof sheathing  133 . In this fashion, toggle  119  is held on the back side of roof sheathing  133  until the appropriate tension is provided by the tightening of nut  131 . 
       FIG. 3  shows mounting apparatus  100  in a post-installation configuration. Once in the set configuration, set pin  127  is removed from the set hole  137  to allow movement of plunger  103 . Nut  131  is tightened, which provides tension to toggle  119  on the underside of roof sheathing  133  while simultaneously driving plunger  103  to displacing sealant  105 . It should be appreciated that nut  131  can be tightened using a power drill or a manual tool. The disposed sealant  105  acts as a liquid flashing inner jack by sealing body  101  on the exterior side of roof sheathing  133 . A flashing outer jack  138  having a hole that fits around body  101  can be slid down body  101 . 
     Once installed, mounting apparatus  100  can include additional components for mounting equipment, devices, and material. For example, a top cap  139  can be used to cover nut  131  and provide a platform for brackets to mount to mounting apparatus  100 . A mounting bracket  141  sized and dimensioned to receive the first end of bolt  107  at a position above top cap  139  and mounting bracket  141  is secured using a washer  143  and a second nut  145 . 
       FIG. 4  shows mounting apparatus  100  in an installed configuration having a mounted solar panel beam  147 . As discussed above, mounting apparatus  100  does not require that a truss/rafter  149  be used to mount equipment. In contrast, mounting apparatus  100  can be simply installed onto roof sheathing  133  as shown in  FIG. 4 . This reduces the number of roof tiles  151  removed for finding the centerline of truss/rafter  149 . Solar beam  147  in  FIG. 4  is a Unirac® 2.5 inch beam. However, it is contemplated that other mounting equipment, devices, and material can be used with mounting apparatus  100 . For example, mounting apparatus  100  can be used to mount solar panels, awnings, cables, wall signs, satellite dishes, roof antennas, roof top unit curbs, safety lanyards, boating accessories, light fixtures, speakers, security cameras, riggings, tethering, seasonal decorations, canopies, raceways, plumbing lines and clean room equipment. In addition, mounting apparatus  100  can be used in class-1 and class-2 division-1 and division-2 hazardous areas and for seismic considerations. 
       FIG. 5A  shows a top view of body  101  used in the embodiments described above. Although body  101  is cylindrical, it is contemplated that various suitable shapes can be used, for example, a rectangle, triangle, square or some other shape. Body  101  has an opening  111  and a first aperture  113 . It is contemplated that body  101  can also include a second aperture  153 , such that movement of plunger  103  disposes sealant  105  through second aperture  153 . In addition, body  101  can include more apertures as necessary to provide a sufficient seal and the position of the apertures can vary, but it is typically around the circumference of opening  111 .  FIG. 5B  shows a cross-sectional view of body  101  at line A-A. Body  101  has a set hole  137  that extends to plunger  103 . Furthermore, it is contemplated that body  101  is a standoff body. 
       FIG. 6A  shows a bottom view of plunger  103 , which is composed of a solid cylinder that fits closely inside the diameter of body  101 . Plunger  103  has a through hole  115  that extends through plunger  103  and has a close fit to bolt  107  as shown in  FIG. 6B . Plunger  103  can be composed of various suitable materials including a metal, ceramic or a polymer having the material strength to receive the force provided by nut  131 . In addition, it is contemplated that plunger  103  and body  101  can be composed of different or the same materials. It should be appreciated that through hole  115  of plunger  103  is typically aligned with opening  111  of body  101  to allow bolt  107  to extend through mounting apparatus  100 . 
     Bolt  107  has a first end  117  and a toggle  119  on a second end  121  as shown in  FIG. 7 . Toggle  119  can be restricted from expanding its wings using a toggle retainer during pre-installation. Bolt  107  can be a threaded bolt that engages with nut  131 . Bolt  107  is typically positioned within body  101 , such that toggle  119  on second end  121  extends through opening  111  on base  109  of body  101  and the first end  117  of bolt  107  extends through the opposite end of body  101 . 
