Patent Description:
Further, the present invention relates to a method for manufacturing a fastener for roof safety products.

Various fasteners, brackets, clamps, etc. by means of which roof safety products, for example snow guards, can be coupled to a roof are known. Snow guards are well established as a necessary accessory for roofs in northern climates. Such devices should be easy to install, anchor reliably, and be capable of retaining a substantial mass of snow. The design of such devices should address maximum, extreme conditions. Typical designs for snow guards or snow barriers have employed tubing fitted through roof-mounted fasteners. Such fasteners have been individually mounted to the roof surface. Various fasteners are designed to be attached to a seam of a seam roof and various other fasteners are designed to be directly attached to a planar roof surface. Some known fasteners are configured to be attached to an upper roof surface having at least one step in the upper roof surface.

For example, a fastener is known which has a planar support configured to be attached to an upper roof surface via a bottom fixture and a stack of sealants. A plate is arranged perpendicular to the planar support. Other elements, for example snow guard rods or tubes, can be coupled to the plate. The plate serves as a base or support for the roof safety product. The plate may be, for example, therefore called a base member. The plate and the planar support are typically made of one piece of metal. In case that the roof surface has a step, a bottom fixture having a specific height is arranged between the planar surface and the upper roof surface at one side of the step. The planar surface is directly arranged on the roof surface at the other side of the step. The height of the bottom fixture is depending on the height of the step. The height of the bottom fixture is typically identical with the height of the step of the roof surface. The bottom fixture has to be replaced in order to attach the fastener to a roof having a step with a different step height in the upper roof surface.

Further, document <CIT> discloses a snow barrier for a roof having brackets mounted on pads. The bracket sits on two pads that spread the load on the roof. The pads serve as bracket support means. The pads are optional, as the brackets may be fastened directly to the roof. The larger, down slope pad, if employed, need not necessarily be fastened to the roof. Bolts or threaded screws through the upper pad attach that pad to the roof. A gap is formed between the bracket, the pads and the upper roof surface. However, document <CIT> does not describe mounting of a bracket to a roof having at least one step in the upper roof surface. Another fastener is known from <CIT>.

In view of the foregoing it would be beneficial to provide a fastener for roof safety products, wherein the fastener can be directly mounted to roofs having steps with different heights of the steps in order to reduce the amount of needed fastener versions.

According to a first aspect of the present invention, there is provided a fastener for roof safety products according to claim <NUM>.

According to a second aspect of the present invention, there is provided a method for manufacturing a fastener for roof safety products according to claim <NUM>.

Various embodiments of the second aspect may comprise at least one feature from the following bulleted list:.

Considerable advantages are obtained by certain embodiments of the invention. A fastener for roof safety products and a method for manufacturing a fastener for roof safety products are provided. The fastener can be directly mounted to roofs having steps with different heights of the steps. Thus, it is not necessary to produce a wide variety of fasteners for different step heights anymore. The same fastener can be used in connection with different steps heights. No separate bottom fixtures or pads are required for mounting.

The invention further provides a rigid structure, which is less problematic from the sealing point of view and has less parts, wherein the fastener can also be mounted to roofs having steps with different heights of the steps. The amount of needed fastener versions can be reduced as one fastener can cover many roof shapes. The fastener according to the present invention is easy to manufacture and easy to install. The fastener according to the present invention enables installation to various roof types with different step heights. The gap further enables moisture to evaporate and dirt to escape from under the fastener, because there is space for air to flow through the gap. The fastener is strong enough for installation of roof safety products and at the same time lighter in weight.

For a more complete understanding of particular embodiments of the present invention and their advantages, reference is now made to the following descriptions, taken in conjunction with the accompanying drawings. In the drawings:.

