Abstract:
The present invention relates to a novel and improved roof flashing assembly for use in supporting hardware needed to install solar panel arrays on shingle roofs. The assembly is both easy to install and provides an improved watertight seal at the location where the assembly is secured to the rafters of the roof over the state of the art.

Description:
BACKGROUND OF INVENTION 
       [0001]    The present invention relates generally to a novel and improved roof flashing assembly that is both easy to install and provides a watertight seal to a composition shingle roof structure. One exemplary application of the flashing assembly is to connect it to hardware used to support guide rails that in turn support solar panel arrays installed on these roof structures. More specifically, the invention relates to a flashing assembly that provides improved and stronger watertight seals over the existing prior art flashing assemblies that also provide stronger support for heavy loads from the solar panel array elements that rest on the flashing assemblies. 
         [0002]    Existing prior art flashing assembly designs are either unsatisfying in providing an adequate seal to prevent water from seeping into holes created while securing the flashing to the roof, are too complicated to install, or require too many individual parts making them more expensive to manufacture. In most traditional roof flashings, the bottom surfaces of the flashings must be pre-treated with a liberal amount of sealant before installing them to provide an effective watertight seal to the roof. Having to pre-treat a flashing is time consuming and may cause the flashing to be inconsistently sealed to the roof and cause leaking. Eliminating the need to pre-treat the flashing would be desirable. 
         [0003]    In some prior art designs, the flashing includes an elevated block that rests above the flashing to seal out water. But at best, the location of the block may only possibly prevent water from entering at the top of the block. This is not ideal as it only addresses potential water leaks at the point where the top of the fastening element secures the flashing to the roof, which is above the flashing and not on the surface of the flashing where leaks are most likely to occur. 
         [0004]    Another prior art design shown in U.S. Pat. Nos. 8,151,522; 8,153,700; 8,166,713; 8,146,299; 8,209,914; 8,245,454; 8,272,174; and 8,225,557 shows a flashing that utilizes an hourglass-shaped rubber seal that sits between an L-shaped bracket and the flashing. But this design does not have a compressive seal between both the flashing and the roof surface, which is included in the present invention. This design, which utilizes a raised mounting surface on the flashing, requires a bearing plate that is also unnecessary in the present invention. The flashing also requires a specific bracket attachment with a hollowed-out shape that conforms to the unique shape of the raised mounting surface on the flashing, and is unnecessary in the present design. 
         [0005]    In another prior art design shown in U.S. Pat. No. 8,549,793, the disclosure teaches a flashing design that does not include a raised mounting surface on the flashing for providing support for mounting attachments. In particular, this design requires multiple seals both above and below the flashing to prevent penetration of liquids into the roof structure that are unnecessary in the present invention. The design also requires that a counter bore be done to remove a portion of the shingle in order to fit seal  6 , which is unnecessary in the present design. 
         [0006]    Finally, U.S. Pat. No. 8,756,881 discloses a solar panel attachment system that includes a flashing with a raised portion and a seal that rests on the top surface of the flashing and is compressed when the fastener is screwed into the rafter of the roof. But this system does not offer a solution that provides a seal between the flashing surface and the roof surface that may also be included in combination with a disk that is used to support the raised portion of the flashing and prevent it from collapsing due to heavy loads like the present invention. 
         [0007]    Thus, a more simplistic flashing assembly that provides the ability to seal potential leaks at the fastener insertion point on shingle roofs and support solar panel arrays that is both easy to use and manufacture is desired. 
       SUMMARY OF THE INVENTION 
       [0008]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0009]    It is an object of this invention to provide a novel and improved roof flashing assembly that provides a watertight seal between the flashing and roof that is both easy to manufacture and install. 
         [0010]    It is an object of this invention that the roof flashing assembly be utilized to seal composition shingle roof structures. 
         [0011]    It is an object of this invention to provide a roof flashing assembly that prevents external liquids from entering the roof structure where the flashing is secured to the roof without using additional liquid sealants on the lower surface of the flashing. 
         [0012]    It is an object of this invention to provide a flashing assembly with a rubber seal in combination with a disk below the raised portion that prevents external liquids from entering the roof structure where the flashing is fastened to the roof. 
         [0013]    It is an object of this invention to provide a flashing assembly such that the disk provides support to the raised portion by distributing any load that is secured to the top of the raised portion of the flashing and prevents it from collapsing downward. 
