GB2561819A

GB2561819A - System for mounting external structures to a roof and apparatus and components for use therein

Info

Publication number: GB2561819A
Application number: GB1705475.0A
Authority: GB
Inventors: Stuart Charles
Original assignee: SKYLINE ENGINEERING ENERGY Ltd
Current assignee: SKYLINE ENGINEERING ENERGY Ltd
Priority date: 2017-04-05
Filing date: 2017-04-05
Publication date: 2018-10-31
Anticipated expiration: 2037-04-05
Also published as: GB2561819A8; GB201705475D0; GB2561819B

Abstract

An apparatus for fixing an external structure to a roof of a building comprises a clamp (20) having plates (22, 23, 24, 26) that can be assembled around four sides of the cross section of an internal rafter of a roof and tightened onto the rafter). The clamp (20) has a shaft (33) that in use projects from within the roof space towards the outside of the roof and a distal end of the shaft provides a means for securing an external structure (100, 200) to the roof. The shaft carries seals which seal against the roof covering to prevent ingress of water. An array of the clamps may support rails for receiving solar panels.

Description

(71) Applicant(s):

SkyLine Engineering Energy Limited 26 Kenilworth Drive, NUNEATON, Warwickshire, CV10 5XP, United Kingdom (72) Inventor(s):

Charles Stuart (56) Documents Cited:

GB 2292583 A GB 2251020 A

GB 2219826 A JP 2013100654 A (58) Field of Search:

INT CL E04B, E04D, E04G, E06C, F24J, H02S Other: EPODOC, WPI (74) Agent and/or Address for Service:

Coulson & Rule

Whitehall Road, Rugby, Warwickshire, CV21 3AE, United Kingdom (54) Title of the Invention: System for mounting external structures to a roof and apparatus and components for use therein

Abstract Title: System for mounting solar panel support framework to roof rafters (57) An apparatus for fixing an external structure to a roof of a building comprises a clamp (20) having plates (22, 23,

24, 26) that can be assembled around four sides of the cross section of an internal rafter of a roof and tightened onto the rafter). The clamp (20) has a shaft (33) that in use projects from within the roof space towards the outside of the roof and a distal end of the shaft provides a means for securing an external structure (100, 200) to the roof. The shaft carries seals which seal against the roof covering to prevent ingress of water. An array of the clamps may support rails for receiving solar panels.

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SYSTEM FOR MOUNTING EXTERNAL STRUCTURES TO A ROOF AND APPARATUS AND

COMPONENTS FOR USE THEREIN

FIELD OF THE INVENTION

The invention relates to systems for supporting and holding external structures, such as, for example, solar panels, roof ladders, fire escape ladders and the like. More specifically but not exclusively, systems according to the invention hold a plurality of solar panels. Even more specifically but not exclusively, the systems are for fixing to a building, for example, onto the outside of a roof. The invention also relates to frame structures and components incorporated in said system.

The invention also relates to an apparatus for fixing external elements of the system to the outside of the roof. More particularly, but not exclusively, the invention relates to a clamp attachable about a member of a roof structure, for example a rafter of a roof.

Aspects of the invention relate to a system, to an apparatus, to a frame structure, to one or more extruded frame members and other components of said system, and to a method.

BACKGROUND OF THE INVENTION

In recent years, the installation of solar panels on the roofs of domestic properties has become more popular. With this surge in popularity came a demand for quick installation of solar panels. Solar panels are heavy and delicate. Roofs need to be waterproof and roof structures need to have sufficient structural robustness to support a normal roof covering and the added weight of the solar panels. It is now known that some installers of solar panels have been damaging roofs and, in some cases, damaging the solar panels because of the methods and fixings that they are using to attach solar panels to roofs. The consequences can be dire: a roof that is no longer waterproof, a roof structure that has collapsed, a solar panel that no longer works.

Conventionally roofs comprise a plurality of spaced rafters that typically run from a top of the roof down to a bottom of a roof. The spaced rafters are covered with a water proof layer of roofing felt that is nailed to the rafters. A plurality of substantially parallel spaced wooden battens or lats are nailed, in a generally transverse arrangement, to the rafters, on top of the layer of roofing felt. A final roof covering, for example, overlapping tiles made of cement, terracotta, slate or the like are hung on or otherwise attached to the battens.

The roofing felt is an important feature of the roof structure since it provides a waterproof membrane that prevents snow and rain from entering into the roof space and damaging the wood of the roof and the ceilings of the rooms below the roof space.

It is customary to fit external structures, such as solar panels, to a roof by working solely from outside of the roof. However, experience shows that working solely from the outside of a roof can create hidden damage to the roof timbers. This “hidden damage” ultimately jeopardises the safety and strength of the roof. Unfortunately this damage may only become apparent many years after the external structure was fitted to the roof and may only present itself when there is a disastrous collapse of the roofing timbers.

Commonly, a fitter employed to install a solar panel or other external structure to a roof may first install fixings to which the external structure is then attached. To do this, the fitter lifts selected tiles and feels for the location of the rafter that lies under the roofing felt, and then nails through the roofing felt into the rafter. Quite often the exact location of the rafter is improperly determined by the fitter, and the fitter may not nail the centre of the rafter. The rafters can be split because the nail or screw that holds external fixings misses the centre of the rafter. This damage severely weakens the overall roof structure but may not come to light until many years later. This becomes more of a problem where the external structure comprises a plurality of solar panels, which are very heavy. If covered by heavy snowfall, the roof timbers may become overloaded, beyond the loads that they were designed to cope with and the rafter damage may result in full or partial collapse of the roof structure.

Quite often the roofing felt is deliberately torn by fitters looking to reveal the rafter and the roof felting is not necessarily repaired. This leaves the roof space exposed to the risk of water ingression through the torn roofing felt, which again is not revealed until rain or snow is blown up under the tiles and enters the roof space of the house.