In <FIG> a commercially available fastener <NUM> for roof safety products is illustrated. The fastener <NUM> has a planar support <NUM> configured to be attached to an upper roof surface (not shown). The planar support <NUM> comprises a plurality of borings <NUM>. Thus, the fastener <NUM> can be directly attached to the upper roof surface, for example using screws or bolts. A plate or base member <NUM> is arranged substantially perpendicular to the planar support <NUM>. The base member <NUM> comprises a coupling area <NUM> or coupling section with a plurality of openings <NUM> through the base member <NUM>. Other elements (not shown), for example roof safety products such as snow guard rods or tubes, can be coupled to the base member <NUM>. The base member <NUM> serves as a base or support for the roof safety products. The base member <NUM> and the planar support <NUM> are made of one piece of metal.

In case that the roof surface has a step, an additional bottom fixture (not shown) and a stack of sealants (not shown) is used for attachment. The separate bottom fixture is arranged between the planar support <NUM> and an upper roof surface at one side of the step. The planar support <NUM> is positioned directly on the upper roof surface at the other side of the step. The height of the bottom fixture is depending on the height of the step of the upper roof surface. The height of the bottom fixture is typically identical with the height of the step of the upper roof surface.

The bottom fixture has to be replaced in order to attach the fastener to a roof having a step with a different step height. In other words, another bottom fixture has to be used for another step height.

In <FIG> another commercially available fastener <NUM> for roof safety products is illustrated. The fastener <NUM> has a planar support <NUM> configured to be attached to an upper roof surface (not shown) having a step (not shown). The shown fastener <NUM> is designed for one particular step height of the upper roof surface only. An extension <NUM> is arranged at one end of the planar support <NUM>. The extension <NUM> is arranged at another level than the planar support <NUM>. The planar support <NUM> and the extension each comprise at least one borings <NUM>. Thus, the fastener <NUM> can be directly attached to the upper roof surface having the step, for example using screws or bolts. A plate or base member <NUM> is arranged substantially perpendicular to the planar support <NUM>. The base member <NUM> comprises a coupling area <NUM> with a plurality of openings <NUM> through the base member <NUM>. Other elements (not shown), for example roof safety products such as snow guard rods, can be coupled to the base member <NUM>. The base member <NUM> serves as a base or support for the roof safety products. The base member <NUM> and the planar support <NUM> are made of one piece of metal.

The entire fastener <NUM> has to be replaced in case of a roof having a step with a different step height. The shown fastener <NUM> can only be used for a step height which is identical with the distance between the planar support <NUM> and the extension <NUM>.

In <FIG> a schematic side view of a fastener <NUM> in accordance with at least some embodiments of the present invention is illustrated. The fastener <NUM> comprises a base member <NUM> having a base portion <NUM> below a coupling section <NUM> of the base member <NUM>. The base member <NUM> serves as a base or support for the roof safety products to be connected to the fastener <NUM>. The base portion <NUM> is a lower edge or lower surface of the base member <NUM>. When the fastener <NUM> is mounted on an upper roof surface having a step, the base portion <NUM> faces towards the upper roof surface. The fastener <NUM> further comprises a first leg <NUM> projecting from the base member <NUM> and having a first length. The first leg <NUM> comprises a first foot <NUM>. Further, the fastener <NUM> comprises a second leg <NUM> projecting from the base member <NUM> and having a second length which is less than the first length. The second leg <NUM> comprises a second foot <NUM>. The feet <NUM>, <NUM> are arranged separated from each other along the base portion <NUM> of the base member <NUM>. Typically, the feet <NUM>, <NUM> are arranged at opposing ends of the fastener <NUM>. The feet <NUM>, <NUM> are arranged at different levels to each other. The feet <NUM>, <NUM> are further separated by material of the base member <NUM>.

The fastener <NUM> is configured to provide a gap <NUM> between the legs <NUM>, <NUM>, the base portion <NUM> of the base member <NUM> as well as an upper roof surface (<NUM>) as the fastener <NUM> is mounted on the upper roof surface <NUM>. The fastener <NUM> is configured to provide varying dimensions of the gap <NUM> depending on a height hS of a step <NUM> of the upper roof surface <NUM> as can be seen in <FIG>.

