Patent Publication Number: US-10316521-B1

Title: Roof edge mounting bracket for extended insulation

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This is a continuation in part patent application, which takes priority from patent application Ser. No. 16/102,873, filed on Aug. 14, 2018, which takes priority from patent application Ser. No. 15/846,329, filed on Dec. 19, 2017, which takes priority from patent application Ser. No. 15/396,836, filed on Jan. 3, 2017. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to building trim and more specifically to a roof edge mounting bracket for extended insulation, which may be used when installing roof edge trim to a building and extending insulation over a constructed wall of the building. 
     Discussion of the Prior Art 
     Roof trim is typically mounted to a wood nailer, which is found on a top of a building. Roof trim includes fascias, drip edges, gutters, copings and the like. Sometimes the wood nailer may rot and not be suitable for attachment of the roof trim. Lately, building designers have been using non-wood nailers and multiple layers of insulation. An attachment height of the roof trim to the wood or non-wood nailer would be too low relative to a top of a building with multiple layers of insulation. The multiple layers of added insulation could be as much as 6-8 inches thick or greater. A device is needed to extend upward the attachment point of the roof trim. U.S. Pat. No. 7,451,572 to Inzeo et al. discloses a roof fascia with extension cleat. Typically, a wood nailer is attached to a top of a pre-cast concrete wall. Roof trim is then attached to a side of wood nailer with fasteners. It has been found that extending insulation over a top of a pre-cast concrete wall increases insulation efficiency. However, a lower portion of roof trim cannot be reasonably secured to a wood nailer. 
     Accordingly, there is a clearly felt need in the art for a roof edge mounting bracket for extended insulation, which may be used when insulation is extended over a top of a pre-cast concrete wall, a concrete block wall, a plurality of insulation filled metal studs, or any other suitable roof/wall combination. 
     SUMMARY OF THE INVENTION 
     The present invention provides a roof edge mounting bracket for extended insulation, which may be used when insulation is extended over a top of a pre-cast concrete wall. A roof edge includes fascias, drip edges, gutters, copings and the like. A roof edge mounting bracket preferably includes a base member and a vertical attachment flange. The base member extends outward in a horizontal orientation from the vertical attachment flange. A lower portion of the vertical attachment flange extends below the base member and an upper portion of the vertical attachment flange extends above the base member. It is preferable that a height of the upper portion is about at least 0.5 inches and the lower portion about 0.5 inches. If multiple layers of insulation are used, the upper portion of the vertical attachment flange will have to be greater than the 0.5 inches. The insulation may be replaced with cover board, or used in conjunction with cover board. The lower portion of the vertical attachment flange may be equal in length, less in length or greater in length than the upper portion of the vertical attachment flange. An angled roof edge bracket includes a base member and a vertical attachment flange. The base member extends from the vertical attachment flange at an acute angle. 
     A cantilevered roof edge bracket preferably includes a cantilevered base member and a vertical attachment flange. The vertical attachment flange does not make contact with an outer surface of a wall. A portion of the cantilevered base member does not make contact with the wall to provide clearance for a non-supporting decorative panel applied to the outer surface of the wall. Insulation is extended outward to an upper portion of the vertical attachment flange. A fascia bracket is attached to the vertical attachment flange (not shown). 
     A plurality of staggered fastener openings are formed through the base member. The roof edge mounting bracket is preferably fabricated from an aluminum extrusion, but other materials and manufacturing processes may also be used. The base member is inserted between a top of a nailer and a bottom of an insulation board. The wood nailer is mounted to a top of a corrugated metal deck. The roof edge mounting bracket is secured to a building with a plurality of fasteners inserted through the plurality of fastener openings and the plurality of fasteners screwed into the nailer. However, if the wood nailer is damaged, longer fasteners must be used, which will be screwed into the corrugated metal deck. The roof trim is attached to the top portion of the vertical attachment flange with a plurality of self-tapping fasteners. 
     A wood nailer is attached to a top of a pre-cast concrete wall. The base member of the roof edge mounting bracket is secured to the top of the wood nailer with a plurality of fasteners. At least one layer of insulation is placed over the existing roof insulation, the wood nailer and the base member. A roof trim may be secured to the upper portion of the vertical attachment flange of the roof edge mounting bracket with a plurality of trim fasteners. 
     The base member of the roof edge mounting bracket may be secured directly to a top of a pre-cast concrete wall with a plurality of fasteners. At least one layer of insulation is placed over the existing roof insulation, the pre-cast concrete wall and the base member. Roof trim may be secured to the upper portion of the vertical attachment flange of the roof edge mounting bracket with a plurality of trim fasteners. 
