SE2150346A1 - Fixing Apparatus for a Roof - Google Patents

Abstract

There is provided a fixing apparatus for coupling external structure to a roof, the fixing apparatus comprising a fixing plate and a connector for coupling to the external structure and for coupling with the fixing plate at a joint, wherein the fixing plate has a convex surface and the connector has a corresponding mating concave surface such that when the connector and fixing plate are coupled together at the joint the concave and convex surfaces interlock. There is also provided a method for mounting external structure to a roof, the method comprising: attaching a fixing plate to the roof; providing a waterproof layer over the fixing plate; and attaching a connector to the fixing plate such that the waterproof layer is pressed between a convex surface of the fixing plate and an interlocking concave end surface of the connector and a fixing apparatus for coupling external structure to a roof, the fixing apparatus comprising a fixing plate and a connector configured to couple the fixing plate to the external structure, wherein the connector is formed at least partially from a flexible material such that the connector can bend in response to movement of the external structure once mounted.

Description

Fixing Apparatus for a Roof The present invention relates to a fixing apparatus for a roof, and especially to a fixing apparatus for mounting external structure on a roof.

The most important considerations when designing and installing a roof structure arewhether the structure will be capable of supporting any loads to which it may besubjected, and whether and for how long the structure will remain waterproof. Theseconsiderations are relevant to domestic and commercial buildings alike, and haveshaped development in the field of roof construction and mounting mechanisms foruse on roofs.

More recently, the desire to mount external structures in addition to the traditionalcomponents of a roof has also increased. Solar panels, for example, are now widelyused even in domestic settings. These need to be fixed securely enough to a roof toprevent damage or loss of the panels in bad weather and in a manner which will notdamage the roof itself. So far, it has not been possible to successfully mount suchexternal structures in a way which will notjeopardize to some extent the integrity ofthe waterproof layer, or will not place a substantial load on the underlying roofstructure.

Traditional roof structures are formed from a number of layers having differentproperties and providing different benefits to the overall structure. ln a typical roof, acorrugated steel base structure commonly called a deck sits directly below a layer ofinsulation, possibly with the addition of an intervening vapor layer. A cover boardprotects the insulation layer and is held flush thereto using plates and fasteners.

A waterproof membrane then often covers the entire roof. lt is crucial that thewaterproof layer is completely impenetrable to water. To this end, where athermoplastic membrane is used, any seals are heat treated to ensure that watercannot reach the internal roof layers. Waterproof layers may be formed from asphaltor tar, other bituminous waterproofing, rubber, polyvinyl chloride, or other waterimpermeable substances. ln some cases, liquid substances are painted or sprayedonto the roof and allowed to harden to provide the waterproof layer.

When it is desired to attach additional external structures, such as lighting orphotovoltaic panels, walkways, decorative panels, ventilation systems, heating pumps, electrical equipment to a roof this is traditionally achieved by the use of railmounting systems which support the Structures. Rail free systems also exist in whichpanels or lighting, for example, are attached directly to the roof surface. Where afolded metal outer roof layer is present, rails can be attached to the ridges formingpart of the outermost surface of the roof as shown in .JP5551800B1. Here, rails arecoupled to the upwardly extending ridges of the corrugated outer roof surface usinga bolt and additional supporting structure. Such a method will not require penetrationof the Waterproof layers of the roof but will not provide a particularly strong couplingand may not be suitable for use in windy conditions, for example.

More recently, the attachment of solar panels to flat or slightly sloped roofs has beenachieved using ballast systems which also do not require penetration of thewaterproof layer. Some such systems are described in WO-A-2015/110254 and WO-A-2013/056101. These, however, involve large loads being placed on the roofinorder to provide the required support and this may cause damage or may beunsuitable for use in the case of more modern buildings where the load will exceedstructural capacity. Such mechanisms may also be dangerous in situations whereadverse weather can be expected.

The rails may in some circumstances be attached to the roof via fixing plates placedon top of the waterproof layer. Bolts running through the rail, waterproof layer, andfixing plate hold the rails in place and the fixing plate itself is attached to the roofusing a number of additional bolts. This will usually allow the external structure to beattached securely enough to prevent damage either to the roof layers or to theexternal structure. However, because the waterproof layer must necessarily bepenetrated in order to attach the bolts there is a risk of leaking, and this can causemajor damage notjust to the roof but to the whole of the building over time. lnaddition to this, the external structure will tend to bend and move under load or inhigh winds. This will transfer forces to the join and will cause rubbing and wear of thewaterproof layers as well as other parts of the roof and the fixings.

Some attempts have been made to limit leakage through holes made in thewaterproof membrane of the roof in order to accommodate coupling to externalstructures. ln US-A-16/160,370 a hole is made through the waterproof layers of theroof to support a rail-less structure. Some protection is provided from water leakingthrough the hole around the edge of the bolt by a waterproof sealing cap which fitsover the bolt head. ln US-A-12/661,379 a protective raised cover section is provided over the joint, again in order to limit leakage of water through the joint. Thesemethods are fairly complex, limit access to the joint, and cannot completely excludethe possibility of leaking and/or rusting.

