GB2454948A

GB2454948A - Roof Tile Support Bracket

Info

Publication number: GB2454948A
Application number: GB0803312A
Authority: GB
Inventors: Mark John Tooley
Original assignee: Solar Century Holdings Ltd
Current assignee: Solar Century Holdings Ltd
Priority date: 2007-11-20
Filing date: 2008-02-25
Publication date: 2009-05-27
Also published as: GB0722714D0; GB0803312D0

Abstract

A tile support bracket (301, fig.3) for supporting a curved roof tile is provided. The roof tile 901 has its upper portion, which includes its normal fixing means, cut off so as to be abutable against a lower edge of a flat panel (201, fig.10), such as a solar panel, so as to incorporate the panel within the roof structure. The bracket (301) is configured to be supported by a roof batten and to support a cut tile (901, 1001).

Description

I

Tile Support Bracket

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority from United Kingdom Patent Application No. 07 22 714.3, filed 20 November 2007, the entire disclosure of which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

1. TechnicalField

The present invention relates to a tile support bracket for supporting a curved roof tile. The invention also relates to apparatus for incorporating a substantially flat panel within a roofing structure that includes curved tiles and a method of supporting curved tiles below a flat panel on a roof structure.

2. Background of the Invention

Procedures for the installation of substantially flat panels upon roofing structures that include curved tiles are known. A requirement to install fiat panels occurs, for example, when installing solar energy collecting devices, such as photo-voltaic devices or solar thermal devices. However, when presented with a substantially curved roof, problems arise in terms of maintaining weather resistance and structural integrity. Consequently, a known approach involves the use of applying additional mortar or lead flashing in order to seal gaps created between the curved roof tiles and the flat device: Such an approach generally achieves the required level of functionality but results in an appearance that is less than aesthetic and in many circumstances would result in rejection of the proposal.

BRIEF SUMMARY OF THE INVENTION

According to an aspect of the present invention, there is provided a tile support bracket for supporting a curved roof tile, wherein said roof tile has an upper portion cut therefrom so as to be abutable against a lower edge of a flat panel; said bracket is configured to be supported by a roof batten; and said bracket is configured to support a cut tile.

According to a further aspect of the present invention, there is provided apparatus for incorporating a substantially flat panel within a roofing structure that includes curved tiles, comprising: a tile support bracket; and flexible waterproof matenal, wherein said flat panel is configured to be retained on the roofing structure and surrounded by said curved tiles; the tiles include nibs at an upper end configured to be supported by rows of battens; a lower edge of the flat panel is abutable against a trimmed course of tiles; the flexible waterproof material is applicable onto the roof structure underneath said trimmed course; and said trimmed course is supportable by said tile support bracket.

According to a further aspect of the present invention there is provided a method of supporting curved tiles below a flat panel on a roof structure, comprising the steps of: removing an upper portion from a plurality of tiles for use as lower course tiles; identifying a lower course location; attaching a tile support bracket to a batten above the lower course location; and attaching each of said lower tiles to one of said support brackets to form a lower course of tiles.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Figure 1 shows a roofing structure that includes curved tiles: Figure 2 shows an example of a substantially flat panel; Figure 3 shows an embodiment of the present invention; Figure 4 shows a cross-sectional view of the brackets shown in figure 3; Figure 5 shows a sheet of metal suitable for construction of the bracket shown in figure 3; Figure 6 illustrates procedures for constructing a roof using an embodiment of the present invention; Figure 7 shows an alternative embodiment of the present invention; Figure 8 shows the application of waterproofing material; Figure 9 shows the application of cut tiles; Figure 10 shows the overlapping of tiles; Figure 11 shows the application of a flat panel; and Figure 12 illustrates an example of a portion of roof utilising an embodiment of the present invention.

DESCRIPTION OF THE BEST MODE FOR CARRYING OUT THE

iNVENTION Figure 1 A roofing structure is shown in Figure 1 that includes curved tiles 101 of the type that line up in vertical columns 102, 103 etc to define contiguous channels 104. These channels are provided to enhance the removal of rainwater from the roof and in many situations they are considered to define a particular aesthetic look. Thus, in many applications, an architect will be constrained to use tiles of this type either to satisfy structural requirements or in order to be compliant with existing buildings in the area.