     In another embodiment, a mounting apparatus  800  has a sealant housed in a doughnut shaped breakable sealant bag  855  as shown in  FIG. 8 . It should be appreciates that using doughnut shaped breakable sealant bag  855  eliminates the optional elements of the airtight sticker and plastic disk described above. Doughnut shaped breakable sealant bag  855  houses the sealant within body  801  without exposing the sealant to air. Thus, doughnut shaped breakable sealant bag  855  prevents premature drying of the sealant in the body. While a circular doughnut shape bag is shown in  FIG. 8 , it is contemplated that other suitable shapes (e.g., torus with rectangle cross-section or triangle cross-section) can be used to house the sealant within body  801 . 
     The operation of mounting apparatus  800  is similar to that described in the embodiment above. A set pin  827  is removed to allow movement of plunger  803  when nut  831  is tightened. When nut  831  is tightened, tension is provided to toggle  819  to secure mounting apparatus  800  onto a surface while plunger  803  simultaneously breaks doughnut shaped breakable sealant bag  855  to expose the housed sealant and disposes the sealant through at least one of the first aperture  813  and the opening  811 . With respect to the other similarly numbered items as described above, the same characteristics apply. 
     In another embodiment, mounting apparatus  900  has sealant beads  957  disposed between plunger  903  and opening  911  of body  901  as shown in  FIG. 9 . Sealant beads  957  are typically used to house dissimilar sealants so they can be combined and mixed together during installation. For example, dissimilar sealants that can be used in sealant beads are two-part epoxy or exothermic welding agents. However, it is contemplated that the same sealant can be used in sealant beads  957 . 
     Mounting apparatus  900  has a plunger  903  that comprises teeth  959  to break sealant beads  957 . However, it should be appreciated that teeth  959  are not required to break sealant beads  957  and that the plunger described in the embodiments above can be used with sealant beads.  FIG. 10A  shows a more detailed view of teeth  959  having serrated edges that are oriented towards the beads.  FIG. 10B  shows that plunger  903  includes a built in mixing nut  961  that turns plunger  903  as mixing nut  961  is tightened. When tightening mixing nut  961 , tension is provided to toggle  919  to secure mounting apparatus  900  onto a surface while plunger  903  simultaneously breaks sealant beads  957  and mixes the sealant. Upon further tightening of mixing nut  961 , the sealant is exposed through at least one of the first aperture  913  and the opening  911 . With respect to the other similarly numbered items as described above, the same characteristics apply. 
     While plunger  903  comprises mixing nut  961  to turn plunger  903 , it should be appreciated that mixing nut  961  can be separate from plunger  903  and that rotation of plunger  903  can be provided by other means. For example, it is contemplated that a nut has a frictional surface, such that the nut will cause plunger to spin when the frictional surface contacts the plunger. 
     In another embodiment, mounting apparatus  1100  has a spring  1163  and spring core  1165  as a shock absorber or dampener as shown in  FIG. 11 . Mounting apparatus  1100  works similar to the embodiments described above. Set pin  1127  is removed to allow plunger  1103  to move within body  1101 . Nut  1131  is tightened to provide tension to toggle  1119  while simultaneously moving plunger  1103  to dispose sealant  1105 . 
     Spring  1163  fits around nut  1131  and spring core  1165  sits above spring  1163 . A second nut  1145  is tightened to compress spring  1163  to any desired travel length  1167 . Thus, spring  1163  and spring core  1165  protects roof sheathing or some other surface from vertical shear where mounting apparatus  1100  is mounted. In addition, mounting apparatus  1100  also works as a shock absorber when exposed to extreme point loads generated by downward “gusting” forces. With respect to the other similarly numbered items as described above, the same characteristics apply. 
     It should be appreciated that the mounting apparatus described above can be modified in a number of ways. For example, the mounting apparatus can be modified to work when sealant is applied manually. In another example, the mounting apparatus can use liquid or gas in place of a compression spring as described above. 
     Other possible applications include redesigning the plunger with a polymeric actuator that uses dielectric elastomers. The dielectric elastomers would allow a device mounted to a single self sealing toggle mount to rotate with the sun. Also, the dielectric elastomers, if used in place of the compression spring, make it possible for the plunger to expand or telescope outward when electric current is applied from a photovoltaic source or otherwise. 
     As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise. 
     The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary. 
     All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention. 
     Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims. 
     It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.