Lightweight composite roofing support system

Abstract

A lightweight composite roofing support system comprises a longitudinally-extending core member comprising a longitudinally-extending first roof contact side comprising a first edge and opposed second edge, a longitudinally-extending second side comprising a second side working surface having a second width and a second length that is greater than the second width, the second side tapering toward the first edge at a first predetermined acute angle, and a longitudinally-extending third side comprising a third side working surface having a third width and a third length that is greater than the third width, the third side tapering toward the second edge at a second predetermined acute angle that is different than the first predetermined acute angle, a first end comprising an integral first recess defining a first handle, and an opposed second end comprising an integral second recess defining a second handle, the core member comprising a wedge-shaped lateral cross-section.

What is claimed is: 
     
         1 . A lightweight composite roofing support system, comprising:
 a longitudinally-extending core member comprising a longitudinally-extending first roof contact side comprising a longitudinally-extending first edge and an opposed longitudinally-extending second edge, a longitudinally-extending second side comprising a second side working surface having a second width and a second length that is greater than the second width, the second side tapering toward the first edge at a first acute angle (α) from the first roof contact side, and a longitudinally-extending third side comprising a third side working surface having a third width and a third length that is greater than the third width, the third side tapering toward the second edge at a second acute angle (β) from the first contact side that is different than the first acute angle (α), a laterally-extending first end comprising an integral first recess defining a first handle or grip, and an opposed laterally-extending second end comprising an integral second recess defining a second handle or grip, the core member comprising a core material and a wedge-shaped lateral cross-section, the core member configured for disposition of a longitudinally-extending resiliently compressible cover layer comprising a resiliently compressible cover material on the first roof contact side to provide a first roofing support.   
     
     
         2 . The roofing support system of  claim 1 , wherein the core material comprises a rigid or substantially rigid engineering thermoset or thermoplastic polymer. 
     
     
         3 . The roofing support system of  claim 1 , wherein the core material comprises an expanded foam comprising polystyrene (EPS), polyethylene (EPE), polypropylene (EPP), polyurethane (EPU), or ethylene-vinyl acetate (EEVA), or a combination thereof. 
     
     
         4 . The roofing support system of  claim 1 , wherein the wedge-shaped lateral cross-section comprises a triangular, scalene trapezoidal, irregular quadrilateral, or truncated triangular shape. 
     
     
         5 . The roofing support system of  claim 1 , wherein the second side working surface and third side working surface each comprise a non-skid surface. 
     
     
         6 . A lightweight composite roofing support system, comprising:
 a longitudinally-extending core member comprising a longitudinally-extending first roof contact side comprising a longitudinally-extending first edge and an opposed longitudinally-extending second edge, a longitudinally-extending second side comprising a second side working surface having a second width and a second length that is greater than the second width, the second side tapering toward the first edge at a first acute angle (α) from the first roof contact side, and a longitudinally-extending third side comprising a third side working surface having a third width and a third length that is greater than the third width, the third side tapering toward the second edge at a second acute angle (β) from the first contact side that is different than the first acute angle (α), a laterally-extending first end comprising an integral first recess defining a first handle or grip, and an opposed laterally-extending second end comprising an integral second recess defining a second handle or grip, the core member comprising a core material and a wedge-shaped lateral cross-section; and   a resiliently compressible cover layer comprising a resiliently compressible cover material, the cover layer disposed on and covering the first roof contact side, the core member and cover layer comprising a first roofing support.   
     
     
         7 . The roofing support system of  claim 6 , wherein the core material comprises a rigid or substantially rigid engineering thermoset or thermoplastic polymer and the cover material comprises a resiliently compressible polymer. 
     
     
         8 . The roofing support system of  claim 6 , wherein the core material comprises a rigid or substantially rigid expanded foam comprising polystyrene (EPS), polyethylene (EPE), polypropylene (EPP), polyurethane (EPU), or ethylene-vinyl acetate (EEVA), or a combination thereof, and the cover material comprises polyurethane (PU), polystyrene (PS), polyisocyanurate (PIR), polyethylene (PE), polypropylene (PP), poly(ethylene-vinyl acetate) (EVA), poly(vinyl chloride) (PVC), or a natural or synthetic rubber, or a combination thereof. 
     
     
         9 . The roofing support system of  claim 6 , wherein the wedge-shaped lateral cross-section shape comprises a triangular, scalene trapezoidal, irregular quadrilateral, or truncated triangular shape. 
     
     
         10 . The roofing support system of  claim 6 , wherein the second side working surface and third side working surface each comprise a non-skid surface. 
     
     
         11 . The roofing support system of  claim 6 , wherein the cover layer comprises a plurality of cover layers comprising a first resiliently compressible cover layer comprising a first resiliently compressible cover material disposed in a central portion of the first roof contact side and second resiliently compressible cover layers comprising second resiliently compressible cover materials disposed proximate the first end and the second end that are different from the first resiliently compressible cover material. 
     