         [0014]    It is an object of this invention to provide a flashing assembly with a flashing having a raised portion with an alternate geometry that provides load distribution while using a rubber seal beneath it to prevent external liquids from entering the roof structure where the flashing is fastened to the roof. 
         [0015]    It is an object of this invention to provide a flashing assembly wherein the alternate geometry redirects liquids on the upper surface of the flashing away from the fastener insertion point on the roof. 
         [0016]    A person with ordinary skill in the relevant art would know that any materials suitable to achieve the objects of the current invention may be chosen. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0018]      FIG. 1  illustrates a profile view of the elements used to assemble an embodiment of the flashing assembly. 
           [0019]      FIG. 2  illustrates an exploded view of the flashing assembly constructed from the elements in  FIG. 1 . 
           [0020]      FIG. 3A  illustrates a front view the flashing assembly constructed from the elements in  FIG. 1 . 
           [0021]      FIG. 3B  illustrates a side view of the flashing assembly constructed from the elements in  FIG. 1 . 
           [0022]      FIG. 4  illustrates a side view of the disk with the bushing inserted in the opening of the disk constructed from the elements in  FIG. 1 . 
           [0023]      FIG. 5  illustrates a perspective view of a completed flashing assembly constructed from the elements in  FIG. 1  that is secured to a solar panel mounting rail. 
           [0024]      FIG. 6  illustrates a profile view of the elements used to assemble an alternate embodiment of the flashing assembly that utilizes no disk element and a modified flashing. 
           [0025]      FIG. 7  illustrates an exploded view of the flashing assembly constructed from the elements in  FIG. 6 . 
           [0026]      FIG. 8A  illustrates a front view the flashing assembly constructed from the elements in  FIG. 6 . 
           [0027]      FIG. 8B  illustrates a side view of the flashing assembly constructed from the elements in  FIG. 6 . 
           [0028]      FIG. 9  illustrates a perspective view of a completed flashing assembly constructed from the elements in  FIG. 6 . 
           [0029]      FIG. 10  illustrates a profile view of the elements used to assemble an alternate embodiment of the flashing assembly that utilizes no disk element and a modified flashing. 
           [0030]      FIG. 11  illustrates an exploded view of the flashing assembly constructed from the elements in  FIG. 10 . 
           [0031]      FIG. 12A  illustrates a front view the flashing assembly constructed from the elements in  FIG. 10 . 
           [0032]      FIG. 12B  illustrates a side view of the flashing assembly constructed from the elements in  FIG. 10 . 
           [0033]      FIG. 13  illustrates a perspective view of a completed flashing assembly constructed from the elements in  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0034]      FIG. 1  illustrates an embodiment of the flashing assembly that is used to secure solar panel mounting rails in a solar panel array on a typical composition shingle roof. The flashing assembly includes a flashing  100 . The flashing  100  is generally flat and rectangular, although alternate dimensions can be used as well. The flashing  100  includes a raised portion  110 , which is completely hollow inside, and an opening  120  preferably located in the center of the raised portion  110  for use in receiving a fastener  150 . The flashing  100  also may include ribs  130 , and alignment markings  135  on the upper surface of the flashing  100  that enable accurate installation and location of the flashing  100  on the roof. The fastener  150  shown is a wood screw that is capable of penetrating shingle roofs and securing itself to the rafters below the surface of the roof, although any suitable fastener can be used. 
         [0035]    The assembly also includes a disk, also referred to as a shell,  160  with an opening  165 . The opening  165  is preferably symmetrical about the center of the disk  160  and is tapered on its upper and lower surfaces. The disk  160  is preferably symmetric about its horizontal center and is preferably a solid disk made from either plastic or metal. The assembly also includes a bushing  170 . The bushing  170  is preferably made of a flexible and solid material like rubber or other suitable material includes an opening  175 . When the assembly is constructed, the bushing  170  is inserted into the opening  165  of disk  160  so that it fits tightly into the opening  165  as shown in  FIG. 4 . The height of the disk  160  can be no greater than the distance between the bottom surface of the flashing  100  and the highest point of the lower surface of the raised portion  110  of the flashing. The bushing  170  is typically in an hourglass-shape that can create a conical compression seal when assembled, but other suitable shapes may suffice if they can also provide a compression seal. The shape of the bushing  170  will depend on the contour of the opening  165  in the disk  160 . When properly inserted, the upper and lower surface of the bushing  170  will conform to the contour of the inner surfaces of the opening  165  and protrude slightly above and below the opening  165  so that it forms a tight seal at the entry point of the opening  120  of the flashing to prevent liquids from entering along the perimeter of the opening  165 . 