According to a first aspect of the present invention, there is provided a fixingapparatus for mounting external structure on a roof, the fixing apparatus comprisinga fixing plate and a connector for coupling to the external structure and to the fixingplate at a joint, wherein the fixing plate has a convex surface and the connector hasa corresponding mating concave surface such that when the connector and fixingplate are coupled together at the joint the concave and convex surfaces interlock.This interlocking function may act to form a seal between the two surfaces, and mayact to form a seal between the two surfaces when a waterproof membrane ispressed between the two surfaces. The upper surface of the fixing plate maycomprise a flat portion surrounding the convex surface and the convex surface itself,which may be located in the center of the plate. interlocking refers to the fact that thesurfaces correspond in shape, however intervening layers such as a waterproof layermay be present between the two mating surfaces when the fixing apparatus isassembled. External structure refers to any structure that might be required to bemounted to a roof, usually outward of an external surface of the roof. Examples ofexternal structure include external lighting, solar panels, walkways, ventilationsystems, heat pumps, decorative panels, or electrical units. Coupling between theconnector and the external structure may or may not be direct, so that interveningfixings may be provided therebetween.

The fixing apparatus avoids the usual problems in terms of water leakage through ajoint while still providing a strength enough to withstand heavier loads and moresevere weather conditions. The raised or convex portion, which may be locatedaround the joint on the fixing plate, prevents water from reaching the joint without therequirement of additional structure as used in some of the existing solutionsdiscussed above. The joint is also strong enough to support heavy loads andadditional attachments or extensions can be included as discussed in more detailbelow. Additional attachments can be used, for example, in order to enable the fixingapparatus to be used to support harnesses during installation of the externalstructure.

Convex refers to the fact that at least a part of the surface of the fixing plate is raisedwith respect to the rest of the plate when it is set on a flat surface. Similarly, the concave surface of the connector must include at least a part of the surface which isindented in order to mate with the convex surface of the fixing plate. The entirety ofone end surface of the connector may be configured to match, mate, or interlock witha part of the surface of the fixing plate. Concave and convex do not thereforenecessarily refer to a hemispherical shape, although this may be the case. Theconcave and convex surfaces may be hemispherical surfaces, or may be shaped soas to form part of the surface of a sphere. The convex surface may be interrupted atthe position of the joint between the fixing plate and connector. A hole forming a partof the joint may be present in the convex surface of the fixing plate and the concavesurface of the connector. Where a dome-shaped concave and convex surface isdescribed, therefore, this will most often include a portion in the center of the surfacewhich is cut-out for a threaded screw to pass through for the purposes of attachingthe plate and connector together.

The above features also provide a strong joint without the need for additionalstructure. A waterproof layer can sit directly between the convex and concavesurfaces and because the shapes of the two surfaces there will be no gap betweenthe waterproof layer and the concave and convex surfaces of the connector andplate respectively. ln embodiments, the convex surface and the concave surface are mating dome-shaped surfaces. ln embodiments, the convex surface and the concave surface aremating frustoconical surfaces. ln both cases positioning and joining of the fixing plateand connector are facilitated because the two can be turned in relation to oneanother while the two surfaces are mating. Both shapes also provide no pathway forwater to pass to the join. ln embodiments, the convex surface of the fixing plate and the concave surface ofthe connector are positioned such that they each surround the joint when the fixingplate and connector are coupled together. Again, this means that the join is raisedwith respect to the surrounding plate, preventing the ingress of water to the join andinto the roof structure beneath. ln embodiments, the fixing plate and connector are configured to be coupledtogether to hold a layer of waterproof material between the two surfaces. Thewaterproof layer is part of existing roof surfaces and by pressing it between the plateand connector leaking can be more effectively prevented. Only one hole is required to be made in the Waterproof layer and this will be raised (as for the hole in the fixingplate) above the level of the rest of the fixing plate and the roof structure. ln embodiments, the layer of Waterproof material is flexible and of uniform thicknessand can be held in place between the two surfaces so as to form a tight seal Witheach surface. ln embodiments, the fixing apparatus comprises the flexible Waterprooflayer. Clearly, Where the tWo surfaces press tightly against the Waterproof layer abetter seal is provided to prevent leakage through the join. ln embodiments, the Whole of each of the concave and convex surfaces is in directcontact With the Waterproof layer When the apparatus is assembled. lt is preferredthat once assembled the tWo mating surfaces of the plate and connector Will presstogether against the Waterproof layer over the Whole of their respective areas toprovide the best possible seal against Water ingress. ln embodiments, the fixing plate and connector are configured to be joined togetherby a bolt extending through the convex surface of the fixing plate. ln embodiments, the connector comprises joining means in an end surface oppositethe concave surface for attachment of the external structure or additional units. ln embodiments, the fixing apparatus comprises a suspension unit configured tocouple the connector to the external structure, the suspension unit being formed atleast partially from a flexible material such that the extension unit can bend inresponse to movement of the external structure When the apparatus is mounted onthe roof and the external structure is mounted thereto. lnclusion of a suspension unitWhich can act as a vibration damper Will prevent rubbing against the Waterproof layerWhich may threaten its integrity over time. Damage to the rest of the fixing apparatusand the roof structure itself by movement of the external structure in the Wind, forexample, can also be avoided. ln embodiments, the flexible material is rubber. Rubber is a convenient, Waterproof,and cheap material Which is effective in absorbing shock impacts or vibrations. ln embodiments, the connector has a height of at least 4cm such that the externalstructure is supported at a distance of at least 4cm from the roof surface once it ismounted on the fixing apparatus. Ensuring a gap of a certain size between the roofsurface and any externally mounted equipment makes access to the roof easier.