Furthermore, it is typical that for each solar panel being installed, a fixing through the roof is required. With such an installation method, when a large number of solar panels are being attached to a roof, the likelihood of rafter, felt or other roof damage is higher. The installation method also takes a considerable time and because it is labour intensive it can be expensive.

The present invention seeks to provide an improvement in the field of solar panel installation systems and in the field of fixing external structures to roofs. The invention has particular application for solar panels and in domestic houses. However, the invention may be utilised in applications other than domestic houses, for example it is foreseen that the invention may have application in commercial buildings, new-build constructions, and in free-standing solar panel farms as examples. Aspects of the invention may have application for fixing external structures such as, for example, ladders and fire escapes, as well as solar panels.

An object of the present invention is to provide a method of fixing external structures such as, for example, ladders, fire escapes, solar panels, to roofs without damaging the rafters, by fitting clamps for supporting the external structures from within the roof space. This has an advantage of cutting down the time spent on the outside of the roof where problems are created by unscrupulous fitters taking short cuts instead of doing the job properly.

A further object of the present invention is to use an internal clamp that wraps around the profile of the rafter and thereby does not impact on the structural integrity of the rafter and provides a secure location to carry brackets that project from the outside of the roof on to which external structures can be mounted.

A further object of the present invention is to provide an internal clamp that enables external structures to be fitted to roofs without breaching the waterproof integrity of the roof.

A further object of the present invention is to provide a method of fixing external structures such as, for example solar panels that alleviates damage to the solar panels and to the roof and yet is fast and less labour intensive.

According to a first aspect, there is provided an apparatus for fixing an external structure to a roof of a building comprising a clamp having plates that can be assembled about an internal rafter of the roof and tightened onto the rafter, said clamp having a shaft that in use projects from within the roof space towards the outside of the roof a distal end of which provides a means for securing an external structure to the roof.

Optionally, each clamp comprises a top plate, a first side plate, a second side plate spaced from the first side plate, and a bottom plate spaced from the top plate such that the plates can be assembled around four sides of the cross section of a rafter. At least one of the side plates may be adjustable to adjust the spacing between the side plates, and at least one of the top and bottom plates may be adjustable to adjust the spacing between them.

Optionally, one of the side plates is provided with the shaft.

Optionally, the top plate is provided with the shaft.

Optionally, the top plate is provided with a plurality of spaced recesses that project upwardly, the bottom plate has recesses that face downwards, and are in alignment with the recesses in the top plate, each of the side plates has a plurality of slots for receiving the top plate and the bottom plate, said plurality of recesses together with the slots being dimensioned and positioned relative to each other to enable different sizes of bracket to be made to fit different crosssectional sizes of rafters.

Optionally, the clamp is assembled around the rafter by slotting the top plate through a slot in each of the side plates, the side plates are located in a selected one of the recesses in the top plate and the bottom plate is inserted through a slot in each of the side plates.

Optionally, the top, bottom, and side plates are interconnected by at least one hinge means and hinge pin, wherein at least one of the side plates is adjustable to adjust the spacing between the side plates, wherein at least one of the top and bottom side plates is adjustable to adjust the spacing between them, and wherein one of the side plates is provided with a boss in which is mounted the shaft.

Optionally, the shaft has an external screw thread and the boss has a screw-threaded bore for receiving the screw-threaded shaft.

Optionally, the top, and at least one side plate are interconnected by a hinge means, at least one of the side plates and/or bottom plate having adjustment means associated therewith for adjusting the spacing between the first and second side plates and/or between the top and bottom plates, and wherein the top plate is provided with the shaft.

Optionally, a spike depends from the underside of the top plate for penetrating a roof rafter.

Optionally, said adjustment means comprises an adjustment pad coupled via an adjustment screw to the bottom plate; and wherein the adjustment pad is situated between the top plate and the bottom plate.

Optionally, the spacing between the first and second side plates is not adjustable.

Optionally, there is provided first and second seal means on the shaft for affecting a seal on two sides of a waterproof membrane of a roof.

Optionally, there is provided third and fourth seal means on the shaft for affecting a seal on two sides of roof covering.

Optionally, a fixing bracket is secured to a distal end of the shaft for attachment to a structure external to the roof.

Optionally, an external frame member is fixed to the fixing bracket that is secured to a distal end of the shaft.

Optionally, there is provided an adjustment wheel for securing a frame member to the fixing bracket.

According to a second aspect, there is provided an apparatus for fixing an external structure to a roof of a building comprising two or more clamps secured at spaced intervals along a rafter of a roof.

Optionally, two or more rows of clamps constructed according to any one of the preceding paragraphs are spaced at intervals extending along the length of the roof.

Optionally, two or more spaced rows of frame members are attached to the distal end of selected shafts, said frames being shaped, positioned, and arranged relative to the external structure to secure and hold support rails.

According to a third aspect, there is provided an apparatus for fixing an external structure to a roof of a building, comprising two or more rows of clamps that are secured from within the roof space to selected rafters that are spaced along the roof, each of the clamps being constructed so that it can be assembled around each rafter and tightened onto the rafter, and having a shaft that projects from within the roof space towards the outside of the roof to form two or more spaced rows of shafts extending along the length of the roof, and two or more spaced rows of frames for attachment to a distal end of selected shafts, said frames being shaped, positioned, and arranged relative to the external structure to secure and hold horizontal support rails.

According to a further aspect, there is provided a system for holding a plurality of solar panels, the system comprising two or more spaced frame members and two or more support rails, the support rails disposed atop the frame members, normal thereto and being locked or otherwise affixed thereto, the two or more support rails being shaped and being spaced apart for receiving therebetween a plurality of solar panels.

Optionally, the system comprises one or more solar panel top clamps for further securing the plurality of solar panels between said support rails.

Optionally, a retainer for locking a support rail to a frame member is provided.

Optionally, the frame member is profiled and has an upper channel, shaped sized and arranged for receiving part of said retainer.

Optionally, the support rail is profiled and has an outwardly projecting portion upon which part, said retainer can be seated.

Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF DRAWINGS

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Figure 1A shows a cross-sectional view of a roof structure taken along the length of a rafter;

Figure 1B shows schematically a view of one side of a sloping roof of a building looking from the outside of the roof, and shows an external structure system for supporting and holding a plurality of solar panels on the outside of the roof. The system comprises, among other things, one or more apparatus for fixing external elements of the system to the outside of the roof;

Figure 2 shows a schematic end view of part a roof structure taken along the length of a rafter showing part of a system for supporting and holding a plurality of solar panels;

Figure 3 is a further schematic view of one side of a sloping roof of a building looking from the outside of the roof, and shows a system for supporting and holding a plurality of solar panels on the outside of the roof. The system comprises, among other things, one or more apparatus for fixing external elements of the system to the outside of the roof;

Figure 4 shows an end view of an apparatus for fixing external elements of the system of Figure 3 to the outside of the roof, the apparatus is in the form of a clamp, a substantial part of which is to be housed internally of the roof structure;

Figure 5 shows a view from a second side of the apparatus of Figure 4;

Figure 6 shows a view from a first side of the apparatus of Figure 4;

Figure 7 shows a cross-sectional view of the apparatus of Figure 4 taken in a plane normal to the length of the rafter;

Figure 8A shows an end view of an apparatus according to another embodiment of the disclosure, the apparatus for fixing external elements to the outside of the roof, the apparatus is in the form of a clamp, a substantial part of which is to be housed internally of the roof structure;

Figure 8B shows a top view of the apparatus of Figure 8A;

Figure 9 shows a view from a first side of the apparatus of Figure 8A;

Figure 10A shows a view from a second side of the internal clamp apparatus of Figure 8A;

Figure 10B shows a cross sectional view of the internal clamp apparatus of Figure 8A, crosssectioned in a plane normal to the length of the rafter;

Figure 11 shows a cross-sectional view of a roof structure taken along the length of a section of rafter and showing an apparatus for fixing external elements to the outside of the roof according to various embodiments of the disclosure;

Figures 12A and 12B show end and perspective views of a clamp according to various embodiments;

Figure 13A shows an end view of an apparatus according to yet other embodiments of the disclosure, the apparatus for fixing external elements to the outside of the roof, the apparatus is in the form of a clamp, a substantial part of which is to be housed internally of the roof structure;

Figure 13B shows a perspective view of the apparatus of Figure 14A, wherein the apparatus is in an open or un-locked state in readiness for being fitted about a rafter of a roof structure or the like;

Figures 14A and 14B show top and side views ofthe clamp of Figures 13A and 13B;

Figure 15 is a perspective view of part of a system for supporting and holding a plurality of solar panels on the outside of the roof incorporating a clamp apparatus according to various embodiments;

Figures 16, 17A and 17B are end, top and bottom views ofthe system of Figure 15;

Figure 18 is a view of a larger section of the system of Figure 15 showing a solar panel located and locked in an installed position by the system;

Figure 19 is a similar view to Figure 15 showing the clamp apparatus located about a rafter;

Figure 20 is a schematic view of a house having a non-pitched (i.e. “flat”) roof and having a system for supporting and holding a plurality of solar panels on the outside of the building installed therein using an alternative apparatus, not in the form of a rafter clamp, according to various embodiments; and

Figure 21 is a schematic illustration of a free-standing type system for supporting and holding a plurality of solar panels.

DETAILED DESCRIPTION OF EMBODIMENTS

Detailed descriptions of specific embodiments of the systems for supporting and holding a plurality of solar panels on the outside of the roof; apparatus for fixing external elements of the system to the outside of the roof; and other components of said systems of the present invention are disclosed herein. It will be understood that the disclosed embodiments are merely examples of the way in which certain aspects of the invention can be implemented and do not represent an exhaustive list of all of the ways the invention may be embodied. Indeed, it will be understood that the systems for supporting and holding a plurality of solar panels on the outside of the roof; apparatus for fixing external elements of the system to the outside of the roof; and other components of said systems described herein may be embodied in various and alternative forms. The Figures are not necessarily to scale and some features may be exaggerated or minimised to show details of particular components. Well-known components, materials or methods are not necessarily described in great detail in order to avoid obscuring the present disclosure. Any specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the invention.

Referring to Figures 1 and 2 there is shown, in cross-section, a part of a sloping roof 10 of a building (not shown). The sloping or pitched roof 10 comprises a plurality of roof tiles 11 that are hung on lats or battens 12. The battens 12 may be wooden and are optionally nailed to the rafters 13. Each of the tiles 11 is optionally of a rectangular cross-sectional shape and optionally may have a shaped surface having ridges or crests 11(a) and troughs or valleys 11(b). There is a plurality of rafters 13 at (not necessarily uniform) spaced intervals along the length of the roof onto which a waterproof membrane 14 (optionally a layer of roofing felt) is nailed. The battens 12 are spaced by a distance that allows each row of tiles 11 to be hung on the battens 12 and each successive row of tiles to overlap the row of tiles immediately beneath. The construction of the roof so far described is fairly conventional.

The spacing between each rafter 13 may be uniform, or may vary. Similarly the cross-sectional shape of each rafter 13 may be uniform, or may vary from one rafter to another, and could be of different thicknesses. Furthermore, some rafters 13 may not be completely straight running along their length and/or, along the length of the rafter, the thickness may vary such that a single rafter may not have uniform thickness. This is particularly so with very old roof designs. The roof structure 10 may be relatively uneven in that some rafters 13 may stick out more than an adjacent one or more of the rafters 13.

The tiles 11 interlock with adjacent tiles 11 in the same row and may be made of materials such as slate, cement, concrete, or clay. Some designs of tiles 11 are nailed to the battens 12 instead of simply being hung on battens 12. There are many designs of tiles 11 ranging from flat tiles, to those that are moulded with crests 11(a) and troughs 11(b) (often called “roman” tiles). The exact design of tile 11 is not a feature of the present invention. Indeed it will be recognised that the apparatus, clamps and systems disclosed herein are configured and arranged such that they can be fitted to a variety of roof structures and building types having a variety of rafter sizes and arrangements, and having a variety of roof coverings. Where the roof coverings are tiles 11, the tiles 11 may have a variety of types, shape and size.