     The base member of the roof edge mounting bracket may be secured directly to a top of a corrugated metal deck with a plurality of fasteners. The corrugated metal deck is attached to a concrete insert in a top of a concrete block with a second plurality of fasteners. At least one layer of insulation is placed over the corrugated metal deck. Roof trim may be secured to the upper portion of the vertical attachment flange of the roof edge mounting bracket with a plurality of trim fasteners. 
     The base member of the roof edge mounting bracket may be secured to a cap channel, which terminates a top of a plurality of insulation filled metal studs with a plurality of fasteners. At least one layer of insulation is placed over existing roof insulation, the cap channel and the base member. The roof trim may be secured to the upper portion of the vertical attachment flange of the roof edge mounting bracket with a plurality of trim fasteners. 
     A roof edge angle bracket includes a base member and a vertical attachment flange. The vertical attachment flange extends upward from an end of the base member. The vertical attachment flange does not include a lower portion. A roof edge vertical bracket preferably includes a vertical attachment flange, a bottom offset lip and an upper retaining lip. The bottom offset lip extends from a bottom of the vertical attachment flange. The upper retaining lip extends upward from a top of the vertical attachment flange. The upper retaining lip includes a turned over lip and a clip extension. The clip extension extends from a top of the turned over lip. 
     Accordingly, it is an object of the present invention to provide a roof edge mounting bracket, which may be used with a damaged wood nailer to mount roof trim on a building. 
     It is a further object of the present invention to provide a roof edge mounting bracket, which may be used to extend upward an attachment height of the roof trim. 
     It is another object of the present invention to provide a roof edge mounting bracket for extended insulation, which may be used when insulation is extended over a top of a pre-cast concrete wall, a concrete block wall, a plurality of insulation filled metal studs or the like. 
     It is yet another object of the present invention to provide an angled roof edge bracket, which may be attached to a wall. 
     It is yet another object of the present invention to provide a cantilevered angled roof edge bracket, which is attached to a top of a vertical wall. 
     It is yet another object of the present invention to provide a roof edge angle bracket, which is attached to a top of a vertical wall. 
     Finally, it is another object of the present invention to provide a roof edge vertical bracket, which is attached to an outer surface of a vertical wall. 
     These and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an end view of a roof edge mounting bracket in accordance with the present invention. 
         FIG. 1 a    is an end view of a roof edge mounting bracket with a lower portion of a vertical attachment flange, which is equal in length to an upper portion of a vertical attachment flange in accordance with the present invention. 
         FIG. 1 b    is an end view of an angled roof edge bracket with a base member pointing upward in accordance with the present invention. 
         FIG. 1 c    is an end view of an angled roof edge bracket with a base member pointing downward in accordance with the present invention. 
         FIG. 1 d    is an end view of a cantilevered roof edge bracket, which provides clearance for a nonsupporting decorative panel in accordance with the present invention. 
         FIG. 1 e    is an end view of an angled roof edge bracket with a base member pointing upward attached to a sloped substrate of a building with a sloped roof in accordance with the present invention. 
         FIG. 2  is a perspective view of a roof edge mounting bracket in accordance with the present invention. 
         FIG. 3  is a cross sectional view of a roof edge mounting bracket attached to either a wood nailer or a corrugated metal deck, and fascia trim attached to the roof edge mounting bracket in accordance with the present invention. 
         FIG. 4  is a cross sectional view of a building with an existing wood nailer, two additional wood nailers, an existing insulation layer and two additional insulation layers with a fascia attached to a top one of the two additional wood nailers. 
         FIG. 5  is a cross sectional view of a building with an existing wood nailer, existing insulation layer and two extended, additional insulation layers with a fascia attached to a top of the existing wood nailer. 
         FIG. 6  is a cross sectional view of a building with a pre-cast concrete wall, existing insulation layer and two extended, additional insulation layers with a fascia attached to a top of the pre-cast concrete wall. 
         FIG. 7  is a cross sectional view of a building with a concrete block wall, a corrugated metal deck and two insulation layers with a fascia attached to a top of the corrugated metal deck. 
         FIG. 8  is a cross sectional view of a building with a plurality of insulation filled metal stud walls, a cap channel, an existing layer of insulation, two additional insulation layers with a fascia attached to a top of the cap channel. 
         FIG. 9  is a cross sectional view of a roof edge angle bracket attached to a top of a wall in accordance with the present invention. 