         [0036]    The flashing assembly is typically used to support a bracket  180 , which in turn is secured to a solar panel rail guide  195  (as shown in  FIG. 5  and discussed further below). The bracket  180  includes an opening  185  for receiving the fastener  150 . An optional washer  190  is also shown and typically rests between the top surface of the bracket  180  and the head of the fastener  150 . The washer  190  is preferably made of a flexible and solid material like rubber or other suitable material and also may include a central opening, although the washer may be solid as well as long as the fastener  150  can penetrate it. When the fastener  150  is tightened, the washer  190  may provide additional protection against external liquids from entering the opening  185  on the bracket  180 . The bracket  180 , fastener  150 , and the washer  190  are separate elements from the flashing assembly that makes up the flashing  100 , bushing  170 , and the disk  160 . 
         [0037]      FIG. 2  shows an exploded view of the flashing assembly as shown prior to being assembled along with the bracket  180 , washer  190 , and fastener  150 . In order for the assembly to work effectively and support the bracket  180  and rail guide  190 , all of the elements shown must be axially aligned along the dashed line. 
         [0038]      FIGS. 3A and 3B  show a cross section of a front view of the assembly and a cross section of a side view of the assembly. In order to assemble the structure shown, the bushing  170  is first inserted into the disk  160  to form a water-tight seal along the contour of the disk  160  as shown in  FIG. 4 . The disk  160  is then inserted below the raised portion  110  such that the opening  175  in the bushing  170  is axially aligned with the opening  120  in the raised portion  110 . The bracket  180  is then placed on top of the raised portion  110  so that the opening  185  of the bracket  180  is axially aligned with the opening  120  of the raised portion. The washer  190  is optionally placed on the upper surface of the bracket  180 . If the washer  190  includes an opening, it is also axially aligned with the opening  185  of the bracket. The fastener  150  is then inserted through the opening of the washer  190 , and through the respective openings  185 ,  120 , and  175  until the threads of the fastener  150  penetrate the rafter of the roof. The fastener  150  is continually tightened until the downward compression force from the fastener  150  enables the washer  190  to create a water-tight seal between the head of the fastener  150  and the bracket  180 , which in turn secures the bracket  180  to the raised portion  110  of the flashing. As the fastener  150  is inserted into the opening  175  of the bushing  170 , the bushing  170  provides a water-tight seal around the fastener  150 . The upper portion of the bushing  170  also provides a water-tight seal between the bracket  180  and the raised portion  110  of the flashing  100 . The solid nature of the disk  160  acts as a bearing plate that supports the raised portion  110  of the flashing  100  from collapsing under the compression force from the fastener  150  by distributing the load across the upper portion  110 . 
         [0039]      FIG. 5  shows a completed assembly of this embodiment that includes the solar panel rail guide  195  attached to the bracket  180 . 
         [0040]      FIG. 6  illustrates another alternate embodiment of the flashing assembly described in  FIGS. 1-5  above. In this embodiment, a variation of the shape of the raised portion on the flashing is provided and a bushing is utilized without a disk. The flashing assembly includes a flashing  100 . The flashing  100  is generally flat and rectangular, although alternate dimensions can be used as well. The flashing  100  includes three distinct raised portions—a central raised portion  112 , and two side raised portions  115 . Each of the raised portions  112  and  115  are hollow inside, and include an opening  120  that is preferably located in the center of the central raised portion  112  for use in receiving a fastener  150 . Each of the raised portions  112  and  115  have bases that are wider than their respective top surfaces and their respective side walls are tapered outward from top to bottom. This enables a heavy load that is placed on the top surfaces to be distributed evenly downward and prevents inward buckling of the sides of the raised portions  112  and  115  even without a bearing plate such as a disk for support. It also directs water or other liquids away from pooling around the opening  120  of the raised portion  110  and is simpler to manufacture. The flashing  100  also may include ribs  130 , and alignment markings  135  on the upper surface of the flashing  100  that enable accurate installation and location of the flashing  100  on the roof. The fastener  150  shown is a wood screw that is capable of penetrating shingle roofs and securing itself to the rafters below the surface of the roof, although any suitable fastener can be used. 
