Plastic/metal composite stress plate and method of using same for securing a thermoplastic roof membrane to a roof deck

Abstract

A two-piece fastener assembly for securing thermoplastic roof membranes to an underlying roof deck having: a metal stress plate coated with a thermoplastic coating on its top surface; an opening in the center portion of the stress plate; and a fastener positioned in the opening of the stress plate for securing the stress plate and one thermoplastic roof membrane to the underlying roof deck. In a method aspect the steps of securing thermoplastic roof membranes to an underlying roof deck, includes: placing a first thermoplastic roof membrane on the roof deck; placing a line of stress plates on the marginal portion of the first thermoplastic roof membrane and securing the stress plates along with the first thermoplastic roof membrane to the roof deck by use of the fastener; placing a second thermoplastic roof membrane to overlap the line of stress plates and the marginal portion of the first thermoplastic roof membrane; and applying heat and pressure to the line of stress plates and the overlapped portion of the first and second thermoplastic roof membranes to fuse them together and provide a waterproof covering over the roof deck.

What is claimed is:  
     
         1 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 a) a metal stress plate of circular configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;    b) a thermoplastic coating covering the top surface of said metal stress plate; and    c) a fastener positioned in said opening of said metal stress plate.    
     
     
         2 . The two-piece fastener assembly of  claim 1  wherein said metal stress plate is formed of stainless steel, galvalume or galvanized metals.  
     
     
         3 . The two-piece fastener assembly of  claim 1  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         4 . The two-piece fastener assembly of  claim 1  wherein said fastener is a screw member having threads thereon.  
     
     
         5 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 a) a metal stress plate of ellipsoidal configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;    b) a thermoplastic coating covering the top surface of said metal stress plate; and    c) a fastener positioned in said opening of said metal stress plate.    
     
     
         6 . The two-piece fastener assembly of  claim 5  wherein said metal stress plate is formed of stainless steel, galvalume or galvanized metals.  
     
     
         7 . The two-piece fastener assembly of  claim 5  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         8 . The two-piece fastener assembly of  claim 5  wherein said fastener is a screw member having threads thereon.  
     
     
         9 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 a) a metal stress plate of square configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;    b) a thermoplastic coating covering the top surface of said metal stress plate; and    c) a fastener positioned in said opening of said metal stress plate.    
     
     
         10 . The two-piece fastener assembly of  claim 9  wherein said metal stress plate is formed of stainless steel or galvanized metals.  
     
     
         11 . The two-piece fastener assembly of  claim 9  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         12 . The two-piece fastener assembly of  claim 9  wherein said fastener is a screw member having threads thereon.  
     
     
         13 . The two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 a) a metal stress plate of rectangular configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;    b) a thermoplastic coating covering the top surface of said metal stress plate; and    c) a fastener positioned in said opening of said metal stress plate.    
     
     
         14 . The two-piece fastener assembly of  claim 13  wherein said metal stress plate is formed of stainless steel, galvalume or galvanized metals.  
     
     
         15 . The two-piece fastener assembly of  claim 13  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         16 . The two-piece fastener assembly of  claim 13  wherein said fastener is a screw member having threads thereon.  
     
     
         17 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and said second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: 
 a) a metal stress plate of circular configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;  
 b) a thermoplastic coating covering the top surface of said metal stress plate;  
 c) a fastener positioned in said opening of said metal stress plate;  
   2) placing said first thermoplastic roof membrane on said roof deck;    3) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    4) inserting said fastener through said opening in said stress plate;    5) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    6) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    7) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         18 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and said second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: 
 a) a metal stress plate of ellipsoidal configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;  
 b) a thermoplastic coating covering the top surface of said metal stress plate;  
 c) a fastener positioned in said opening of said metal stress plate;  
   2) placing said first thermoplastic roof membrane on said roof deck;    3) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    4) inserting said fastener through said opening in said stress plate;    5) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    6) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    7) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         19 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and said second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: 
 a) a metal stress plate of square configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;  
 b) a thermoplastic coating covering the top surface of said metal stress plate;  
 c) a fastener positioned in said opening of said metal stress plate;  
   2) placing said first thermoplastic roof membrane on said roof deck;    3) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    4) inserting said fastener through said opening in said stress plate;    5) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    6) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    7) applying heat and pressure to the overlapped portion of the thermoplastic membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         20 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and said second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: 
 a) a metal stress plate of rectangular configuration defined by a top surface and a bottom surface having an opening in its center portion for receiving a fastener therethrough;  
 b) a thermoplastic coating covering the top surface of said metal stress plate;  
   c) a fastener positioned in said opening of said metal stress plate;    2) placing said first thermoplastic roof membrane on said roof deck;    3) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    4) inserting said fastener through said opening in said stress plate;    5) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    6) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    7) applying heat and pressure to the overlapped portion of the thermoplastic membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         21 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 1) a metal stress plate of circular configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
   d) a first circumferential portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and 
 e) a second circumferential portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned in said opening of said metal stress plate.    
     