This may be required particularly in a fire, but also for repair and replacement of roofparts, of the external structure, or of the fixing mechanism itself. The connector mayhave a height of at least 2cm to 6cm, preferably at least 3cm to 5cm, and preferablyat least 4cm. The standard height for the connector of 5cm therefore provides for agap between the roof surface and the mounted external equipment which makesrepair and access easier and can make drying out of the roof more straightforvvard ifthis is needed at any time. Some example dimensions for parts of the plate andconnector are provided in figures 11 and 12 and the associated description.

According to a second aspect of the present invention, there is provided a methodfor mounting external structure to a roof, the method comprising: coupling a fixingplate to the roof and attaching a connector to the fixing plate at a joint such that aconvex surface of the fixing plate interlocks with a mating concave surface of theconnector, wherein the connector is configured to be coupled to the externalstructure. ln embodiments, the method comprises: attaching the fixing plate to the roof;providing a Waterproof layer over at least a part of the fixing plate; and attaching aconnector to the fixing plate such that the Waterproof layer is pressed between theconvex surface of the fixing plate and the interlocking concave end surface of theconnector. ln embodiments, the method comprises mounting the external structure to theconnector. ln embodiments, the method comprises mounting the external structure on theconnector via a flexible suspension unit which is configured to bend in response tomovement of the external structure.

According to a third aspect of the present invention, there is provided a fixingapparatus for coupling external structure to a roof, the fixing apparatus comprising afixing plate and a connector configured to couple the fixing plate to the externalstructure, wherein the connector is formed at least partially from a flexible materialsuch that the connector can bend in response to movement of the external structureonce mounted. ln embodiments, the flexible material is rubber. ln embodiments, the connector comprises a first metal portion for coupling to thefixing plate and second portion at least party formed from the flexible material forcoupling to the external structure. ln embodiments, the first and second portions of the connector are configured to beremovably coupled together.

Embodiments of the present invention will now be described, by way of example only, with reference to the following diagrams wherein: Figure 1 shows a section of a roof structure and a fixing apparatus mounted thereto; Figure 2A is a plan view of a fixing plate and pins for attachment to a roof; Figure 2B is a side view of the fixing plate of figure 2A; Figure 2C is a view from above of the fixing plate of figure 2A showing the surface which faces upwards when mounted on a roof; Figure 3A is a side view of the fixing plate; Figure 3B is a cross-sectional view through the fixing plate and connector along the line A-A shown in figure 3A; Figure 3C is a view of the top surface of the fixing plate and bolt for attachment to the connector; Figure 3D is a view of the connector showing the concave surface for interlocking with the convex surface of the fixing plate; Figure 4A is a plan view of a cross-section through a fixing apparatus; Figure 4B is a side view of the cross-section shown in figure 4A; Figure 5 shows a connector with safety ring attached; Figure 6A is an exploded view of a fixing apparatus including a rubber suspension unit; Figure 6B is a side view, partially exploded, of the fixing apparatus of figure 6A; Figure 6C is a view from below of the fixing apparatus of figure 6A; Figure 6D is a view from above of the fixing apparatus of figure 6A; Figure 7 shows a connector, suspension unit, and safety ring on the left and a connector and suspension unit on the right; Figure 8 shows a portion of a roof with external structure mounted via a plurality of fixing apparatuses; Figure 9A shows a plan view of a roof section with walkway, solar panels, and heating pump or ventilation system attached using a fixing system comprising a fixing plate and connector; Figure 9B shows a view from above of the roof section shown in figure 9A; Figure 9C shows a plan view of the roof section shown in figure 9A; Figure 10 shows detail of a mounting system for angled equipment Figure 11 shows a plate and connector from the side and above with example dimensions; Figure 12 shows a cross sectional view of a connector with example dimensions.

The fixing apparatus described herein is intended for use in coupling external oradditional structure to a roof. This external structure may comprise solar panels,railings, walkways, cladding, railings or any similar structure required to be supportedexternally to a building. Figure 1 illustrates the position of a fixing apparatus 1 on theunderlying roof structure in one example. The fixing plate 3 sits directly on top of alayer of insulation 5 or on top of an additional cover layer for the insulation. The fixingplate 3 will usually, as in this case, be attached to the underlying roof layers usingsome type of mechanical fixing mechanism such as screws or plugs 6 as shown toprovide sufficient strength to the fixing. ln certain cases, it may be that no fixingmechanism is required, and the fixing plate can simply be placed on the roof, or thefixing plate can be attached to the roof by means of adhesive portions or anadhesive layer on the back surface. including one or more additional mechanicalfixings 6 between the plate and the roof is of course preferable. This provides extrastrength and helps with alignment of the various parts of the apparatus during theinstallation process. The additional fixings are also particularly useful if installation ona sloped roof is required. Fixings may pass through the insulation layer 5 and coupleto structures below this such as a corrugated support layer or deck 7 shown in figure1.

