AU2006203219A1

AU2006203219A1 - System and method for mounting an apparatus on a roof

Info

Publication number: AU2006203219A1
Application number: AU2006203219A
Authority: AU
Inventors: Richard Unwin
Original assignee: SOLARPOWER Pty Ltd
Current assignee: SOLARPOWER Pty Ltd
Priority date: 2005-07-26
Filing date: 2006-07-26
Publication date: 2007-02-15

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990

ORIGINAL

COMPLETE SPECIFICATION STANDARD PATENT Invention Title: "SYSTEM AND METHOD FOR MOUNTING AN APPARATUS ON A

ROOF"

The following statement is a full description of this invention, including the best method of performing it known to me/us:

TITLE

0 System and Method for Mounting an Apparatus on a Roof (Ni FIELD OF THE INVENTION 5 The invention relates to mounting systems for building rooftops. In particular, although not exclusively, the invention relates to a system and method 0,N for mounting solar collector panels on tile roofs.

(N

BACKGROUND TO THE INVENTION The increase in greenhouse gas emissions has resulted in a long overdue public awareness of solar water heating. One particular result of rising greenhouse gas emissions has been the public awareness of the use of renewable energy in residential and small scale commercial buildings. Therefore various designs and manufactures exist for providing solar energy to produce hot water for small and medium sized buildings.

Solar hot water systems generally include one or more solar collector panels and a storage tank. Cold water from a supply is circulated through the collector where the water is heated using energy from the sun, and the resulting hot water is then pumped to the storage tank. As with conventional hot water storage tanks, the hot water then may be supplied from the tank for residential or business uses.

Securely and safely mounting solar collector panels on roofs, and tile roofs in particular, has presented a difficult challenge to the solar industry.

Ceramic roofing tiles are generally brittle and are subject to cracking or breaking under any significant localised forces. Solar collector panels are often large, heavy and awkward to raise into position and then secure on a roof.

Prior art methods for securing rectangular solar collector panels to tile roofs include removing a rectangular section of roofing tiles. A solar collector panel is then fitted into the space from where the tiles were removed, and the panel is secured directly to the underlying roof battens. Some of the tiles are CO then replaced around the edges of the panel and the gaps between the tiles and N the panel are sealed to prevent water leakage. Such a technique is problematic 0 however for several reasons. Removing the tiles leaves the roof open to the D elements during installation; removed tiles must be handled carefully so as not to damage neighbouring tiles; and it is very difficult to permanently seal the edges around the panel.

(Other prior art techniques for mounting solar panels on tile roofs include hanger brackets where the top edge of the panels are mounted to a roof using Ibolts screwed through holes that are drilled through the tiles. That technique is also problematic however as it creates areas of high localised stress on tiles through which the bolts are installed, which can damage the tiles and result in roof leaks. Further, wind gusts can force the lower ends of the panels upward and then drop the ends back onto the roof tiles, again damaging the tiles. Also, during installation the entire panels must be held in place as the bolts are installed through the hanger brackets. Typically the hanger brackets are mounted along the top edge of a panel at a factory or before the panel is raised onto a roof. Bolts are then screwed one at a time through the hanger brackets and into a roof. If a panel is not securely held in place during such installation, any slight movement of the panel after only one or two bolts are installed can overload and damage the tiles. Temporary securing of the awkward panels, generally done by hand, also can be dangerous for workers.

There is therefore a need for an improved system and method for mounting an apparatus such as a solar panel on a roof, which system and method overcomes many of the above described disadvantages of the prior art.

OBJECTS OF THE INVENTION Therefore an object of the present invention is to overcome or at least alleviate one or more of the above limitations including providing a system and method for mounting an apparatus on a roof.