     
         22 . The two-piece fastener assembly of  claim 21  having a low height profile of from about 0.030″ to about 0.350″.  
     
     
         23 . The two-piece fastener assembly of  claim 21  wherein said metal stress plate is formed of stainless steel or galvanized metals.  
     
     
         24 . The two-piece fastener assembly of  claim 21  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         25 . The two-piece fastener assembly of  claim 21  wherein said fastener is a screw member having threads thereon.  
     
     
         26 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 1) a metal stress plate of ellipsoidal configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first circumferential portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second circumferential portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned in said opening of said metal stress plate.    
     
     
         27 . The two-piece fastener assembly of  claim 26  having a low height profile of from about 0.030″ to about 0.350″.  
     
     
         28 . The two-piece fastener assembly of  claim 26  wherein said metal stress plate is formed of stainless steel or galvanized metals.  
     
     
         29 . The two-piece fastener assembly of  claim 26  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         30 . The two-piece fastener assembly of  claim 26  wherein said fastener is a screw member having threads thereon.  
     
     
         31 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 1) a metal stress plate of square configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first parametrical portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second parametrical portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned in said opening of said metal stress plate.    
     
     
         32 . The two-piece fastener assembly of  claim 31  having a low height profile of from about 0.030″ to about 0.350″.  
     
     
         33 . The two-piece fastener assembly of  claim 31  wherein said metal stress plate is formed of stainless steel or galvanized metals.  
     
     
         34 . The two-piece fastener assembly of  claim 31  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         35 . The two-piece fastener assembly of  claim 31  wherein said fastener is a screw member having threads thereon.  
     
     
         36 . A two-piece fastener assembly for securing two thermoplastic roof membranes to an underlying roof deck comprising: 
 1) a metal stress plate of rectangular configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first parametrical portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second parametrical portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned in said opening of said metal stress plate.    
     
     
         37 . The two-piece fastener assembly of  claim 31  having a low height profile of from about 0.030″ to about 0.350″.  
     
     
         38 . The two-piece fastener assembly of  claim 31  wherein said metal stress plate is formed of stainless steel, galvalume or galvanized metals.  
     
     
         39 . The two-piece fastener assembly of  claim 31  wherein said thermoplastic coating is a material selected from a group consisting of polyvinyl chloride, thermoplastic olefins, chlorinated polyethylene, chlorosulfonated polyethylene, nylon and ethylene propylene diene rubber.  
     
     
         40 . The two-piece fastener assembly of  claim 31  wherein said fastener is a screw member having threads thereon.  
     
     
         41 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: a metal stress plate of circular configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first circumferential portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second circumferential portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned is said opening of said metal stress plate;    4) placing said first thermoplastic roof membrane on said roof deck;    5) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    6) inserting said fastener through said opening in said stress plate;    7) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    8) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    9) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         42 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) a metal stress plate of ellipsoidal configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first circumferential portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second circumferential portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned is said opening of said metal stress plate;    4) placing said first thermoplastic roof membrane on said roof deck;    5) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    6) inserting said fastener through said opening in said stress plate;    7) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    8) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    9) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         43 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: a metal stress plate of square configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first parametrical portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second parametrical portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate;    3) a fastener positioned is said opening of said metal stress plate    4) placing said first thermoplastic roof membrane on said roof deck;    5) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    6) inserting said fastener through said opening in said stress plate;    7) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    8) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    9) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.    
     
     
         44 . A method of securing a first thermoplastic roof membrane to a second thermoplastic roof membrane and securing said first and second thermoplastic roof membranes to an underlying roof deck comprising the steps of: 
 1) providing a two-piece fastener assembly comprising: a metal stress plate of rectangular configuration defined by a circumferential edge and having a top surface and a bottom surface, and an opening in its center portion for receiving a fastener therethrough, said metal stress plate comprising: 
 a) a first flat surface surrounding said opening;  
 b) a second flat surface adjacent to said circumferential edge;  
 c) a third flat surface extending between said first flat surface and said second flat surface;  
 d) a first parametrical portion, extending above said second flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said second flat surface with said third flat surface; and  
 e) a second parametrical portion, extending above said first flat surface and towards said third flat surface at an angle of from about 25° to about 70°, connecting said first flat surface and said third flat surface;  
   2) a thermoplastic coating covering the top surface of said metal stress plate; and    3) a fastener positioned is said opening of said metal stress plate;    4) placing said first thermoplastic roof membrane on said roof deck;    5) placing said stress plate on a marginal portion of said first thermoplastic roof membrane;    6) inserting said fastener through said opening in said stress plate;    7) threading said fastener through said first thermoplastic roof membrane into said roof deck to fasten the thermoplastic roof membrane to the roof deck;    8) placing said second thermoplastic roof membrane to overlap said stress plate and said marginal portion of said first thermoplastic roof membrane; and    9) applying heat and pressure to the overlapped portion of the thermoplastic roof membranes thereby causing a fusion of the second thermoplastic roof membrane to the stress plate and the first thermoplastic roof membrane to provide a waterproof covering over said roof deck.