Figure 1 also illustrates connector 9 coupled to fixing plate 3. A waterproof layer 11covers at least a part of the roof structure. This layer may be sprayed onto thesurface or may comprise a separate layer of material that is placed onto the roof andheld in place between the fixing plate and the connector. ln some examples thewaterproof layer is also fixed to the rest of the roof surface as usual by way of heattreatment or similar means. ln the figure, the waterproof layer is shown with a portionremoved in order to make visible parts of the fixing apparatus lying below. Thewaterproof layer may cover only a small section of the fixing plate near to theposition of the join with the connector 9 as shown or may cover an area slightlylarger than the fixing plate. ln such a case the fixing plate may sit on top of anadditional waterproof layer covering all or the majority of the roof surface. There will then be two waterproof layers present, one of which will be clamped between the fixing plate and the connector and will help to prevent leakage of water at theposition of the fixing plate. The waterproof layers may be formed from a flexiblesheet material made from, for example, PVC, rubber, synthetic rubber such as EPDM rubber, bitumen, or asphalt. ln some cases, the waterproof layer will be clamped between the fixing plate and theconnector around the join but will also extend over a large area at least the size ofthe fixing plate in order to extend over the edges thereof, and possibly over thewhole of the roof surface. As set out below in more detail, a number of fixingapparatuses will usually be coupled to the same roof in order to support the requiredexternal structure, and the same waterproof layer may extend between these and be held in place between the fixing plate and connector of each apparatus.

The present fixing system requires very little interruption of the waterproof layerwhich reduces the likelihood of leaking. The waterproof layer 11 extends above thefixing plate. A hole is required to be made in the waterproof layer to allow a devicesuch as a bolt to pass through to couple the fixing plate to the connector, howeverthis hole is raised in relation to the rest of the roof surface as explained below.Leaking through the joint is prevented both because the water is stopped fromtravelling upwards towards any hole in the waterproof layer by gravity and due to thetight fit provided between the mating surfaces of the plate 3 and connector 9 (with a waterproof layer compressed between the two surfaces in most cases). ln some embodiments, fixing between the connector 9 and plate 3 may not require ahole to be made in the waterproof layer. Fixing may be magnetic, for example. Thiswill provide a good seal, but the fixing point will not be strong and may only be usable where small loads or bending forces are expected. ln figure 2A, a plan view of the fixing plate is shown. Here, 4 plugs 6 are used to holdthe fixing plate 3 to the roof. This means of fixing is typical where a flat plate of thistype is used as part of a roof structure. The plate 3 includes additional fixing holes 13 to provide an option to fix the plate at additional or different points. A connector 9 is shown coupled to the fixing plate 3 with a waterproof layer 11 held between. Figure2B shows a side view of the fixing apparatus of figure 2A, and figure 2C is a view from above of the same apparatus. ln this case the plate 3 includes a number of fixing holes 13 which provides someadaptability in terms of how the plate is attached to the underlying roof surface. Herefour nails, screws, or other fixers 6 are shown and eight additional fixing holes 13 arepresent, however this configuration is not limiting and there is the option of fixing theplate using any number of fixers or no fixers as mentioned above. Any number offixing holes can also be provided in the plate and the exact number will depend onthe surface configuration and the strength of the material that the plate is to be fixedto. ln some cases, it is possible to install the system without anchoring the plate tothe roof using additional mechanical fixing means, and the plate can be held in placeby the Waterproof layer itself extending over the plate. This will be possible where theadditional strength from fixings is not required, such as when the fixing system isproviding extra support for mounted structure or apparatus. Fixing means forcoupling the plate to the roof may not be required, for example, when the fixingsystem is being used to provide additional support for heating pumps.

Figure 3B shows a cross-section through the apparatus along line A-A shown in theside view of figure 3A. ln figure 4A the cross section of figure 3B is blown up and isshown in plan view and a side view of the same cross section is shown in figure 4B.The fixing plate 3 includes a convex portion 15 in its upper surface which mates witha similarly shaped concave 17 portion forming at least part of an end surface of theconnector 9 (in this case the whole of the end surface of the connector mates with acorresponding surface of the fixing plate).