Figure 1B shows in greater detail a system 100 for supporting and holding a plurality of solar panels (not shown) on the outside of the roof 10. The system 100 comprises an external frame structure 15 for holding solar panels. The frame structure 15 comprises two or more frame members 17 (also referred to as “slip extrusions 17”) that extend down the slope of the roof 10. In Figure 1B only one of the frame members 17 is shown. These frame members 17 are fixed to frame-fixing brackets 18 that are connected to apparatus 20. The apparatus 20 takes the form of a, predominantly internally disposed, mounting clamp 20 as shown in Figures 4 to 7. Part of the mounting clamp 20 projects from inside the roof space 19 to the outer surface of the roof 10.

In use, two or more clamps 20 are assembled around the cross section of selected rafters 13. The two or more clamps 20 are spaced at intervals along the roof structure and are predominantly located under the waterproof membrane 14. The clamps 20 on each selected rafter 13 are aligned (in a generally transverse direction) with those on other rafters 13. Mounted on the frame members 17 are support rails 21 (also referred to as “cross member extrusions 21”) that extend in a direction normal to the length of the frame members 17. Suitable mounting brackets (not shown in Figure 3, but for an example, see solar panel top clamp 159 in Figure 15) are mounted on the rails 21 for securing the solar panels 16 in place.

It will be appreciated that solar panels 16 are extremely heavy items, but they are also delicate and cannot be subjected to bending or twisting or other stresses that could cause them to fracture. Where roofs are not level the frame members 17 and support rails 21 may be spaced away from the roof tiles 11. Advantageously, this may enable any obstructions to be cleared and provides pairs of straight support rails 21 for securely holding the solar panels 16, which are typically of a uniform, generally rectangular shape. In other arrangements, the system, 100 may be located as close to the roof covering 11 as possible in order to improve waterproofing. In Figure 1B, only four roof tiles 11 are shown so that the waterproof membrane 14 below can be illustrated. Similarly, the waterproof membrane 14 illustrated is not drawn completely over the rafters 13 and in this way, the rafters 13 can also be seen in Figure 1B.

A schematic end view of part a roof structure 10 taken along the length of a rafter 13 and showing part of the system 100 for supporting and holding a plurality of solar panels 16 is shown in Figure 2. In Figure 2 no water proof membrane 14 or roof covering tiles 11 have been shown in order to aid illustration of the system 100. A plan view of the system 100 taken from the outside of the roof 10 is shown in Figure 3. Figure 3 illustrates how, optionally, two clamps 20 attached to a first rafter 13a, together with frame fixing brackets 18 couple a slip extrusion 17 to the roof 10. As shown, the slip extrusion 17 runs generally in the same axial direction as the first rafter 13a. Three cross member extrusions 21 are illustrated as having been coupled to the slip extrusion 17. Though not shown in Figures 1B, 2 or 3 and perhaps better illustrated in Figure 15, the slip extrusion 17 and cross-member extrusions 21 are profiled. The cross member extrusions 21 can slide along the top of an upper channel of the slip extrusion 17 and can be affixed thereto by a securing foot (see 162 in Figure 15) that is slidably moveable in that upper channel. This is described in more detail below with respect to the clamp 120 embodied in Figures 14 - 19. The frame structure 15 is of a uniform, size and dimension, and uniform pitches or spaces between parallel cross member extrusions 21 allow solar panels 16 to be slid in and along a channel of the cross member extrusions 21. In this way once the framework 15 is assembled, a series of solar panels 16 can be quickly, accurately and securely installed to complete the system 100. By first installing clamps 20; and then rapidly assembling a framework 15 of uniform size, a plurality of solar panels 16 can be rapidly assembled on a roof (or other structure) in a secure manner which does not compromise the structural integrity of the roof. The framework 15 of the system 100 is thereby relatively quickly and securely installed by using the clamps 20.

Referring to Figures 4, 5, 6 and 7 there is shown a first embodiment of a clamp 20 for fitment to selected spaced rafters 13 as illustrated in Figure 3. Figures 4, 5, 6 and 7 show end, second side, first side and cross-sectional views of the clamp 20 and will generally be referred to collectively. The clamp 20 comprises a top plate 22, a bottom plate 23, a first side plate 24, and a second side plate 25. It is preferred that the clamp 20 is made of galvanised steel, however it may be made of other suitable materials, such as other metals, for example aluminium, robust plastics material, and suitable combinations thereof.

The top plate 22 of the clamp 20 is provided with a plurality of spaced recesses 26 that project upwardly. The bottom plate 23 has similar recesses 27 that face downwards. The recesses 27 in the bottom plate 23 are in vertical alignment with the recesses 26 in the top plate 22. Each of the side plates 24 and 25 is provided with one or more or a plurality of slots 28, (see Figures 5, 6, and 7) for receiving the top and bottom plates 22, 23. The plurality of recesses 26 and 27 together with the plurality of slots 28 enable the internal dimensions of the clamp 20 to be adjusted and thus made-to-fit different cross-sectional sizes of rafters 13. The clamps 20 are assembled by slotting the top plate 22 through aligned top slots 28 of the first and second side plates 24 and 25; and the side plates 24 and 25 are located in selected recesses 26 in the top plate 22. In a similar manner the bottom plate 23 is inserted through bottom slots 28 in each of the first and second side plates 24 and 25 at positions to engage in one of the recesses 27.

The bottom plate 23 is provided with a screw-threaded hole (see Figure 7) that receives an adjusting screw 29 that engages with an adjustment plate 30 (also referred to as adjustment pad 30) which in use can be tightened up against the a bottom side of a rafter 13. Similarly one of the side plates 25 is provided with one or more (in this illustrated embodiment, two) screwthreaded holes that receive adjusting screws 29a that in use can be tightened up against the side of the rafter 13.