The base member <NUM>, the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> are formed of one single piece. Typically, the base member <NUM>, the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> are made of metal. An example material may be stainless steel. The base member <NUM>, the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> may be completely or partially covered with paint.

The first foot <NUM> and the second foot <NUM> are both orientated substantially perpendicular or perpendicular to the base member <NUM>. Each foot <NUM>, <NUM> is configured to be attached to an upper roof surface <NUM> having a step. The fastener <NUM> is capable of being attached to an upper roof surface <NUM> having steps <NUM> with different step heights hS.

In <FIG>, three different step heights hS1 < hS2 < hS3 are schematically shown. Of course, there is in reality only one step height hS present at a time. It can be seen that the base portion <NUM> of the base member <NUM> is parallel or substantially parallel to the upper roof surface <NUM> when the fastener <NUM> is attached to a roof having a step height hS3. The base portion <NUM> of the base member <NUM> is typically parallel or substantially parallel to a contacting surface <NUM> of the first foot <NUM> and/or a contacting surface <NUM> of the second foot. However, the base portion <NUM> is not necessarily straight, but could be instead also curved or otherwise shaped. The base portion <NUM> is shaped such that a gap <NUM> is present between the base portion <NUM> and the upper roof surface <NUM> as the fastener is mounted to the upper roof surface. Consequently, the base portion <NUM> of the base member <NUM> is located at a different level than the first foot <NUM> and at a different level than the second foot <NUM>. The shape of the gap <NUM> is substantially rectangular or rectangular, for instance. In case of a smaller step height hS2, the shape of the gap <NUM> changes, i.e. the lower edge <NUM> or lower surface of the base member and the upper roof surface <NUM> are orientated at an angle to each other. In case of an even smaller step height hS3, the shape of the gap <NUM> changes further, i.e. the lower edge <NUM> or lower surface of the base member <NUM> nd the upper roof surface <NUM> are orientated at an even larger angle to each other. The fastener <NUM> is configured to provide varying dimensions of the gap <NUM> depending on the height hS of the step <NUM> of the upper roof surface <NUM>. The shape of the gap <NUM> may be, for example, depending on the base portion <NUM> and the height hS of the step <NUM> either substantially rectangular or substantially trapezoidal.

A height difference between the first foot <NUM> and the second foot <NUM> may be, for example, in the range between <NUM> and <NUM>. In other words, the feet <NUM>, <NUM> are not arranged on the same level. The second foot <NUM> is arranged above the first foot <NUM>. The contacting surface <NUM> of the first foot <NUM> and the contacting surface <NUM> of the second foot <NUM> are typically parallel to each other. Thus, the fastener <NUM> can be arranged on the upper roof surface <NUM> such that a step <NUM> is located between the feet <NUM>, <NUM>. The step <NUM> may be located adjacent to the first foot <NUM> or between the first foot <NUM> and the second foot <NUM>, for instance.

The fastener <NUM> further comprises a coupling section <NUM>. The coupling section <NUM> comprises typically at least one opening through the base member <NUM>. A rod (not shown) or tubing of a snow guard may be, for example, coupled to the fastener by inserting a part of the rod or tubing through the opening.

In <FIG> a schematic perspective view of a further <NUM> fastener in accordance with at least some embodiments of the present invention is illustrated. The fastener <NUM> comprises a base member <NUM> from which a first leg <NUM> including a first foot <NUM> and a second leg <NUM> including a second foot <NUM> project. The base member <NUM>, the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> are formed of one single piece. Typically, the base member <NUM>, the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> are made of metal. Typically, a planar metal substrate is cut or punched in order to obtain a single piece having a predefined shape. Normally, the single piece is formed from a steel plate having a thickness in the range between <NUM> and <NUM>, for example <NUM>. Also any openings or borings are made at the same time within the outer contour of the cut or punched piece of metal. Subsequently, the cut or punched piece of metal is bent into a defined form in order to obtain the fastener <NUM>. The fastener <NUM> may be further completely or partially covered with paint.