O SUMMARY OF THE INVENTION Accordingly, in one form, the present invention is system for mounting an n apparatus on a roof. The system comprises an upper bracket for securing to a Iroofing structure through holes in a roofing material. A lower bracket, having a transverse section, is also for securing to a roofing structure through holes in a roofing material. A first plurality of polymer spacers is for placing between the upper bracket and the roofing material. A second plurality of polymer spacers is for placing between the lower bracket and the roofing material. Means are then IN included for securing the apparatus to both the upper bracket and the lower bracket.

According to another form, the present invention is a method for mounting an apparatus on a roof, the method comprising the steps of: drilling a plurality of pilot holes through a roofing material; securing through the pilot holes an upper bracket and a lower bracket to underlying roofing structure, wherein a polymer grommet separates the brackets from a roofing material; raising the apparatus to the roof and resting it against a transverse section of the lower bracket; and securing the apparatus to the upper and lower brackets.

Further features and advantages of the present invention will become apparent from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS To assist in understanding the invention and to enable a person skilled in the art to put the invention into practical effect, preferred embodiments of the invention will be described by way of example only with reference to the accompanying drawings, in which: FIG. 1 is a schematic diagram showing a perspective view of a bracket system for mounting apparatuses such as solar panels on a roof according to an embodiment of the present invention; FIG. 2 is a schematic diagram of a detailed end view of an L-bracket assembly and a plate bracket assembly according to an embodiment of the present invention; FIG. 3 is a schematic diagram of a detailed side view of an L-bracket assembly and a plate bracket assembly according to an embodiment of the present invention; FIG. 4 is a schematic diagram of an end view of a lower bracket assembly according to an embodiment of the present invention; FIG. 5 is a schematic diagram of a perspective view of a top bracket and lower bracket installed on a tile roof according to an embodiment of the present invention; FIG. 6 is a schematic diagram of a perspective view of a fully installed pair of collector panels according to an embodiment of the present invention; FIG. 7 is a schematic diagram of a close up view of a lower bracket installed on a tiled roof according to an embodiment of the present invention; and FIG. 8 is a flow diagram illustrating the steps of a method for installing a rooftop apparatus such as a solar panel according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Embodiments of the present invention are presented as apparatus components and method steps related to a system and method for mounting an apparatus on a roof. Elements of the apparatus are illustrated in concise outline form in the drawings, showing only those specific details that are necessary to understanding the embodiments of the present invention, but so as not to clutter the disclosure with excessive detail that will be obvious to those of ordinary skill in the art in light of the present description.

In this patent specification, adjectives such as first and second, left and right, top and bottom, upward and downward, etc., are used solely to define one element or method step from another element or method step without necessarily requiring a specific relative position or sequence that is described by the adjectives. Words such as "comprises" or "includes" are not used to define an exclusive set of elements or method steps. Rather, such words merely define a minimum set of elements or method steps included in a particular embodiment of the present invention.

Referring to FIG. 1 ti view of a bracket system 1( 130 on a roof according to 100 includes three relativeli middle bracket 110, and a I secured to roofing boards s through a roofing material 130 are then secured to the assembly 135, a plate bracl for securing the solar panel additional figures described Referring to FIG. 2 tI an L-bracket assembly 135 embodiment of the present 200 that is bolted to a top s 110 using bolts 205. A bolt L-bracket 200. A bolt 125[ into a batten 120. A spacin not exert an excessive leve bracket assembly 140 is tho Plate 225 is used to clamp Referring to FIG. 3 tl an L-bracket assembly 135 embodiment of the present shown again here. The pla clamping the solar panels 1 The brackets 105, 1 corrosion resistant aluminiL extending the life of the sys can result from non-galvani iere is a schematic diagram showing a perspective 10 for mounting apparatuses such as solar panels in embodiment of the present invention. The system horizontal bracket members: a top bracket 105, a )wer bracket 115. The brackets 105, 110, 115 are uch as roof battens 120 using bolts 125 that are fitted iot shown in FIG. Apparatus such as solar panels brackets 105, 110, 115. Detail views of an L-bracket et assembly 140, and a lower bracket assembly 145 s to the brackets 105, 110, 115 are shown in the below.