Figure 2 An example of a substantially flat panel is illustrated in Figure 2. An object of the invention is to incorporate a flat panel of the type shown in Figure 2 onto a roofing structure of the type shown in Figure 1.

In this example, the flat panel is a solar energy collecting device, that is effectively one tile space deep and four tile spaces wide.

Panel 201 includes an lower edge 202, side edges 203 and an upper edge 204. In an embodiment of the invention, an object is to provide appropriate interfaces at these edges with curved tiles to facilitate the use of solar panels while maintaining weather resistance and an appropriate aesthetic look.

Figure3 An embodiment of the present invention is shown in Figure 3, consisting of a tile support bracket 301 for supporting a curved roof tile of the type shown in Figure 1. In order to make use of the bracket shown in Figure 3, an upper portion of a roof tile is cut off such that the resulting cut edge is then abutable against a lower edge 202 of a flat panel. The removal of this top portion of a tile results in the removal of nibs on the underside of the tile used for supporting the tile from a batten (of the type shown in Figure 6). The bracket is configured to be supported by a roof batten and the bracket in turn supports the cut tile.

The embodiment of Figure 3 is formed by folding a strip of metal, such as a strip of aluminium. An illustration of an unfolded strip is shown in Figure 5.

The majority of folds are applied during a manufacturing process with a minority of additional folding taking place during the fabrication in the roof structure.

The embodiment of Figure 3 includes a clip which is formed from elongated portions 302 and 303. Portion 302 is configured to fit over a cut edge of a roof tile and portion 303 is configured to fit under the cut edge of a roof tile. Lips 304 and 305 are provided to aid the gripping of the cut tile. In this embodiment, the bracket also includes a raised portion consisting of a first raised element 306 and a second raised element 307. Raised elements 306 and 307 provide a raised portion adapted to support the underside of a panel.

In this way, it is possible for the lower edge 202 of the panel to effectively abut against the top edge of the tiles with the tiles themselves supported by respective brackets. The lower portion of the panel does not overlap the tiles (as would normally be the case for overlapping courses of tiles) but instead it is supported by the raised elements 306 and 307.

The bracket also indudes a batten hook 308 for hooking the bracket from a batten, as illustrated in Figure 9.

Figure 4 A cross-sectional view of the bracket shown in Figure 3 is given in Figure 4. In particular batten hook 308 can be seen to under-hang the rest of the apparatus. A further lip 401 is provided on elongate portion 303 to aid gripping of a cut tile. Bracket 301 is configured to receive a cut tile into opening 402 in order to support a cut tile whilst itself being supported by a batten.

Figure 5 A sheet of flat metal such as aluminium or another suitable metal, suitable for construction of bracket 301 is shown in Figure 5. Elongate portions 302 and 303 can be seen and an extended portion 501 is shown which is folded appropriately in order to form raised elements 306 and 307. In this example, apertures 502 and 503 are provided which, when folded up, overlay each other so as to provide an opening through bracket 301. This opening is configured to receive a fixing device such as a screw or nail in order to further secure bracket 301 to a roof batten. In alternative embodiments, these apertures may not be required.

Figure 6 Procedures for constructing a roof using an embodiment of the present invention are detailed in Figure 6. In this example battens 601, 602, 603 etc have been attached to the roof structure. These battens allow conventional tiles to be supported by the presence of nibs extending from the under surface towards the upper end of each tile. In this example, a first course has been laid (from right to left) as illustrated by arrow 604. Thus, a first tile 605 has been applied to the roof supported by batten 601. A second tile 606 is then applied again supported by batten 601 but also overlapping a portion of tile 605.

Having completed the first course of tiles, a second course of tiles will be laid in a similar fashion. Thus, the second course will be supported from batten 602 and again an overlap would occur in that each new tile would overlap the tile immediately to its right. However, for the purposes of this illustration, it is assumed that the next course will include a flat panel such as a solar panel with curved tiled being supported below the panel.

A course of tiles lying below the panel such as a solar panel will be referred to herein as a lower course. To incorporate the solar panel, an upper portion is removed from a set of tiles for use as lower tiles in the lower course.