         [0041]    The assembly also includes a bushing  270 . The bushing  270  is preferably made of a flexible and solid material like rubber or other suitable material includes an opening  275 . The flashing assembly is typically used to support a bracket  180 , which in turn is secured to a solar panel rail guide  195 . The bracket  180  includes an opening  185  for receiving the fastener  150 . An optional washer  190  is also shown and typically rests between the top surface of the bracket  180  and the head of the fastener  150 . The washer  190  is preferably made of a flexible and solid material like rubber or other suitable material and also may include a central opening, although the washer may be solid as well as long as the fastener  150  can penetrate it. When the fastener  150  is tightened, the washer  190  may provide additional protection against external liquids from entering the opening  185  on the bracket  180 . The bracket  180 , fastener  150 , and the washer  190  are separate elements from the flashing assembly that makes up the flashing  100  and the bushing  270 . 
         [0042]      FIG. 7  shows an exploded view of the flashing assembly as shown prior to being assembled along with the bracket  180 , washer  190 , and fastener  150 . In order for the assembly to work effectively and support the bracket  180  and rail guide  190 , all of the elements shown must be axially aligned along the dashed line. 
         [0043]      FIGS. 18A and 8B  show a cross section of a front view of the assembly and a cross section of a side view of the assembly. In order to assemble the structure shown, the bushing  270  is inserted below the central raised portion  112  such that the opening  275  in the bushing  270  is axially aligned with the opening  120  in the central raised portion  112 . The bracket  180  is then placed on top of all three of the raised portion  112  and  115  so that the opening  185  of the bracket  180  is axially aligned with the opening  120  of the central raised portion  112  so that the bottom of the bracket  180  covers the same amount of each of the top surfaces of the side raised portions  115 . This allows even distribution of any load that is placed on top of the raised portions  112  and  115 . The washer  190  is optionally placed on the upper surface of the bracket  180 . If the washer  190  includes an opening, it is also axially aligned with the opening  185  of the bracket. The fastener  150  is then inserted through the opening of the washer  190 , and through the respective openings  185 ,  120 , and  275  until the threads of the fastener  150  penetrate the rafter of the roof. The fastener  150  is continually tightened until the downward compression force from the fastener  150  enables the washer  190  to create a water-tight seal between the head of the fastener  150  and the bracket  180 , which in turn secures the bracket  180  to the raised portion  110  of the flashing. As the fastener  150  is inserted into the opening  275  of the bushing  270 , the bushing  270  provides a water-tight seal around the fastener  150 . The upper portion of the bushing  270  also provides a water-tight seal between the bracket  180  and the raised portion  110  of the flashing  100 . The v-shaped walls form a space  116  between the central raised portion  112  and the side raised portions  115  create an avenue for water or other liquids to be evacuated and prevent them from collecting at the opening  120  of the central raised portion  112 . Also, when the fastener  150  is tightened and creates a compressive downward force coupled with the downward force resulting from the load of the solar panel rail guide  195 , the v-shaped walls also distribute the downward force evenly and prevents the raised portions  112  and  115  from collapsing downward. Finally, the v-shaped walls serve to re-shape the bushing  270  into a conical shape as shown in  FIG. 8A  and creates a water-tight compression seal resulting from the downward force as well.  FIG. 9  shows a completed assembly of this embodiment. 
         [0044]      FIG. 10  illustrates another alternate embodiment of the flashing assembly described in  FIGS. 1-9  above. In this embodiment, like the embodiment described in  FIGS. 6-9 , a variation of the shape of the raised portion on the flashing is provided and a bushing is utilized without a disk. The flashing assembly includes a flashing  100 . The flashing  100  is generally flat and rectangular, although alternate dimensions can be used as well. The flashing  100  includes three distinct raised portions—a central raised portion  113 , and an outer raised portion  116 . The outer raised portion  116  is preferably circular in shape with an opening  123  as shown. Each of the raised portions  113  and  116  are hollow inside, and include an opening  120  that is preferably located in the center of the central raised portion  113  for use in receiving a fastener  150 . Each of the raised portions  113  and  116  have bases that are wider than their respective top surfaces and their respective side walls are tapered outward from top to bottom. This enables a heavy load that is placed on the respective top surfaces to be distributed evenly downward and prevents inward buckling of the sides of the raised portions  113  and  116  even without a bearing plate such as a disk for support. It also directs water or other liquids away from pooling around the opening  120  of the raised portion  113  and is simpler to manufacture. The flashing  100  also may include ribs  130 , and alignment markings  135  on the upper surface of the flashing  100  that enable accurate installation and location of the flashing  100  on the roof. The fastener  150  shown is a wood screw that is capable of penetrating shingle roofs and securing itself to the rafters below the surface of the roof, although any suitable fastener can be used. 