iere is a schematic diagram of a detailed end view of and a plate bracket assembly 140 according to an invention. The assembly 135 includes an L-bracket Jrface of either a top bracket 105 or a middle bracket 210 is then used to secure the solar panel 130 to the Sshown threaded through the top bracket 105 and g sleeve 215 is used to ensure that the bolt 125 does of force on a roofing material (not shown). A plate ,n secured to the top bracket 105 using bolt 220.

an edge of a panel 130.

iere is a schematic diagram of a detailed side view of and a plate bracket assembly 140 according to an invention. Each of the elements from FIG. 2 are te 225 is shown bridging two solar panels 130 and 30 to the top bracket 105 using bolt 220.

10, 115 may be made of various materials including m. Galvanized steel bolts 125 are also effective for tem 100 and minimizing rust mark roof streaking that zed fasteners. A typical size of the upper bracket 105 is 25x38x1l.6mm stock and a typical size of a lower bracket 115 is 60x60x3mm angle stock.

Referring to FIG. 4 ti bracket assembly 145 acco Here the lower bracket 115 of the lower bracket 115 pr( of the roof. The transverse 130 from sliding down the r installed on a tiled roof con, 215 is again used to minimi spacing sleeves 215 are nc toroidal polymer grommet 4 roofing tiles 400 to further n the tiles 405 through which grommets 405 also may be bracket 110.

The present inventio such as solar collector pane installed on a roof first and and quickly and safely secL installation, the L-shaped Ic which a collector panel 130 installing the L-bracket assi risking the panels 130 slidir provided by the present inv rooftop apparatus.

Referring to FIG. 5 tl a top bracket 105 and lowe embodiment of the present such middle brackets 110 E solar panels 130 that are in iere is a schematic diagram of an end view of a lower rding to an embodiment of the present invention.

is an L-shaped bracket, and a transverse section 116 )jects upward and substantially orthogonal to a plane section 116 thus helps prevent the collector panels )of. Further, FIG. 4 illustrates the lower bracket 115 ;isting of overlapping roof tiles 400. A spacing sleeve ze localized stress on the tiles 400. Generally such t required on galvanized steel roofs. Further, a 05 is placed between the lower bracket 115 and the Iinimize stress on the tiles 400 and to seal holes in the bolt 125 and sleeve 215 are placed. Similar used to secure the upper bracket 105 and middle n thus enables an improved installation of apparatus ,ls 130 on a roof. The brackets 105, 110, 115 can be :hen the solar panels 130 can be raised to the roof red to the brackets 105, 110, 115. During wer bracket 115 provides a stable ledge against can rest. Workers can then focus on aligning and ;mbly 135 and plate bracket assembly 140, without ig off the roof. The added safety and convenience antion thus may allow fewer workers to safely install a iere is a schematic diagram of a perspective view of r bracket 115 installed on a tile roof according to an invention. A middle bracket 110 is not shown as re not required in many circumstances, such as for stalled in non-cyclone susceptible environments.

O Referring to FIG. 6 there is a schematic diagram of a perspective view of N a fully installed pair of collector panels 130 according to an embodiment of the 0 present invention. Transverse bolts 600 are shown installed through a vertical N portion of the lower bracket 115. The bolts 600 act to prevent the panels 130 from lifting up from the bracket 115 during high wind conditions.

O Referring to FIG. 7 there is a schematic diagram of a close up view of a 1 lower bracket 115 installed on a tiled roof according to an embodiment of the present invention. Grommet 405 is shown compressed between the bracket 115 Iand a roof tile 400 using bolt 125. As the grommet 405 is installed on the crest of the tile 400 it provides a reliable and long-life weatherproof seal.