         FIG. 10  is a cross sectional view of a vertical roof edge bracket attached to an outer surface of a wall in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to the drawings, and particularly to  FIG. 2 , there is shown a perspective view of a roof edge mounting bracket  1 . With reference to  FIGS. 1 and 3 , the roof edge mounting bracket  1  preferably includes a base member  10  and a vertical attachment flange  12 . The base member  10  extends outward in a horizontal orientation from the vertical attachment flange  12 . A lower portion  14  of the vertical attachment flange  12  extends below the base member  10  and an upper portion  16  of the vertical attachment flange  12  extends above the base member  10 . It is preferable that a height of the upper portion  16  is about at least 0.5 inches and the lower portion  14  is about 0.5 inches. If multiple layers of insulation are used, the upper portion  16  of the vertical attachment flange  12  will have to be greater than 0.5 inches. With reference to  FIG. 1 a   , the lower portion  14 ′ of the vertical attachment flange  12 ′ may be equal in length, less in length or greater in length than the upper portion  16 ′ of the vertical attachment flange  12 ′ of a roof edge mounting bracket  1 ′. 
     With reference to  FIG. 1 b   , an angled roof edge bracket  1 ″ includes a base member  10 ′ and a vertical attachment flange  12 . The base member  10 ′ extends upward from the vertical attachment flange  12  at an acute angle A. With reference to  FIG. 1 c   , an angled roof edge bracket  1 ′″ includes a base member  10 ″ and a vertical attachment flange  12 . The base member  10 ″ extends downward from the vertical attachment flange  12  at an acute angle A. With reference to  FIG. 1 d   , a cantilevered roof edge bracket  1 ″″ includes a cantilevered base member  10 ′″ and the attachment flange  12 . The vertical attachment flange  12  does not make contact with an outer surface  19  of a wall  17 . The cantilevered base member  10 ′″ does not make contact with the wall  17  to provide clearance for a non-supporting decorative panel  21  applied to the outer surface  19  of the wall  17 . Insulation  23  is extended outward to the upper portion  16  of the vertical attachment flange  12 . The cantilevered roof edge bracket  1 ″″ is attached to a top of the wall  17  with a plurality of fasteners  25 . A fascia bracket (not shown) is attachable to the vertical attachment flange  12 . The insulation  23  may be replaced with cover board, or used in conjunction with cover board. 
     With reference to  FIG. 1 e   , the angled roof edge bracket  1 ″ is attached to a top of a sloped substrate  27  of a building with a sloped roof with the plurality of fasteners  25 . At least one layer of insulation  23  is retained on the base member  10 ′ and by the vertical attachment flange  12 . The at least one layer of insulation  23  continues to an outer surface of a wall  31 . 
     A plurality of staggered fastener openings  18  are preferably formed through the base member  10 . The purpose of the staggered holes is to enable contractors to easily conform to insurance specifications. The roof edge mounting bracket  1  is preferably fabricated from an aluminum extrusion, but other materials and manufacturing processes may also be used. The base member  10  is inserted between a top of a wood nailer  100  and a bottom of an insulation board  102 . The wood nailer  100  is mounted to a top of a corrugated metal deck  104 . The roof edge mounting bracket  1  is secured to a building with a plurality of fasteners  20  inserted through the plurality of fastener openings  18  and fastened into the wood nailer  100  or a non-wood nailer. The plurality of fastener openings are preferably slots but could be any suitable shape. However, if the wood nailer  100  is damaged, longer fasteners  22  must be used, which will be fastened into the corrugated metal deck  104 . The insulation board  102  is attached to the wood nailer with a plurality of fasteners  106 . Fascia trim  108  includes a base portion  110  and a cover portion  112 . The base portion  110  is attached to the top portion  16  of the vertical attachment flange  12  with a plurality of self-tapping fasteners  24 . However, other designs of roof trim may also be used. A roof membrane  114  is laid over the insulation board  102  and located between the base portion  110  of the fascia trim  108  and the lower portion  14  of the vertical attachment flange  12 . 
     With reference to  FIG. 4 , in a prior art configuration, an existing wood nailer  204  is attached to a top of a pre-cast wall  202 . An existing insulation layer  206  is placed over a roof  208  of a building  200 , adjacent the existing wood nailer  204 . Two additional wood nailers  210  are attached on top of the existing wood nailer  204  and two additional insulation layers  212  are attached to a top of the existing insulation layer  206 . The fascia trim  108  is attached to a top one of the two additional wood nailers with fasteners  214 . 
     With reference to  FIG. 5 , the existing wood nailer  204  is attached to a top of the pre-cast concrete wall  202 . The base member  10  of the roof edge mounting bracket  1  is secured to the top of the existing wood nailer  204  with a plurality of fasteners  216 . The existing insulation  206  is placed over the existing roof  208 . At least one layer of additional insulation  218  is placed over the existing insulation  206 , the existing nailer  204  and the base member  10 . The fascia trim  108  is secured to the upper portion  16  of the vertical attachment flange  12  of the roof edge mounting bracket  1  with a plurality of trim fasteners  220 . A roof membrane  225  is preferably laid over a top of the additional insulation  218  and located between the base portion  110  of the fascia trim  108  and the lower portion  14  of the vertical attachment flange  12 . The fascia trim  108  is capable of being attached to the upper portion  16  of the vertical attachment flange  12  at different heights relative to the base member  10 . 