     
         12 . The roofing support system of  claim 11 , wherein the first resiliently compressible cover layer comprising the first resiliently compressible cover material has a first thickness and comprises polyurethane (PU) and the second resiliently compressible cover layers and second resiliently compressible cover materials have a second thickness that is less than or equal to the first thickness and comprise polyurethane (PU), poly(ethylene-vinyl) acetate (EVA), natural rubber, or synthetic rubber, or a combination thereof. 
     
     
         13 . The roofing support system of  claim 6 , wherein the first roof contact side comprises a plurality of spaced apart first side recesses, and further comprising a flexible, longitudinally-extending base disposed between the core member and the cover layer that is selectively attachable to and detachable from the core member on the first roof contact side, the base comprising a planar base member, a plurality of spaced apart base protrusions extending upwardly from an upper surface of the base member, a first tapered retainer lip extending inwardly and upwardly along a longitudinally-extending first base edge, a second tapered retainer lip extending inwardly and upwardly along a longitudinally-extending second base edge, an upwardly-extending first recess insert disposed along a first base end, and an upwardly-extending second recess insert disposed along an opposed second base end, wherein in an attached position and condition the base member is disposed against the first roof contact side, the first tapered retainer lip is disposed over and retains the first edge, the second tapered retainer lip is disposed over and retains the second edge, the first recess insert is disposed in the first recess, the second recess insert is disposed in the second recess, and the plurality of spaced apart base protrusions are disposed in and engage the spaced apart first side recesses, and wherein the cover layer is attached to a bottom surface of the base and the base and cover layer are disposed on and covering the first roof contact side. 
     
     
         14 . The roofing support system of  claim 6 , wherein the first roof contact side comprises a first side recess, and further comprising a hook and loop attachment device disposed between the core member and the cover layer, the attachment device comprising a first sheet of a hook material comprising a plurality of hooks or a loop material comprising a plurality of loops that is disposed in and attached to the first side recess and a second sheet, respectively, of loop material comprising a plurality of loops or hook material comprising a plurality of hooks that is attached to the cover layer, wherein in an attached position and condition the first sheet and the second sheet are in pressed engagement with the plurality of hooks engaging the plurality of loops, and wherein the cover layer is selectively attachable to and detachable from the core member using the attachment device. 
     
     
         15 . The roofing support system of  claim 14 , wherein the first side comprises a peripherally-extending rim that encloses and defines a sidewall of the first side recess. 
     
     
         16 . The roofing support system of  claim 6 , wherein the core member further comprises an integral longitudinally-extending shelf that also extends outwardly and laterally away from at least one of the second side or the third side and comprises a lower surface that is coplanar with the first roof contact side and that, respectively, subsumes at least one of the second edge or third edge. 
     
     
         17 . The roofing support system of  claim 16 , wherein the integral longitudinally-extending shelf further comprises an integral upwardly-protruding rim on a distal edge thereof. 
     
     
         18 . A lightweight composite roofing support system connector comprising a longitudinally-extending connector comprising a first connector end and an opposed second connector end joined together by a longitudinally-extending intermediate portion, the first connector end configured for selective engagement/disengagement within a first roof support and the second connector end configured for selective engagement/disengagement within a second roof support, wherein upon engagement the connector is configured to connect the first roof support and the second roof support. 
     
     
         19 . The lightweight composite roofing support system connector of  claim 18 , wherein the first roof support and the second roof support each comprise: a longitudinally-extending core member comprising a longitudinally-extending first roof contact side comprising a longitudinally-extending first edge and an opposed longitudinally-extending second edge, a longitudinally-extending second side comprising a continuous second side working surface having a second width and a second length that is greater than the second width, the second side tapering toward the first edge at a first acute angle (α) from the first roof contact side, and a longitudinally-extending third side comprising a continuous third side working surface having a third width and a third length that is greater than the third width, the third side tapering toward the second edge at a second acute angle (β) from the first contact side that is different than the first acute angle (α), a laterally-extending first end comprising an integral first recess defining a first handle or grip, and an opposed laterally-extending second end comprising an integral second recess defining a second handle or grip, the core member comprising a core material and a wedge-shaped lateral cross-section shape; and a cover layer comprising a compressible cover material, the cover layer disposed on and covering the first roof contact side, the core member and cover layer, wherein the first recess defines a first slot that opens into the first roof contact side proximate the first end and the second recess defines a second slot that opens into the first roof contact side proximate the second end, the first connector end configured for mating engagement within one of the first slot or second slot of the first roof support, the second connector end configured for mating engagement within one of the second slot or first slot, respectively, of the second roof support. 
     
     
         20 . The lightweight composite roofing support system connector of  claim 19 , wherein the first connector end comprises an irregular pentagonal or hexagonal first end lateral cross-section shape and the second connector end comprises an irregular pentagonal or hexagonal second end lateral cross-section shape, and wherein, respectively, the first slot comprises an irregular pentagonal or hexagonal first slot lateral cross-section shape and the second slot comprises an irregular pentagonal or hexagonal second slot lateral cross-section shape.