Those skilled in the art of installing rooftop apparatus will thus appreciate the significant advancements of the present invention over the prior art. The invention is both a system 100 that enables effective and safe installation of a rooftop apparatus, and a method for performing such installation. Various types of rooftop apparatus may be installed using the system 100 and method of the present invention, including panels 130 for hot water recirculating solar collectors and photovoltaic solar collectors.

Referring to FIG. 8 there is a flow diagram illustrating the steps of a method 800 for installing a rooftop apparatus such as a solar panel 130 according to an embodiment of the present invention. First, at step 805 pilot holes are drilled through a roofing material such as roof tiles 400. At step 810 upper and lower brackets 105, 115 are secured through the pilot holes to underlying roof structure such as roof battens 120. Optionally, a middle bracket 110 also may be installed. At step 815 an apparatus such as a solar panel 130 is raised to the roof and rested against the L-shaped lower bracket 115. Finally, at step 820 the apparatus is secured to the brackets 105, 115.

The present invention is therefore an improved system 100 and method 800 for mounting an apparatus on a roof. Advantages of the invention include the fact that roofing materials such as roofing tiles 400 do not need to be removed during installation; fewer workers may be required to install an awkward apparatus such as a solar panel 130 because the brackets 105, 115 are installed before a solar panel 130 is raised to the roof and the brackets proved an effective means for stabilizing a panel 130 while the panel 130 is secured to the c brackets 105, 115; weatherproofing holes in a roof is simplified because there are no large gaps created in the roofing material; and, on tile roofs, simple IDgrommets 405 and sleeves 215 effectively decrease localized stress on roofing tiles 400 and minimize the risk of cracking tiles 400 during installation and use of the rooftop apparatus.

N The above description of various embodiments of the present invention is 0 provided for purposes of description to one of ordinary skill in the related art. It is

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IDnot intended to be exhaustive or to limit the invention to a single disclosed 0 10 embodiment. As mentioned above, numerous alternatives and variations to the present invention will be apparent to those skilled in the art of the above teaching. Accordingly, while some alternative embodiments have been discussed specifically, other embodiments will be apparent or relatively easily developed by those of ordinary skill in the art. Accordingly, this patent specification is intended to embrace all alternatives, modifications and variations of the present invention that have been discussed herein, and other embodiments that fall within the spirit and scope of the above described invention,

Claims

1. A system for mounting an apparatus on a roof, the system comprising: an upper bracket for securing to a roofing structure through holes in a roofing material; a lower bracket, having a transverse section, for securing to a roofing structure through holes in a roofing material; a first plurality of polymer spacers for placing between the upper bracket and the roofing material; a second plurality of polymer spacers for placing between the lower bracket and the roofing material; and means for securing the apparatus to both the upper bracket and the lower bracket.

2. The system of claim 1, wherein the upper and lower brackets are secured to the roofing structure using bolts inserted through spacing sleeves.

3. The system of claim 1, further comprising a middle bracket for positioning between the upper bracket and the lower bracket.

4. The system of claim 1, wherein the lower bracket is an L-shaped bracket. The system of claim 1, wherein the apparatus is a solar panel.

6. A method for mounting an apparatus on a roof, the method comprising the steps of: drilling a plurality of pilot holes through a roofing material; underly from a section

7. to the ;ecuring through the pilot holes an upper bracket and a lower bracket to ing roofing structure, wherein a polymer grommet separates the brackets •oofing material; aising the apparatus to the roof and resting it against a transverse of the lower bracket; and ;ecuring the apparatus to the upper and lower brackets. he method of claim 6, wherein the upper and lower brackets are secured )ofing structure using bolts inserted through spacing sleeves. rhe method of claim 6, further comprising securing a middle bracket the pilot holes to the underlying roofing structure rhe method of claim 6, wherein the lower bracket is an L-shaped bracket. Fhe method of claim 6, wherein the apparatus is a solar panel. system for mounting an apparatus on a roof as described herein with ce to the accompanying drawings.

8. throug

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12. P method for mounting an apparatus on a roof as described herein with reference to the accompanying drawings.