Lightweight roofing support system and method of making and using

Abstract

A lightweight composite roofing support system is disclosed. The roofing support system includes a longitudinally-extending core member having a wedge-shaped lateral cross-section, a first side, and a second side, the first side and the second side tapering toward one another at a first predetermined acute angle (α), the core member comprising a core material. The roofing support system also includes a cover layer comprising a cover material, the cover layer disposed on and covering at least one of the first side and the second side, the cover material being substantially more compressible than the core material, the core member and cover layer comprising a first roofing support.

What is claimed is: 
     
         1 . A lightweight composite roofing support system, comprising:
 a longitudinally-extending core member having a wedge-shaped lateral cross-section, a first side, and a second side, the first side and the second side tapering toward one another at a first predetermined acute angle (α), the core member comprising a core material; and   a cover layer comprising a cover material, the cover layer disposed on and covering at least one of the first side and the second side, the cover material being substantially more compressible than the core material, the core member and cover layer comprising a first roofing support.   
     
     
         2 . The roofing support system of  claim 1 , wherein core member comprises a third side, the first side and the third side tapering toward one another at a second predetermined acute angle (β) that is different than the first predetermined acute angle (α). 
     
     
         3 . The roofing support system of  claim 2 , wherein the wedge-shaped lateral cross-section comprises a generally triangular-shaped cross-section with the third side opposite the first predetermined angle (α) formed by the first side and the second side, and wherein the cover layer is disposed on and covering at least one of the first side, second side, or third side. 
     
     
         4 . The roofing support system of  claim 2 , wherein the first predetermined acute angle (α) is selected so that when the first side is placed with the first predetermined acute angle (α) converging upslope against a first roof having a first pitch the second surface is substantially horizontal, and wherein the second predetermined acute angle (β) is selected so that when the first side is placed with the second predetermined acute angle (β) converging upslope against a second roof having a second pitch the third side is substantially horizontal, and wherein the first pitch and the second pitch are different. 
     
     
         5 . The roofing support system of  claim 2 , wherein the core member comprises a longitudinally-extending molded shell and a longitudinally-extending base attached to the molded shell by an attachment, the base having the cover layer disposed on a lower surface thereof. 
     
     
         6 . The roofing support system of  claim 5 , wherein the longitudinally-extending molded shell comprises the second side, the third side, a first end, and an opposed second end, the first end and the second end attached to respective opposed ends of the second side and the third side, and wherein the base and cover layer disposed thereon comprises the first side and is attached to respective lower portions of the second side, third side, first end, and opposed second end. 
     
     
         7 . The roofing support system of  claim 6 , wherein the longitudinally-extending molded shell comprises a flange disposed on the lower portions of the second side, third side, first end, and opposed second end, the flange defining a pocket configured to receive the base and cover layer disposed thereon. 
     
     
         8 . The roofing support system of  claim 7 , wherein the longitudinally-extending molded shell comprises a plurality of attachment structures disposed on the flange. 
     
     
         9 . The roofing support system of  claim 8 , wherein the attachment structures comprise a plurality of lugs having a plurality of openings therethrough that are configured to receive a plurality of fasteners configured for attachment to a roof deck. 
     
     
         10 . The roofing support system of  claim 6 , wherein the longitudinally-extending molded shell comprises a plurality of laterally extending internal ribs disposed on a lower surface of the second side and the third side. 
     
     
         11 . The roofing support system of  claim 5 , wherein the base comprises a selectively attachable and detachable attachment, and further comprising a plurality of different bases and/or cover layers that are configured for disposition on a plurality of different roof decks. 
     
     
         12 . The roofing support system of  claim 11 , wherein the longitudinally-extending molded shell comprises a plurality of bores extending through the first side and the third side, the bores configured to receive a plurality of selectively attachable and detachable base fasteners that are configured to provide the selectively attachable and detachable attachment. 
     
     
         13 . The roofing support system of  claim 11 , wherein the uppermost surfaces of the first side, the third side, or both, comprise a non-skid surface. 
     
     
         14 . The roofing support system of  claim 1 , wherein the core material comprises an engineering thermoset or thermoplastic polymer and the cover material comprises an open cell or closed cell foam. 
     
     
         15 . The roofing support system of  claim 14 , wherein the core material comprises polyethylene, polystyrene or polyurethane. 
     
     
         16 . A method of making a lightweight composite roofing support system, comprising:
 forming a longitudinally-extending core member having a wedge-shaped lateral cross-section, a first side, and a second side, the first side and the second side tapering toward one another at a first predetermined acute angle (α), the core member comprising a core material; and   attaching a cover layer comprising a cover material, the cover layer disposed on and covering at least one of the first side and the second side, the cover material being substantially more compressible than the core material, the core member and cover layer comprising a first roofing support.   
     
     
         17 . The method of  claim 16 , wherein forming the core member comprises molding an engineering thermoset or thermoplastic polymer, and attaching comprises adhering the cover material onto the core member or molding the cover material onto the core member to form the cover layer. 
     
     
         18 . A method of using a lightweight composite roofing support system, comprising:
 forming a longitudinally-extending core member having a wedge-shaped lateral cross-section, a first side, and a second side, the first side and the second side tapering toward one another at a first predetermined acute angle (α), the core member comprising a core material; and attaching a cover layer comprising a cover material, the cover layer disposed on and covering at least one of the first side and the second side, the cover material being substantially more compressible than the core material, the core member and cover layer comprising a first roofing support; and   placing the first roofing support on a pitched roof and configuring the system so that one of the first side or the second side provides a substantially horizontal work surface configured to hold a predetermined roofing load.   
     
     
         19 . The method of  claim 18 , wherein placing comprises disposing the first roofing support proximate a peak of the roof on one side of the roof with the first predetermined acute angle (α) facing the peak, the method further comprising:
 forming a second roofing support substantially identical to the first roofing support; 
 placing the second roofing support opposite the first roofing support over the peak on another side of the roof with the first predetermined acute angle (α) facing the peak. 
 
     
     
         20 . The method of  claim 19 , further comprising disposing a predetermined roofing load on both the first roofing support and the second roofing support above the peak.