The convex 15 and concave 17 surfaces of the plate 3 and connector 9 may befrustoconical or dome shaped, although any shape for the surfaces can be usedprovided that the surfaces of the plate and connector correspond to one another inorder to provide a mating fit. The mating surfaces of the plate and connectortherefore represent the inverse version of one another or are complementary.Domed or frustoconical convex and concave surfaces on the plate and on the connector end surface respectively will provide a good seal and allow for turning of the connector relative to the plate to fix the two together by means of a bolt 19. Adome or bowl-shaped protrusion in the upper surface of the plate is shown in figures3B and figure 3C. The end of the connector 9 configured to sit over this onceassembled will comprise a corresponding dome or bowl-shaped indent 17 into whichthe protrusion can fit as shown in figure 3D. The connector will generally include athreaded borehole 21 through which a bolt 19 can be inserted to fix the connector 9and plate 3 together. Figure 3D shows a cross section 50 through line C-C in thefigure, a bird”s eye view 51 of the concave surface and a plan view 52 of the connector in which the concave surface is visible.

The connector 9 shown in the figures is cylindrical and thus has a circular cross-section, however this need not be the case. The connector may have a square,rectangular, hexagonal, or triangular cross-section, or may have a cross section orany other shape. Including edges (rather than the smooth surface of a cylinder) mayhelp with installation or replacement, for example, if it is required to screw and unscrew the connector from the fixing plate 3.

As can be seen in figure 3B, a hole 23 extends through the fixing plate in the centreor apex of the convex surface 15 and through a waterproof layer 11 located betweenthe fixing plate and the connector. A threaded bore 21 also extends part of the wayinto the connector through the centre of the concave end face. A bolt 19 can bepassed through the hole in each of the plate and the waterproof layerfor coupling tothe connector via the threaded bore. ln this way, the connector can be screwed into proper connection with the fixing plate and tightened until a tight seal is formed.

The connector 9 also includes a bore 25 in the end surface opposite the concavesurface for fixing to rails or other external structure, or for coupling with additionalmodules as set out in more detail below. The threaded bore 21 for receiving a bolt 19to attach the fixing plate 3 to the connector 9 and the bore 25 in the opposite endface of the connector should not meet. There should be provided a solid region 27between the two within the connector such that there is no pathway for water from one end of the connector to the other. Preferably, this region should be at least 0.5cm to 5cm, more preferably 1cm to 3cm, and most preferably around 2cm, inheight so that the ends of the two bores are separated by at least this distance. Thedepth of the bores may be around 1.5cm each to allow for the use of standard boltsor may be different if the connector is to be used with non-standard bolts. The totalheight of the connector may therefore be between 3cm and 7cm, preferably between4cm and 6cm, and most preferably around 5cm. A height of 5cm is most preferablebecause this allows the use of standard 1.5cm bolts at both ends of the connectorwith a 2cm solid portion in the centre, or a 2cm distance between the ends of the twoboreholes required for the bolts. The connector may have a diameter of between3cm and 10cm, more preferably between 4cm and 8cm, more preferably between4cm and 6cm and most preferably around 5cm. Larger sizes (for example a diameterof 20cm or larger) may be used if additional support is required. Correspondingmeasurements can be used for a largest distance across the connector in the case where the cross section is not circular.

The presence of the connector, being associated with a certain height, therefore alsoensures that there is at least a small gap between the roof and any externalstructure. This provides easier access to the roof during a fire and means that holescan easily be made in order to allow hot and noxious gases to escape. An air gapmay also be beneficial in terms of access to the external structures for replacement and maintenance and to allow airing of the same structures where necessary.

The connector and the fixing plate may each be formed from stainless steel whichwill provide the required level of strength without rusting. The fixing plate can also begalvanised (i.e. with a coating of zinc) for additional strength or can be formedentirely from a zinc or magnesium-based material. The connector may also begalvanized or can be formed completely or partly from plastic. Plastic will generally be acceptable when this component is not required to be particularly strong.

As can be seen in figures SB, 4A, and 4B in particular, the waterproof layer 11extends between the convex surface 15 of the plate 3 and the concave surface 17 of the connector 9 and extends right up to the edge of the hole 23 formed through the plate for the bolt. This will preferably be the case in order to provide a better seal,however the waterproof layer can in some examples extend only part of the way upthe convex surface 15 if desired or may extend only up to where the convex 15 andconcave 17 surfaces begin such that once assembled the convex and concavesurfaces are in direct contact with one another. The Waterproof layer 11 may beflexible such that it will bend to conform to the surfaces of the plate and connectorand may be pressed between the two once the apparatus is installed. ln someexamples, the waterproof layer may be sprayed onto the roof and fixing plate afterthe fixing plate or a number of fixing plates have been positioned. Once thewaterproof layer is present, the connector can be coupled to the plate to form theseal and provide the required framework for mounting external structure such as solar panels.

The convex surface 15 of the fixing plate may be formed by bending of the plate orthe plate may be formed in the desired shape by moulding. ln either case, there maybe a corresponding concave surface 29 on the underside 31 of the platecorresponding to the convex surface 15 on the top side 33. lfthis is the case, asshown in figures 4A and 4B, the head of the bolt 19 or the nut 35 fixing the plate andconnector will not protrude above the underside of the plate and will not prevent theplate from being placed flush with the roof surface. The nut or bolt head may be fixedin place at the underside of the plate by welding or similar means to provideadditional strength and leak resistance to the join. There may also (or instead) be a sealing ring provided between the bolt head or separate nut and the fixing plate.