The adjustment pad 30 and adjustment screws 29a can be adjusted to accommodate different sizes of rafters 13. In this way the clamp 20 can be securely clamped to a rafter 13 (provided that the rafter’s size is within a range appropriate for a particular size of clamp 20).

Referring again to Figures 4, 5, 6 and 7, one of the side plates 24 is provided with an integral boss 31. The boss 31 which has a screw threaded bore 32 for receiving a screw-threaded shaft 33. The shaft 33 has a screw threaded bore 34 at its distal end for receiving a screw 35. The screw 35 is used to secure the frame fixing bracket 18 to the shaft 33. The frame fixing bracket 18 is used to secure the frame members 17 to the clamp 20. This is generally illustrated in Figure 2, however, because the frame members 17 shown sit directly on top of the screw 35, the frame fixing bracket 18 can only be seen because part of the frame member 17 is shown with a “cut-away”.

Referring again to Figures 4, 5, 6 and 7, threaded onto the shaft 33 is a first seal 36 which, in use, engages the underside surface of the waterproof membrane 14 (not shown in Figures 4, 5, 6 and 7) and a second seal 37 which can be tightened down onto the external surface of the membrane 14 to maintain the waterproof integrity of the roof 10. Third and fourth seals 38 and 39 are threaded onto the shaft 33; third seal 38 in use engages the underside surface of a roof tile 11 and fourth seal 39 can be tightened down onto the external surface of that roof tile 11.

An adjusting wheel 53 may be provided near the distal end of screw 35 and is used to secure the slip extrusion 17 to the clamp 20.

Figures 8A, 8B, 9, 10A and 10B show a second embodiment of the present invention in the form of an internal clamp 20. In Figures 8A, 8B, 9, 10A and 10B the same reference numbers have been used for the same parts or parts performing a similar function as in the clamp 20 shown in Figures 4 - 7.

Referring specifically to Figures 8A, 8B, 9, 10A and 10B, the clamp 20 comprises a top plate 22, a bottom plate 23, a first side plate 24, and a second side plate 25. As shown in Figure 8B, the top plate 22 has the shape pf a in other words, it is generally rectangular with all four corners cut-away.

The top, bottom, first and second plates 22, 23, 24, 25 each have a hinge 55 formed at two opposing edges of the plates 22, 23, 24, 25. Adjacent plates 22, 23, 24, 25 are connected together by hinge pins that are inserted into the hinges 55. Other suitable forms of hinge or pivotal connection may be used. It is preferred that the clamp 20 is made of galvanised steel, although it could be made of any other suitable material, for example other metals such as aluminium, robust plastics material and/or combinations thereof. To accommodate bigger or smaller sizes of rafter 33 the top, bottom, first and second plates 22, 23, 24, 25 are manufactured in a range of sizes. Each clamp has a degree of adjustment in order to securely clamp and attach the clamp 20 to a rafter 13.

The bottom plate 23 is provided with a screw-threaded hole 29a (see Figure 10B) that receives an adjusting screw 29 (see Figure 8A) that engages with an adjustment plate 30. In use, the adjustment plate 30 can be tightened up against the bottom face of a rafter 13. Similarly one of the side plates 24 maybe provided with one or two screw- threaded holes that may receive adjusting screws that in use can engage a second adjustment plate. In use the second adjustment plate can be tightened up against the side of a rafter 13. The adjustment plates 30 can be adjusted to accommodate different sizes of rafters 13 and to ensure a good and secure attachment of the clamp 20 to a rafter 13. The top plate 23 may comprise a spike 70 which can be driven into the top face of a rafter 13 when the clamp 20 is secured to the rafter 13 to prevent slippage.

One of the side plates 24 is provided with an integral boss 31 which has a screw threaded bore 32 for receiving a threaded shaft 33. Again, the integral boss 31 is disposed along side the second side plate such that the shaft 33 protrudes through the roof 10 at a location that is off-set from the centre of a rafter 13. The shaft 33 has a screw threaded bore 34 for receiving a screw 35 that secures a frame fixing bracket 18 on which the frame members 17 (shown in Figure 2) are secured.

Threaded onto the shaft 33 is a first seal 36 which, in use, engages the underside surface of the waterproof membrane 14 and a second seal 37 which can be tightened down onto the external surface of the membrane 14 to maintain the waterproof integrity of the roof. Third and fourth seals 38 and 39 are threaded onto the shaft 33; third seal 38 in use engages the underside surface of a roof tile 11 and fourth seal 37 can be tightened down onto the external surface of a roof tile 11.

To fix the clamp 20 of Figures 8A, 8B, 9, 10A and 10B to a rafter, one of the hinge pins is removed and the top, bottom, first and second side plates 22, 23 24, 25 are assembled around the perimeter of a rafter 13 under the waterproof membrane 14. The hinge pin that was removed is then reinserted into the hinge 55 and the adjusting screws are tightened to press the adjustment plates 30 against the rafter 13 and thus secure the clamp 20 to the rafter 13. It will be appreciated that the installation of a plurality of clamps 20 on a roof structure 10 can be carried out from within the internal roof space 19. Conveniently therefore this work can be conducted regardless of weather conditions.

In use, a first set of two or more clamps 20 of Figures 4 - 7 or 8A - 10B are assembled around a selected rafter 13 and secured at spaced intervals along the length of the selected rafter 13.

A second set of clamps 20 constructed in accordance with Figures 4-7 or 8A - 10B are assembled around and secured to another rafter 13 spaced along the roof 10. In this way first and second rows of frame-fixing brackets 18 protrude to the exterior of the roof 10 in readiness for receiving the rest of a frame structure 15.