     With reference to  FIG. 6 , the base member  10  of the roof edge mounting bracket  1  is secured to a top of a pre-cast concrete wall  222  with a plurality of fasteners  224 . Existing insulation  226  is placed over an existing roof  228 . At least one layer of additional insulation  230  is placed over the existing insulation  226 , the pre-cast concrete wall  222  and the base member  10 . The fascia trim  108  is secured to the upper portion  16  of the vertical attachment flange  12  of the roof edge mounting bracket  1  with a plurality of trim fasteners  220 . A roof membrane  225  is preferably laid over a top of the additional insulation  230  and located between the base portion  110  of the fascia trim  108  and the lower portion  14  of the vertical attachment flange  12 . The fascia trim  108  is capable of being attached to the upper portion  16  of the vertical attachment flange  12  at different heights relative to the base member  10 . 
     With reference to  FIG. 7 , the base member  10  of the roof edge mounting bracket  1  is secured to a top of a corrugated metal deck  232  with a plurality of fasteners  224 . The corrugated metal deck  232  is attached to a concrete insert  236  in a top of a concrete block  234  with a plurality of block fasteners  238 . At least one layer of insulation  240  is placed over the corrugated metal deck  232  and the base member  10 . The fascia trim  108  is secured to the upper portion  16  of the vertical attachment flange  12  of the roof edge mounting bracket  1  with a plurality of trim fasteners  220 . A roof membrane  225  is preferably laid over a top of the at least one layer of insulation  240  and located between the base portion  110  of the fascia trim  108  and the lower portion  14  of the vertical attachment flange  12 . The fascia trim  108  is capable of being attached to the upper portion  16  of the vertical attachment flange  12  at different heights relative to the base member  10 . 
     With reference to  FIG. 8 , the base member  10  of the roof edge mounting bracket  1  is secured to a top of a cap channel  242  with a plurality of fasteners  224 , which terminates a top of a plurality of metal studs  244 . Stud insulation  245  is placed within the plurality of metal studs  244 . Existing insulation  246  is placed over an existing roof  248 . At least one layer of additional insulation  250  is placed over the existing insulation  246 , the cap channel  242  and the base member  10 . The fascia trim  108  is secured to the upper portion  16  of the vertical attachment flange  12  of the roof edge mounting bracket  1  with a plurality of trim fasteners  220 . A roof membrane  225  is preferably laid over a top of the at least one layer of additional insulation  250  and located between the base portion  110  of the fascia trim  108  and the lower portion  14  of the vertical attachment flange  12 . The fascia trim  108  is capable of being attached to the upper portion  16  of the vertical attachment flange  12  at different heights relative to the base member  10 . 
     With reference to  FIG. 9 , a roof edge angle bracket  2  includes a base member  310  and a vertical attachment flange  312 . The vertical attachment flange  312  extends upward from an end of the base member  310 . The vertical attachment flange  312  does not include a lower portion. The base member  310  is attached to a top of a wall  314  with a plurality of fasteners  316 . At least one layer of insulation  318  contacts an inside surface of the vertical attachment flange  312  and a top of the base member  310 . The roof membrane  225  is preferably laid over a top of the at least one layer of insulation  318  and located between a base portion  110  of the fascia trim  108  and the vertical attachment flange  312 . The base member  110  is secured to the vertical attachment flange  312   1  with the plurality of trim fasteners  220 . 
     With reference to  FIG. 10 , a roof edge vertical bracket  3  preferably includes a vertical attachment flange  320 , a bottom offset lip  322  and an upper retaining lip  324 . The bottom offset lip  322  extends from a bottom of the vertical attachment flange  320 . The upper retaining lip  324  extends upward from a top of the vertical attachment flange  320 . The upper retaining lip  324  includes a turned over lip  326  and a clip extension  328 . The clip extension  328  extends from a top of the turned over lip  326 . A roof membrane  325  is laid over the at least one layer of insulation  227  and an outside surface of a wall  330 . The vertical attachment flange  320  is placed on the roof membrane  325  and attached to the wall  330  with a plurality of fasteners  332 . A top and bottom of a fascia cover  334  is retained on the offset lip  322  and the clip extension  328 . A spring clip  336  extending from an inside surface of the fascia cover  334  is used to lock the fascia cover on the roof edge vertical bracket  3 . 
     While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.