The bolt 19 in other embodiments may be integral with the fixing plate. The plate withits convex surface 15 and the bolt 19 extending from the top of the convex surfacecan then be integrally formed by moulding or by a similar method. There will be nohole in the fixing plate 3 where itjoins to the connector 9 in this embodiment, whichwill be beneficial in terms of preventing leakages.

Once the fixing plate 3 and connector 9 are coupled to the roof, external structuresuch as a framework of rails for supporting solar panels or cladding can be coupled directly to the connectors, for example via the threaded borehole in the upper endsurface. Alternatively, additional units may be included between the connector andany external structure or instead of any external structure. A hook or a ring 37 maybe coupled to the connector 9 as shown in figure 5 to provide an anchor point forsafety gear during installation of the external structure. This may be done byscrewing a bolt extending from the base of the ring into the borehole 25 of theconnector. When a plurality of fixing apparatuses are mounted on a roof duringinstallation such rings may be useful for clipping harnesses to as an additional safetymeasure for workers. Because the rings are simply screwed into the existingstructure and are able to be unscrewed, these can be mounted when necessary andcan be removed for replacement with some other structure at any time. Coupling viascrew and thread provides a strong and easily removable fixing, however anymethod for fixing the ring to the connector may be used. ln some cases, it may be desirable for the external structure to be able to bemounted at an angle. Rather than including a ring, an extension portion may becoupled to the connector as an additional unit in order to increase the gap betweenthe roof and the external structure where needed. The extension portion may simplyscrew into to end face of the connector as for the safety ring 37 described above.The extension portions may be different heights in order to allow for the mounting ofangled panels and other external structures, or may provide for adjusting the angleof the mounted structure. Mounting one side of a panel, for example, using a shortextension portion and another side using a taller extension portion is an easy way toachieve an angled mounting. Rather than including extension portions ofdifferentheights, the connector portion itself may be available in a number of different heightsfor use in mounting a sloping external structure. Connectors may be available, forexample, with a standard height of 5cm and in larger sizes having heights of 7cm,10cm, 15cm, and so on.

Any size of extension can be provided to give maximum flexibility in terms of theconfiguration, or such extension portions can be adjustable so that their height canbe adapted as needed even after attachment with the connector and/or the externalstructure. Adjustment may be achieved by means of a screw which extends into theconnector further or less far as desired. ln order to provide an adjustable height forthe external structure without compromising on strength an additional adjustmentmechanism may be provided. The extension portion may be coupled to theconnector by screwing it all of the way in as usual, but an extendable leg may instead be provided by another screw (or a different mechanism) to achieve thedesired height adjustment.

Different sizes of connector may alternatively or additionally be provided to allowsome flexibility in the positioning of the mounted structures. lf a number of angledpanels, such as solar panels, are to be mounted then this can be achieved byincluding a first size of connectorfor fixing one side of the panel and a second, taller,connector for fixing a second side. This will then automatically result in the panelbeing mounted at an angle.

Rather than a safety ring or extension portion, a rubber suspension unit 39 may befixed between the connector and the external structure. Figures 6A to 6D illustrate afixing apparatus 1 including an additional rubber suspension unit 39. ln this case, thesuspension unit 39 screws into the borehole 25 in the upper end of the connector 9as for the safety ring 37 described above with reference to figure 5. The externalstructure, which may include supporting rails, is attached to the rubber suspensionunit for example by way of an additional borehole in the uppermost end thereof. Therubber suspension portion damps vibrations which would othen/vise transfer to theroof structure causing wear and damage. Such a rubber suspension unit may bebetween 2cm and 6cm in height, preferably around 4cm in height. The unit may havearound the same diameter as the connector portion where cylindrical connectors andsuspension units are used or may have the same cross section. ln embodiments, theconnector itself may be formed entirely, mostly, or partially from rubber in order toprovide the damping function of the rubber suspension unit without the requirementof an additional coupling or additional height. An upper portion of the connector maybe formed from rubber, for example. The whole or substantially the whole of theconnector portion may be formed from rubber, however this will mean sacrificingstrength to an extent. The suspension unit 39 may be formed of rubber with metalend faces thereon for additional strength where coupling to other parts of the fixing isrequired. The rubber suspension unit may be formed from rubber with steel orstainless steel plates glued or fixed to both ends to provide additional strength.

The additional units described above can be used alone or together. A safety ring 37can be coupled to the top of a rubber suspension unit 39, which is in turn coupled toa connector 9 as shown in figure 7A (left hand side), for example. This can provide extra flexibility to the join when a worker is moving around on the roof and is coupledto the ring via a harness, preventing wear to the connector and the rest of the fixing.

Where a number of fixing apparatuses are mounted on a roof, different additionalunits can be mounted to each depending on requirements. ln figure 7A, the leftimage shows a fixing plate with connector, rubber suspension unit, and safety ringfitted. Obviously, once the apparatus is mounted on a roof an additional waterprooflayer will in most cases be present between the connector and plate. On the right,the safety ring has been removed and a threaded borehole 41 is visible in the topend surface of the rubber suspension unit for coupling to other units or to externalstructure.