The clamps 20 in each row along the length of a selected rafter 13 are aligned with adjacent clamps 20 with the shafts 33 on the left or right side of the selected rafter 13. The spacing between clamps 20 along the length of a selected rafter is not critical because the elongate frame member 17 can be attached to a clamp 20 anywhere along its length by virtue of it being an extruded profiled section. Accordingly a number of clamps 20 positioned along another successive rafter 13 need not be located with any particular alignment to those on the first rafter because again, the purpose of the number of clamps 20 positioned along that successive rafter is to allow a further frame member 17 or slip extrusion 17 to be secured thereto. Whilst regular spacing of the frame members 17 may be beneficial to create an evenly supported frame structure 15, it is not critical that the spacing is exact. This is a further benefit of the present system 100 over known systems. The clamps 20 can be installed from within the roof space and if internal obstacles prohibit the placement of a clamp 20 in a specific location, it can be placed along a rafter 13 further along from or closer to the last clamp 20 on that rafter 13 without consequence. The frame member 17 can still be secured to each of those clamps 20 provided that they are all attached to a single substantially straight rafter 13.

The frame-fixing bracket 18 and seals 37, 38, and 39 are removed from the shaft 33 when the shaft 33 is pushed through a hole in the waterproof membrane 14 to bring the distal end of the shaft 33 into contact with the underside of a tile 11. The shaft 33 is adjusted to lift the tile 11 slightly. This serves two purposes; firstly it aids visual location of the positions of the clamps 20 from the outside of the roof 10 and secondly it allows sufficient length of the shaft 33 to project through the thickness of the tiles 11. The seal 37 is adjusted to bring it into contact with the underside of the waterproof membrane 14 and locked in place by set screws.

Once all the internal clamps 20 are secured to the rafters 13, the external frame members 17 and rails 21 are fitted on the outside of the roof 10 from outside of the roof 10. This is achieved by removing a roof tile 11 at each location where a shaft 33 lifts a tile 11.

Firstly the second external seal 37 is screwed onto the shaft 33 and tightened onto the waterproof membrane 14. The seal 38 is screwed onto the shaft 33 at a position to contact the underside of the tile and locked in place by a set screw 44.

The tile 11 that is removed is either drilled through at the position where the shaft 33 is located or, alternatively a section of the removed tile is cut out with a stone cutting saw (not shown). The tile 11 is then replaced, and a plastic panel or neoprene rubber membrane 42 may be prepared by drilling or cutting a hole in it to receive the shaft 33. The panel 42 may be used to cover the top surface of the drilled or cut tile 11. The panel 42 may be placed on the shaft 33 and the fourth seal 39 is screwed onto the shaft 33 to clamp the panel 42 in place and secured by locking screws 46.

The solar panels 16 are slidingly inserted between two rows of the support rails 21 and using top clamping devices (not shown), which may optionally be designed for specific solar panels 16, are clamped in place. The advantage of using parallel rows of rails 21 is that they can be adapted for use with many different solar panels of different sizes from different manufacturers by simply by adding fewer or greater numbers of support rails 21 onto the frame members or slip extrusions 17 (and by adjusting the spacing of the clamps 20 along the roof 10 (if required)).

Referring to Figure 11 there is shown a further modification to the internal clamps 20 of Figures 4 to 10B. In this modification the shafts 33 are adjusted so that they terminate close to the underside of the roofing felt 14. Each shaft 33 is provided with an internal plate 46. Optionally the plate 46 has a small spike that is long enough to penetrate the roofing felt. The spike provides a means whereby one can locate where the clamp 20 is when trying to find it from outside the roof space 19. The internal plate 46 has two screw-threaded holes (not shown) for receiving fixing screws or bolts (not shown) for securely fixing the bracket 18 to the plate 46. The surface of the internal plate 46 that confronts the underside of the roofing membrane 14 has a seal (not shown) or is coated with a sealant compound (not shown) to provide a waterproof seal with the roofing membrane 14.

The frame-fixing bracket 18 is modified to have a hole to receive the spike (where there is a spike) and one or more holes to receive fixing bolts or studs (not shown). The frame-fixing bracket 18 is a thin strip of metal shaped so that it rises to the height of the thickness of the roofing tile 11 and is of a length that projects beyond the lower edge 36 of the overlapped roofing tile 11. At the distal end ofthe frame-fixing bracket 18 there is a flange 49 to which the frame members 17 can be secured. The flange 49 is strengthened against bending by a supporting flange 50.

In use of the frame-fixing bracket 18 shown in Figure 11, a roofing tile is removed at the location of each internal clamp 20 and the spike 34 where fitted is located by touch. Holes are cut into the membrane 22 to receive fixing screw or screws and the bracket 18 is securely fixed to the internal plate 46. A seal or sealant (not shown) is located between the bracket 18 and the waterproof membrane 14 and the plate 46. The tile that was removed to give access is then replaced leaving the flanges 49 and 50 of the frame-fixing bracket 18 projecting from the underside of the tile.

In Figures 12A to 12B there is shown yet a further embodiment of clamp 20 wherein the optional integral boss 31 of previous arrangements is omitted and the shaft 33 is located in a bore provided in the top plate 22. Seals 36, 37, 38, 39 (not shown) may be coupled to the shaft 33 for sealing against a waterproof membrane 14 and tile 11 as required. A frame fixing bracket 18 (not shown) may be coupled to the shaft 33 for attaching the frame members 17 of a system 100 to the clamp 20.

Again, a bottom plate 23 may have an adjustment screw 29 and an adjustment plate 30 for ensuring a tight and secure location of the clamp 20 about a rafter 13. In this arrangement, the bottom plate 23 comprises apertures or bores, through which the first and second side plates 24, 25 (which may optionally have a circular cross-section such that they are more rod-like than plate like), can extend. First and second securing nuts 55a, 55b can be used to couple the bottom plate 23 to the sides 24, 25.

In Figures 13A to 14B there is shown yet a further embodiment of clamp 20. Figure 13A shows an end view of the clamping apparatus 20, Figure 13B shows a perspective view of the apparatus 20 and Figures 14A and 14B show top and side views of the clamp 20. Again the clamp has a centrally positioned shaft 33, and in this arrangement, the top, bottom, first and second plates 22, 23, 24, 25 each have a hinge 55 formed at two opposing edges of the plates 22, 23, 24, 25. Adjacent plates 22, 23, 24, 25 are connected together by hinge pins that are inserted into the hinges 55. Other suitable forms of hinge or pivotal connection may be used. It is preferred that the clamp 20 is made of galvanised steel, although it could be made of any other suitable material, for example other metals such as aluminium, robust plastics material and/or combinations thereof.