         [0045]    The assembly also includes a bushing  370 . The bushing  370  is preferably made of a flexible and solid material like rubber or other suitable material includes an opening  375 . The bushing  370  is preferably in a conical shape that conforms to the contour of the central raised portion  113 , but other suitable shapes may suffice if they can also provide a compression seal and conform to the contour of the central raised portion  113 . When properly inserted beneath the central raised portion  113 , the bushing  370  will conform to the contour of the inner surfaces of the central raised portion  113  so that it forms a water-tight seal at the entry point of the opening  120  of the central raised portion  113  to prevent liquids from entering along the perimeter of the opening  375 . The bottom of the bushing  370  also will protrude slightly below the bottom surface of the flashing  100  to prevent liquids from entering at the bottom of the opening  375 . 
         [0046]    The flashing assembly is typically used to support a bracket  180 , which in turn is secured to a solar panel rail guide  195 . The bracket  180  includes an opening  185  for receiving the fastener  150 . An optional washer  190  is also shown and typically rests between the top surface of the bracket  180  and the head of the fastener  150 . The washer  190  is preferably made of a flexible and solid material like rubber or other suitable material and also may include a central opening, although the washer may be solid as well as long as the fastener  150  can penetrate it. When the fastener  150  is tightened, the washer  190  may provide additional protection against external liquids from entering the opening  185  on the bracket  180 . The bracket  180 , fastener  150 , and the washer  190  are separate elements from the flashing assembly that makes up the flashing  100  and the bushing  370 . 
         [0047]      FIG. 11  shows an exploded view of the flashing assembly as shown prior to being assembled along with the bracket  180 , washer  190 , and fastener  150 . In order for the assembly to work effectively and support the bracket  180  and rail guide  190 , all of the elements shown must be axially aligned along the dashed line. 
         [0048]      FIGS. 12A and 12B  show a cross section of a front view of the assembly and a cross section of a side view of the assembly. In order to assemble the structure shown, the bushing  370  is inserted beneath the central raised portion  113  such that the opening  375  in the bushing  370  is axially aligned with the opening  120  in the central raised portion  112 . The bracket  180  is then placed on top of both the central raised portion  113  and the outer raised portion  116  so that the opening  185  of the bracket  180  is axially aligned with the opening  120  of the central raised portion  113  and so that the bottom of the bracket  180  covers the same amount of each of the top surface of each side of the outer raised portion  116 . This allows even distribution of any load that is placed on top of the raised portions  113  and  116 . The washer  190  is optionally placed on the upper surface of the bracket  180 . If the washer  190  includes an opening, it is also axially aligned with the opening  185  of the bracket. The fastener  150  is then inserted through the opening of the washer  190 , and through the respective openings  185 ,  120 , and  375  until the threads of the fastener  150  penetrate the rafter of the roof. The fastener  150  is continually tightened until the downward compression force from the fastener  150  enables the washer  190  to create a water-tight seal between the head of the fastener  150  and the bracket  180 , which in turn secures the bracket  180  to the raised portion  110  of the flashing. As the fastener  150  is inserted into the opening  375  of the bushing  370 , the bushing  370  provides a water-tight seal around the fastener  150 . The upper portion of the bushing  370  also provides a water-tight seal between the bracket  180  and the raised portion  180  of the flashing  100 . The v-shaped walls form a space  122  between the central raised portion  113  and the outer raised  116  create an avenue for water or other liquids to be evacuated and prevent them from collecting at the opening  120  of the central raised portion  113 . Also, when the fastener  150  is tightened and creates a compressive downward force coupled with the downward force resulting from the load of the solar panel rail guide  195 , the v-shaped walls also distribute the downward force evenly and prevents the raised portions  113  and  116  from collapsing downward. Finally, the v-shaped walls serve to create a water-tight compression seal resulting from the downward force as well.  FIG. 13  shows a completed assembly of this embodiment. 
         [0049]    While the invention has been described in connection with certain embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.