The fastener <NUM> can then be attached to an upper roof surface having a step. The fastener <NUM> is designed to be used in connection with upper roof surfaces having different step heights. The feet <NUM>, <NUM> are separated from each other and arranged at different levels to each other. The first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM> are separated by material of the base member <NUM>. The platelike base member <NUM> serves as a base or support for the roof safety products to be connected to the fastener <NUM>. Between the first leg <NUM> comprising the first foot <NUM>, the second leg <NUM> comprising the second foot <NUM>, a lower edge <NUM> or lower surface of the base member <NUM> as well as an upper roof surface (not shown) a gap or space is present as the fastener <NUM> is mounted on the upper roof surface. Typically, the contacting surface <NUM> of the second foot <NUM>, which is attached to the upper roof surface above the first foot <NUM>, is greater than the contacting surface <NUM> of the first foot <NUM>. The shown second foot <NUM> is L-shaped. In other words, the second foot <NUM> is designed such that a part of the second foot <NUM> is arranged on one side of the base member <NUM> and another part of the second foot <NUM> is arranged on the other side of the base member <NUM>. The first foot <NUM> is only bent to one side of the base member <NUM>. The feet <NUM>, <NUM> may include one boring or more than one boring for attaching the fastener <NUM> with screws or bolts to the upper roof surface, for instance. The fastener <NUM> is configured to provide varying dimensions of the gap or space depending on a height of a step of the upper roof surface <NUM>. In other words, the gap has first dimensions in case of a first step height and different second dimensions for a different second step height.

The base member <NUM> comprises a coupling section <NUM>. The coupling section <NUM> typically comprises one opening <NUM> or several openings. The shape of the opening is depending on the roof safety product to be connected to the fastener <NUM>. For example, the shape of the opening <NUM> may be circular, rectangular or of any other desired shape. In the shown embodiment, two tubes of a snow guard can be connected to the fastener <NUM>, for instance. The opening <NUM> is formed such that the tubes to be received can have either a circular or an oval cross-section. Further, the opening <NUM> may comprise an upper section, a middle section and a lower section as shown in <FIG>. In such a case, a single unit comprising a first tube, a second tube and a plate connecting the first tube and the second tube may be inserted into the opening <NUM> of the coupling section <NUM>. The base member <NUM> may additionally comprise other openings or borings useful for connecting the roof safety product to the fastener <NUM>.

In <FIG> a schematic side view of an even further fastener <NUM> in accordance with at least some embodiments of the present invention is illustrated. The fastener <NUM> comprises a base member <NUM> from metal. Additionally, the fastener <NUM> comprises a first leg <NUM> comprising a first foot <NUM> and a second leg <NUM> comprising a second foot <NUM>. The first leg <NUM> and the second leg <NUM> each project from the base member <NUM>. The feet <NUM>, <NUM> are separated from each other and arranged at different levels to each other. Each foot <NUM>, <NUM> comprises a contacting surface <NUM> configured to be coupled to an upper roof surface <NUM>. The contacting surfaces <NUM> of the feet <NUM>, <NUM> may be, for example, arranged parallel to each other. In other cases, the contacting surfaces <NUM> of the feet <NUM>, <NUM> are not arranged parallel to each other. A contacting surface <NUM> of at least one of the feet <NUM>, <NUM> may be adapted for use with a particular form of the upper roof surface <NUM>.