Figure 8 shows how external structure 43 may be mounted on a roof using a pluralityof fixing apparatus. ln this case a frame 45 formed from several metal bars is fixed toa number of fixing apparatuses 1 mounted every meter or so on a roof. Solar panels 47 are coupled to this frame. ln this way some space can be maintained between thepanels, the frame structure, and the roof which is beneficial in terms of access and incase of fire as explained above.

The fixing plate 3 in an embodiment is installed such that it sits on top of awaterproof layer 11 covering the whole roof. An additional waterproof layer may beprovided in order to cover the plate and this can be sealed to the uppermost surfaceof the roof outside of the perimeter of the plate in order to provide further protectionfrom the ingress of water. Installation of the fixing plate above the waterproof roofcovering allows the system to be installed easily at any time, even after the roof hasbeen completely assembled and waterproofed. As explained above, the fixing platecan also sit underneath the waterproof layer 11 in which case no additionalwaterproof layer is required (although this can be provided if desired).

The structure of the interlocking portions of the fixing plate and connectorthemselves may be enough to prevent the ingress of water or waterproofing may notbe required (for example if used on concrete flooring) in which case no waterprooflayer may be provided therebetween. A waterproof layer may also be providedprefixed to the concave or convex surface of the connector or plate, or prefixed toboth such that coupling of the plate and connector causes the waterproof layer orlayers to be held tightly between the interlocking surfaces of the two parts. ln figure 9A, some examples of external structure are shown mounted to a roofsection (in this case a flat roof) using fixing plates and connectors. ln this case, awalkway 53, solar panels 55, and a ventilation system 57 are shown. Obviously, many different types of external structure can be mounted as desired. Theconfiguration and the type of equipment shown in figure 9A is by way of exampleonly. The walkway is supported by rails 59 separated along the length of thestructure and each fixed to the roof at two fixing points. All fixing points in the figureare provided with rubber suspension units 39 to help to prevent damage to the roof,although this need not necessarily be the case. Solar panels 55 are supported ateach corner by fixing apparatuses 1, with central fixing points being shared betweentwo panels as described in more detail below. The ventilation system 57 is supportedat each corner.

The same mounted external structure is shown in each of figures 9B and 9C. ln 9C,some of the fixing plates are equipped with an additional waterproof layer 49 in thevicinity of the joint between the fixing plate and connector and others are not. Thismay depend on whether the fixing plate 3 is already provided underneath awaterproof covering, or whether it is desired to add additional waterproofing. Externalequipment is mounted with minimal additional supporting structure being required.This is beneficial during mounting of the equipment because workers do not run therisk of tripping over mounting rails prior to mounting the panels or walkway. Railsgenerally extend in one direction only in a particular section of roof for theconfiguration shown in figures 9A to 9C, which further reduces the risk of trippingbecause workers are able to simply walk between the rails. ln figure 10, some detail of a mounting mechanism for angled solar panels 55 isprovided. Although the mounting mechanism is used to mount solar panels in thisexample it is suitable for mounting any sloping panel or object, such as decorativepanels. Lower angled support members 61, shown in detail as image D, are coupledeither directly to the connector 9 or, as in this case, to a suspension unit coupled tothe connector. Each support member comprises a bolt 63 and two angled bars 65 forcoupling to one side of each solar panel. The angle of the bars may be fixed, forexample at between 2° and 45° to the roof, preferably between 5° and 20° to theroof, and most preferably at around 10° to the roof surface. lt is also possible toinclude support members for which the angle of the bars can be adjusted by way of ahinged joint to provide greater flexibility. Upper angled support members 67, shownin detail as image E, are used to mount the higher end of the sloping panel. Thestructure of the upper support members is slightly different and comprises twoupwardly extending bars 69 as shown which form the apex of a triangle for stability.Two additional support bars 71 are then coupled to this triangular section. The angles of the two additional support bars 71 from the horizontal is configured tomatch the angle of the support bars of the lower support member (and the desiredangle of the solar panels) from the roof. The coupling between the support bars andthe solar panel may use any fixing means providing the required level of strength.Clip fixings, and screw fixings are both suitable examples.

Figure 11 illustrates some preferred measurements for the plate and connector.Measurements are shown in the figures in millimeters. The height of the connectormay be between 30mm and 80mm, preferably between 40mm and 70mm, morepreferably between 50mm and 60mm and most preferably around 58mm. The lengthof a side of the plate may be between 300m and 500m, preferably between 350mand 400m, and most preferably around 390mm (or 390m). The plate shown in thefigure is square in this case, but it may alternatively have sides of different length ormay be of a different shape, such as a 0ir0ular plate. For a circular plate the diameterof the plate may be between 300m and 500m, preferably between 350m and 400m,and most preferably around 390mm (or 390m). ln figure 12, preferred dimensions for the connector are provided. The height of theconnector may be between 30mm and 80mm, preferably between 40mm and 70mm,more preferably between 50mm and 60mm and most preferably around 58mm (asshown above with respect to figure 11). The diameter of the connector if a circularconnector is used, or the width of a cross section through the center of the connectorif not, may be between 20mm and 80mm, preferably between 40mm and 60mm, andmost preferably around 50mm. The depth of the borehole extending into theconnector from its upper surface may be between 10mm and 30mm, preferablybetween 15mm and 25mm, and most preferably around 25mm. The height of theconcave portion in the base of the connector (and correspondingly of the convexportion of the plate) may be between 5mm and 15mm, preferably between 8mm and13mm, and most preferably around 11mm. The concave portion if dome shaped maythen have a diameter of around 50mm and height of around 11mm.