Thus, over the region where the solar panel is to be located, lower tiles will be supported by a bracket as the type shown in Figures 3 to 5 and not supported directly by a batten such as 402. Thus, at the appropriate locations the tile support brackets are attached to batten 402 whereafter a cut tile is attached to each of the brackets so as to form a lower course of tiles.

Depending upon the exact configuration of the tile support brackets, they may be configured to be used in conjunction with hook devices which are located at the bottom uncut tile edges in order to fully support the cut roof tiles.

The hook devices are attached at the upper uncut edge of the first row of tiles shown at 607 in order to support a second row of tiles which will be applied at 608 and which will form the lower course abutting the solar panel. An illustration of hooked devices in use is provided in Figures 8 to 10.

Figure 7 An alternative embodiment of the present invention is shown in Figure 7. This embodiment is suitable for using without hook devices as it is an extended tile support bracket which attaches to both a cut top edge and uncut bottom edge of tiles in the lower course. Tile support bracket 701 comprises a first clip 702 for securing the cut top edge of a tile. Further provided is a second clip 703 to support the bottom uncut edge of the tile. Raised elements 704 and 705 are provided which are analogous to raised elements 306 and 307 in tile support bracket 301. Similarly, a batten hook 706 is provided which is analogous to batten hook 308.

A tile support bracket such as 701 is suitable where precise measurements between battens can be ascertained. However, an arrangement using tile support bracket 301 provides greater flexibility in terms of gaps between battens. It is important that the bottom edges of tiles are secured to prevent them being lifted by gusts of wind or other weather conditions. The system using tile support bracket 301 allows for at least a centimetre tolerance between battens. Tile support brackets (whether in accordance with 301 or 701) support the weight of panels such as 201.

Figure 8 In a preferred method of assembly, a waterproofing material is applied to the lower course before the tile brackets are attached. Alternatively, the order of these steps may be reversed. In addition, depending upon the configuration the hook devices may be applied at differing stages of the procedure. The hook devices may, depending upon their configuration, be S-shaped and may either hook over the top edge of the course of tiles below or may be attached to the underlying batten, for example by nailing or adhesive etc. In a preferred embodiment, the waterproofing material takes the form of a metal flashing, possibly implemented as corrugated aluminium sheeting 801.

As shown in Figure 8. A series of hook devices 802, 803, 804 and 805 are shown. In addition, a series of tile support brackets of the configuration shown in Figure 3 are shown at 806, 807, 808 and 809. Thus, for example, tile support bracket 806 will support the top cut edge of a tile whilst hook device 802 will support the lower uncut edge of the same tile. Tile support brackets 806 to 809 are attached by being hooked over batten 602.

Figure 9 Aluminium flashing 801 is curled over the back of the brackets. This forms a barrier to prevent water or any debris from entering the roof space.

After the application of aluminium flashing 801, along with tile support brackets and hook devices, cut tiles may be applied as illustrated in Figure 9. A first cut tile 901 has been applied being supported by tile support brackets 808 and 809 and hook devices 804 and 805. Cut tile 901 overlaps lower course tile 605. Tiles are in this embodiment laid from right to left therefore the next tile to be applied will overlap with cut tile 901. Depending upon the configuration, part of each tile support bracket such as 808 and 809 may be further folded in order to fully restrain cut tile 901.

If brackets according to the alternative embodiment shown in Figure 7 are to be used, these are applied instead of support brackets 808 etc and hook devices 804 etc are not required.

Figure 10 Tile 901 is also shown in Figure 10 along with a further cut tile 1001 applied thereafter. Tile 1001 overlaps tile 901. Uncut tiles 1002 and 1003 are shown which complete this course. Uncut tile 1002 overlaps cut tile 1001 and uncut tile 1003 overlaps uncut tile 1002.

Figure 11 After the lower course of tiles has been completed, including the cut section for receiving a solar panel, the solar panel 201 is inserted into place, as illustrated in Figure 11. The solar panel is secured to battens 602 and 603 and its weight is supported by tile support brackets 806, 807, 808 and 809.