The bottom plate 23 is provided with a screw-threaded hole that receives an adjusting screw 29 (see Figure 8A) that engages with an adjustment pad 30. In use, the adjustment pad 30 can be tightened up against the bottom face of a rafter 13. In this arrangement neither of the side plates 24 is provided with adjusting screws but in other arrangements adjustment screws could be included for use in engaging a second and/or third adjustment plate. In use the adjustment plate 30 can be adjusted to accommodate different sizes of rafters 13 and to ensure a good and secure attachment of the clamp 20 to a rafter 13. The top plate 23 does not comprise a spike 70, but rather, in this arrangement, the shaft 33 can travel right through the top plate 22 and could be used to penetrate the timber of a rafter to prevent slippage of the clamp 20 relative to the rafter 13. As shown in Figure 13B, the second side 25 can pivot about hinge 55 and can be locked by a removable dowell (not shown) in a closed and locked state.

Referring now to the system shown in Figures 15 to 19, in which, like numerals have, where possible, been used to denote like parts, albeit with the addition of the prefix Ί00”, the profiled nature of the frame member (slip extrusion) 117, support rail (cross-member extrusion) 121, and solar panel top clamp 159 is well illustrated. Optionally, but beneficially, the profiles of these components are uniformly shaped along their length. The components 117, 121 and 159 are formed by extrusion. Optionally, they may all be formed of a steel, aluminium, other metal, metal alloy, a suitable plastics material and/or a combination thereof.

The frame member 117 has an upper, open channel 167b and a lower open channel 167a. The frame fixing member 118 may be shaped and sized in a complementary manner to the shape of the lower channel 167a such that it can be received therein. As shown in Figures 15, 16 and 17B, the lower channel 167a has a generally rectangular cross-sectional shape with an narrower open bottom portion, edged by first and second rails 167c, 167d. The frame fixing member 118 can be received in the lower channel 167a of the frame member 117. The frame member 117 can then be pushed toward the next clamp 120 installed along the same rafter for coupling the frame fixing member 118 of that next clamp 120 to the same frame member 117. In this way multiple frame fixing members 118 can be received in the lower channel 167a and held therein by the first and second rails 167c, 167d. The adjustment wheel 153 associated with each clamp 120 can then be tightened up against outer bottom surfaces of the first and second rails 167c, 167d of the frame member 117 such that the frame member 117 is securely attached thereto.

For ease, speed and to ensure secure attachment, a retainer means or retainer 166 is optionally provided (see Figure 16B). The retainer 166 comprises a locking foot 162 having a ledge 162a which can be seated over a lower profiled portion of a cross-member extrusion 121 (see Figure 15). The locking foot 162 comprises a screw fitting 165, to which a one-way rotatable nut 163 is coupled. The rotatable nut 163 is shaped such that in one orientation relative to the locking foot 162, its maximum width W is less than a maximum width “w” of the open section of the upper channel 167b (see Figure 17A). In a second orientation relative to the locking foot 162, the oneway rotatable nut 163 has a maximum width that is greater than the maximum width “w” of the open section of the upper channel 167b. In this way, the retainer 166 can be manipulated onto the support rail (cross-member extrusion) 121 (using the locking foot 162 and ledge 162a) and dropped into the upper channel 167b of the frame member 117 (using the one-way rotatable nut 163). By swivelling the locking foot 162 relative to the rotatable nut 163, the rotatable nut can be positioned such that it cannot be released through the open end of the upper channel 167b. IN this way, the locking foot 162 is properly seated on the support rail (cross-member extrusion) 121. The screw fitting 165 can then be tightened affixing the cross-member extrusion 121 to the frame member 117 in a quick, reliable and secure manner. A retainer 166 may be located either side of the cross-member extrusion 121 at every intersection of the cross-member extrusion 121 with a frame member 117 (in Figure 15 only one retainer is shown, but see Figure 19 where two retainers 166 lock a support rail 121 to a frame member 117). In this way a grid-like frame structure, such as that illustrated in Figures 18 and 19 can be assembled relatively quickly, even over a large roof area.

Returning to Figure 15, the profiled shape of the support rail 121 can be seen. The support rail 121 is symmetrical and as viewed end on comprises: a lower right channel 121a which is general square “C”-shaped; a lower left channel 121b which is a mirror-image of the lower right channel 121a; a first medial channel 121c which is generally “T”-shaped and has and open top section; and a second upper medial channel 121 d which is generally rectangular and has an open top section. The open top section of the second upper medial channel 121 d is sized and shaped to receive the solar panel top clamp 159. As shown in Figure 18, once all of the solar panels 116 to be held between a spaced pair of rails 121 have been slidably loaded therein (only one solar panel 116 is shown in Figure 18), the top clamps 159 can be seated into the second upper medial channel 121 d of the support rail 121 and thus with the installation of two components (one top clamp 159 on either side of the solar panel 116), all of the solar panels 116 held between the pair of rails 121 are secured within the system 200. Optionally, the top clamps 159 comprise one or more screw fittings 159a (see Figure 17A) for further ensuring that the top clamps 159 are securely affixed to the support rails 121.

It can be appreciated that various changes may be made within the scope of the present invention, whereas in the above embodiments of the present invention the projecting shafts 33, 133 are used to support and carry frame members 17, 117 and support rails 21, 121 for mounting solar panels 16, 116 on a roof 10. The shafts 33, 133 could be used for securing any type of external structure to a roof such as, for example, temporary roof ladders or permanent ladders that provide emergency escape routes over roofs in the case of fire or other hazards. Additionally, the frame system 100, 200 can be used for installing a plurality of solar panels 16, 116 in alternative applications, in such applications the clamps 20, 120 may not be required. For example, in a building without a pitched roof one or more alternative brackets could be used to attach the frame structure 15 to a vertical wall and in such a manner that the frame structure is angled. See for example Figure 20 which shows a building 390 having one or more alternative brackets 320 and a system 100, 200 holding a plurality of solar panels 16, 116. Further alternatively, and as shown in Figure 21, one or more alternative brackets 420 and systems 100, 200 holding a plurality of solar panels 16, 116 may be mounted to the ground in a solar panel farm.