Claims (21)

Claims

1. A fixing apparatus (1) for mounting external structure on a roof, the fixing apparatus comprising a fixing plate (3) and a connector (9) configured tobe coupled to the external structure and to the fixing plate (3) at a joint,wherein the fixing plate (3) has a convex surface (15) and the connectorhas a corresponding mating concave surface (17) such that when theconnector (9) and fixing plate (3) are coupled together at the joint theconcave and convex surfaces interlock.

2. The fixing apparatus (1) of claim 1, wherein the convex surface (15) and the concave surface (17) are mating dome-shaped surfaces.

3. The fixing apparatus (1) of claim 1, wherein the convex surface (15) and the concave surface (17) are mating frustoconical surfaces.

4. The fixing apparatus (1) of any of claims 1 to 3, wherein the convex surface (15) of the fixing plate and the concave surface (17) of the connector (9)are positioned such that they each surround the joint when the fixing plate(3) and connector (9) are coupled together.

5. The fixing apparatus (1) of any of claims 1 to 4, wherein the fixing plate (3) and connector (9) are configured to support a layer of Waterproof material(11) between the two interlocking surfaces When they are coupled togetherat the joint.

6. The fixing apparatus (1) of claim 5, wherein the fixing plate (3) and connector (9) are configured to support a layer of Waterproof material (11) that isflexible and of uniform thickness such that the layer of Waterproof material(11) is held in place between the two surfaces so as to form a tight sealwith each surface.

7. The fixing apparatus (1) of any of claims 5 and 6, comprising the layer of Waterproof material (11).

8. The fixing apparatus (1) of any of claims 6 or 7, wherein the concave and convex surfaces are configured such that the Whole of each of the concave and convex surfaces are in direct contact with the waterproof layer (11)when the apparatus is assembled.

9. The fixing apparatus (1) of any of claims 1 to 8, wherein the fixing plate (3)and connector (9) are configured to be joined together by a bolt extendingthrough the convex surface (15) of the fixing plate.

10. The fixing apparatus (1) of any of claims 1 to 9, wherein the connector (9)comprisesjoining means in an end surface opposite the concave surface(17) for attachment of the external structure or additional units.

11. The fixing apparatus (1) of any of claims 1 to 10, comprising a suspensionunit (39) configured to couple the connector (9) to the external structure,the suspension unit (39) being formed at least partially from a flexiblematerial such that the suspension unit (39) can bend in response tomovement of the external structure when the apparatus is mounted on theroof and the external structure is mounted thereto.

12. The fixing apparatus (1) of claim 11, wherein the flexible material is rubber.

13.The fixing apparatus (1) of any of claims 1 to 12, wherein the connector (9)has a height of at least 4cm such that the external structure is supported ata distance of at least 4cm from the roof surface once it is mounted on thefixing apparatus (1 ).

14.A method for mounting external structure to a roof, the method comprising:coupling a fixing plate (3) to the roof and attaching a connector (9) to thefixing plate (3) at a joint such that a convex surface (15) of the fixing plateinterlocks with a mating concave surface (17) of the connector, whereinthe connector (9) is configured to be coupled to the external structure.

15. The method of claim 14 comprising: attaching the fixing plate (3) to the roof;providing a Waterproof layer (1 1) over at least a part of the fixing plate; andattaching the connector (9) to the fixing plate such that the waterprooflayer is pressed between the convex surface (15) of the fixing plate (3) andthe interlocking concave surface (17) of the connector (9).

16. The method of claim 15, comprising coupling the external structure to theconnector (9).

17. The method of claim 16, comprising mounting the external structure to theconnector (9) via a flexible suspension unit (39) which is configured tobend in response to movement of the external structure.

18. A fixing apparatus (1)for coupling external structure to a roof, the fixingapparatus comprising a fixing plate (3) and a connector configured tocouple the fixing plate (3) to the external structure, wherein the connectoris formed at least partially from a flexible material such that the connectorcan bend in response to movement of the external structure oncemounted.

19. The fixing apparatus (1) of claim 18, wherein the flexible material is rubber.

20. The fixing apparatus (1) of any of claims 18 and 19, wherein the connectorcomprises a first metal portion for coupling to the fixing plate and secondportion (39) at least party formed from the flexible material for coupling tothe external structure.

21. The fixing apparatus (1) of claim 20, wherein the first and second portions ofthe connector are configured to be removably coupled together.