The fastener <NUM> is configured to provide a space or gap <NUM> between the first leg <NUM> comprising the first foot <NUM> and the second leg <NUM> comprising the second foot <NUM>, the base or base portion <NUM> of the base member <NUM> and an upper roof surface <NUM> as the fastener <NUM> is mounted on the upper roof surface <NUM>. As can be seen from <FIG>, the dimensions of the space or gap <NUM> below the base portion <NUM> of the base member <NUM> of the fastener <NUM> are depending on a height of a step <NUM> of the upper roof surface <NUM>. Two different heights of a step <NUM> are shown. In case of the lower height of the step, the space or gap <NUM> is substantially in the form of a trapezoid. In the other case, the gap <NUM> is substantially in the form of a rectangular. Of course, the fastener <NUM> can also be mounted on upper roof surfaces having another height of the step than shown in <FIG> for illustration purposes. However, the base portion <NUM> is typically not in direct contact with a part of the upper roof surface.

Consequently, the amount of needed fastener versions can be reduced as one fastener <NUM> can cover many roof shapes. The fastener <NUM> according to the present invention is easy to manufacture and easy to install. At the same time, a rigid structure is provided and the fastener <NUM> is less problematic from the sealing point of view. The fastener <NUM> as such can be formed of one single piece of metal, for instance. The fastener <NUM> according to the present invention enables installation to various roof types with different step heights. The space or gap <NUM> further enables moisture to evaporate and dirt to escape from under the fastener <NUM>, because there is space for air to flow through. The fastener <NUM> is strong enough for installation of roof safety products and at the same time lighter in weight.

In <FIG> a schematic top view of a yet further fastener <NUM> in accordance with at least some embodiments of the present invention is illustrated. As shown, the footprint of the second foot <NUM> is greater than the footprint of the first foot <NUM>. The second foot <NUM> is typically mounted above the first foot <NUM> to the upper roof surface. The first foot <NUM> is mounted to the upper roof surface on a first side of the step and the second foot <NUM> is mounted to the upper roof surface on a second side of the step. The base portion <NUM> of the base member <NUM> extends over the step from the first side to the second side between the feet <NUM>, <NUM>. Of course, the feet <NUM>, <NUM> may have other shapes and sizes than shown in <FIG>. The feet <NUM>, <NUM> further typically include at least one boring <NUM> for mounting the fastener to the roof using threaded screws, nails, bolts or other attachment means.

It is to be understood that the embodiments of the invention disclosed are not limited to the particular structures, process steps, or materials disclosed herein, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts and within the scope of the invention as defined in the appended claims.

In addition, various embodiments and examples of the present invention may be referred to herein along with alternatives for the various components thereof.

In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of embodiments of the invention.

At least some embodiments of the present invention find industrial application in fastening of roof safety products, for example in mounting of snow guards.

Claim 1:
A fastener (<NUM>) for roof safety products, the fastener (<NUM>) comprising:
- a base member (<NUM>),
- a first leg (<NUM>) projecting from the base member (<NUM>), the first leg (<NUM>) comprising a first foot (<NUM>), and the first leg (<NUM>) having a first length between the base member (<NUM>) and the first foot (<NUM>), and
- the first foot (<NUM>) being orientated perpendicular or substantially perpendicular to the the first leg (<NUM>),
- a second leg (<NUM>) projecting from the base member (<NUM>), the second leg (<NUM>) comprising a second foot (<NUM>), and the second leg (<NUM>) having a second length between the base member (<NUM>) and the second foot (<NUM>), wherein the second length is less than the first length,
- wherein the first foot (<NUM>) and the second foot (<NUM>) are orientated perpendicular or substantially perpendicular to the base member (<NUM>), the first leg (<NUM>) and the second leg (<NUM>),
- wherein the fastener (<NUM>) comprises a coupling section (<NUM>) configured to be coupled to a roof safety product,
- wherein the first foot (<NUM>) and the second foot (<NUM>) both comprise a boring (<NUM>) for mounting the fastener to the roof,
characterized in that
- the second leg (<NUM>) is projecting from the base member (<NUM>) on the same side of the base member surface as the first leg (<NUM>), and in that
- the feet (<NUM>, <NUM>) are arranged at different levels to each other seen in a direction perpendicular to the plane of the feet.