Depending upon the exact configuration, solar panel 201 may be fitted before or after application of uncut tiles 1002 and 1003.

Figure 12 After solar panel 201 has been located, it will be abutting against a lower course of tiles 1201, a first side tile 1202 and a second side tile 1203. To complete the installation, an upper course of tiles 1204 is added such that the upper course tiles at the position of the solar panel will overlap the top edge 204 of the solar panel. Thus, the upper course of tiles 1204 is supported on a batten by nibs extending from the tiles in the usual manner, without the nibs being cut, and arranged such that the lower portions overlap the upper edge 204 of the flat panel.

It can be seen that the configuration of the preferred embodiment allows many different arrangements of solar panels and the proportion of the roof onto which solar panels have been attached may be varied according to particular requirements. After being secured to the roof, the solar panels provide for the direct heating of water or for the generation of electricity and appropriate plumbing and/or electrical connections would be made to the panels as is well known, in order to provide energy to the dwelling or to provide an additional source of energy to the national grid system.

Claims

Claims 1. A tile support bracket for supporting a curved roof tile, wherein: said roof tile has an upper portion cut therefrom so as to be abutable against a lower edge of a fiat panel; said bracket is configured to be supported by a roof batten; and said bracket is configured to support a cut tile.
2. A bracket according to claim 1, constructed by folding a strip of metal.
3. Apparatus according to claim 2, wherein a majority of folds in said metal strip are pre-manufactured and at least one of said folds is folded in during roof assembly to restrain a tile.
4. Apparatus according to any preceding claim, wherein said bracket includes a clip for securing the cut top edge of a tile.
5. Apparatus according to any of claims 2 to 4, wherein said bracket includes a raised portion adapted to support the underside of the panel.
6. Apparatus according to claim 5, wherein the panel is a solar energy collection panel that is supported partially by said raised portion.
7. Apparatus according to claim 6, wherein said solar energy collection panel has dimensions that are compatible with the size of a plurality of tile units.
8. Apparatus according to any preceding claim, wherein said bracket is configured to be used in conjunction with a hook device located at the bottom uncut tile edge in order to fully support said roof tile.
9. Apparatus for incorporating a substantially flat panel within a roofing structure that includes curved tiles, comprising: a tile support bracket; and flexible waterproof material, wherein said flat panel is configured to be retained on the roofing structure and surrounded by said curved tiles; the tiles include nibs at an upper end configured to be supported by rows of battens; a lower edge of the flat panel is abutable against a trimmed course of tiles; the flexible waterproof material is applicable onto the roof structure underneath said trimmed course; and said trimmed course is supportable by said tile support bracket.
10. Apparatus according to claim 9, wherein said support bracket is constructed by folding a strip of metal.
II. Apparatus according to claim 10, wherein said bracket includes a clip for securing the cut top edge of a tile.
12. Apparatus according to claim 11, wherein said bracket is configured to be used in conjunction with a hook device located at the bottom uncut tile edge in order to fully support said roof tile.
13. Apparatus according to any of claims 10 to 12, wherein said bracket includes a raised portion adapted to support the underside of the panel.
14. A method of supporting curved tiles below a flat panel on a roof structure, comprising the steps of: removing an upper portion from a plurality of tiles for use as lower course tiles; identifying a lower course location; attaching a tile support bracket to a batten above the lower course location; and attaching each of said lower tiles to one of said support brackets to form a lower course of tiles.
15. A method according to claim 14, wherein a water-proofing material is applied to the lower course location before the tile support brackets are attached.
16. A method according to claim 14, wherein said flat panel is located above said tower course of tiles with a lower edge of said panel abutting against the top cut edge of the lower course of tiles.
17. A method according to claim 16, wherein tiles are arranged to abut against side edges of the panel by removing side edges from said tiles.
18. A method according to any of claims 14 to 16, further comprising the step of attaching a hook device to the bottom uncut edge of each tile.
19. A method according to claim 16, wherein an upper course of tiles is supported by nibs without being cut and are arranged such that lower portions of said upper course tiles overlap an upper edge of the flat panel.
20. A method according to claim 191 wherein said panel collects solar energy and heat energy or electrical energy is derived from said panel after installation.