Claims

1. Apparatus for fixing an external structure to a roof of a building comprising a clamp having plates that can be assembled about an internal rafter of the roof and tightened onto the rafter, said clamp having a shaft that in use projects from within the roof space towards the outside of the roof a distal end of which provides a means for securing an external structure to the roof.

2. Apparatus according to claim 1 wherein each clamp comprises a top plate, a first side plate, a second side plate spaced from the first side plate, and a bottom plate spaced from the top plate such that the plates can be assembled around four sides of the cross section of a rafter, wherein at least one of the side plates is adjustable to adjust the spacing between the side plates, and wherein at least one of the top and bottom plates is adjustable to adjust the spacing between them.

3. Apparatus according to claim 1 or 2 wherein one of the side plates is provided with the shaft.

4. Apparatus according to claim 1 or 2 wherein the top plate is provided with the shaft.

5. Apparatus according to claim 1 wherein the top plate is provided with a plurality of spaced recesses that project upwardly, the bottom plate has recesses that face downwards, and are in alignment with the recesses in the top plate, each of the side plates has a plurality of slots for receiving the top plate and the bottom plate, said plurality of recesses together with the slots being dimensioned and positioned relative to each other to enable different sizes of bracket to be made to fit different cross-sectional sizes of rafters.

6. Apparatus according to claim 5 wherein the clamp is assembled around the rafter by slotting the top plate through a slot in each of the side plates, the side plates are located in a selected one of the recesses in the top plate and the bottom plate is inserted through a slot in each of the side plates.

7. Apparatus according to claim 2 wherein the top, bottom, and side plates are interconnected by at least one hinge means and hinge pin, wherein at least one ofthe side plates is adjustable to adjust the spacing between the side plates, wherein at least one of the top and bottom side plates is adjustable to adjust the spacing between them, and wherein one of the side plates is provided with a boss in which is mounted the shaft.

8. Apparatus according to claim 7 wherein the shaft has an external screw thread and the boss has a screw-threaded bore for receiving the screw-threaded shaft.

9. Apparatus according to claim 2 wherein the top, and at least one side plate are interconnected by a hinge means, at least one of the side plates and/or bottom plate having adjustment means associated therewith for adjusting the spacing between the first and second side plates and/or between the top and bottom plates, and wherein the top plate is provided with the shaft.

10. Apparatus according to claim 9 wherein a spike depends from the underside of the top plate for penetrating a roof rafter.

11. Apparatus according to claim 9 or 10 wherein said adjustment means comprises an adjustment pad coupled via an adjustment screw to the bottom plate; and wherein the adjustment pad is situated between the top plate and the bottom plate.

12. Apparatus according to any of claims 9 to 11 wherein the spacing between the first and second side plates is not adjustable.

13. Apparatus according to any one of the preceding claims wherein there is provided first and second seal means on the shaft for affecting a seal on two sides of a waterproof membrane of a roof.

14. Apparatus according to claim 13 wherein there is provided third and fourth seal means on the shaft for affecting a seal on two sides of roof covering.

15. Apparatus according to any one of the preceding claims wherein a fixing bracket is secured to a distal end of the shaft for attachment to a structure external to the roof.

16. Apparatus according to claim 15 wherein an external frame member is fixed to the fixing bracket that is secured to a distal end of the shaft.

17. Apparatus according to claim 16 wherein there is provided an adjustment wheel for securing a frame member to the fixing bracket.

18. Apparatus for fixing an external structure to a roof of a building comprising two or more clamps secured at spaced intervals along a rafter of a roof.

19. Apparatus according to claim 18 wherein two or more rows of clamps constructed according to any one of the preceding claims are spaced at intervals extending along the length of the roof.

20. Apparatus according to claim 19 wherein two or more spaced rows of frame members are attached to the distal end of selected shafts, said frames being shaped, positioned, and arranged relative to the external structure to secure and hold support rails.

21. Apparatus for fixing an external structure to a roof of a building, comprising two or more rows of clamps that are secured from within the roof space to selected rafters that are spaced along the roof, each of the clamps being constructed so that it can be assembled around each rafter and tightened onto the rafter, and having a shaft that projects from within the roof space towards the outside of the roof to form two or more spaced rows of shafts extending along the length of the roof, and two or more spaced rows of frames for attachment to a distal end of selected shafts, said frames being shaped, positioned, and arranged relative to the external structure to secure and hold horizontal support rails.

22. A system for holding a plurality of solar panels, the system comprising two or more spaced frame members and two or more support rails, the support rails disposed atop the frame members, normal thereto and being locked or otherwise affixed thereto, the two or more support rails being shaped and being spaced apart for receiving therebetween a plurality of solar panels.

23. A system according to claim 22 comprising one or more solar panel top clamps for further securing the plurality of solar panels between said support rails.

24. A system according to claim 22 or 23 comprising a retainer for locking a support rail to a frame member.

25. A system according to claim 24 wherein the frame member is profiled and has an upper 5 channel, shaped sized and arranged for receiving part of said retainer.

26. A system according to claim 25 wherein the support rail is profiled and has an outwardly projecting portion upon which part, said retainer can be seated.

10

27. A system according to any of claims 22 to 26 attached to a building.

28. A system according to any of claims 22 to 26 attached to the ground.

29. A system according to any of claims 22 to 26 attached to a building using one or more

15 apparatus according to any of claims 1 to 17.

Intellectual

Property

Office

Application No: GB1705475.0 Examiner: Eleanor Wade