WO2013124613A2

WO2013124613A2 - Roof item attachment apparatus and method

Info

Publication number: WO2013124613A2
Application number: PCT/GB2013/000175
Authority: WO
Inventors: Paul Christopher DAVIS; Michael Harry John SHARE
Original assignee: Davis Paul Christopher; Share Michael Harry John
Priority date: 2012-02-21
Filing date: 2013-04-19
Publication date: 2013-08-29
Also published as: GB2511223B; GB2511223A8; GB201407653D0; WO2013124613A3; GB2511223A

Abstract

Roof item attachment system (110), for fixing an item to a tiled or slated roof, comprising: a plate (112) dimensioned to match and replace an existing slate or tile; the plate (112) having an upper surface (114) and a plurality of protuberances (116, 117); a bracket/mount (118) comprising two portions (120, 122) where a first arm portion (120) of the bracket/mount (118) is configured to engage at least two of the protuberances (116, 117) to allow the bracket/mount (1 18) to be firmly fixed in various positions onto the plate (112); the first arm portion having a longitudinally extending open-ended slot (126) that adjoins a notch (128) in the second portion (122) of the bracket (118), to facilitate unrestricted movement of the bracket (during adjustment) in a first direction (Χ-Χ') width-wise across the plate.

Description

ROOF ITEM ATTACHMENT APPARATUS AND METHOD

FIELD OF INVENTION The present invention is in the field of roof fixing systems; and particularly a system and method for fixing items such as various types of solar panels to tiled or slated roofs.

BACKGROUND OF INVENTION

In recent years, high world energy prices have encouraged owners of residential and commercial properties to install solar photo-voltaic and solar thermal roof panels. Fixing such panels to roofs, especially tiled and slated roofs can be a problem. At the present time installing roof panels without causing damage to an existing roof that will lead to ingress of water is frequently a time consuming task. The use of conventional fixing methods can lead to a number of problems; for example, broken tiles/slates, and water ingress through holes drilled in the roof to attach panel fixing members.

Current UK installation guidelines state that "All roof penetrations must be durably sealed using purpose made products capable of maintaining the seal during the movement and changes in temperature to which they will be subjected. Holes drilled through roofing felt and/or roof tiles/slates sealed with mastic or silicone sealant are not considered durable." Also "External brackets or mounting frames shall be constructed to safely bear the imposed static and wind loads and must be adequately ballasted or fixed to a structural member".

At the present time such " purpose made products " are generally not available; especially for use with slate roofs. Similar problems exist in securely fitting other equipment to roofs in a weatherproof manner; for example, advertising hoardings and telecommunications equipment. SUMMARY OF THE INVENTION

In a first aspect the present invention comprises a roof item attachment apparatus, for fixing an item to a tiled or slated roof, comprising: a plate dimensioned to match and replace an existing slate or tile; said plate having an upper surface and a plurality of protuberances/recesses extending therefrom; a bracket/mount comprising two portions wherein a first portion of said bracket/mount is configured to engage at least two of said protuberances/recesses to allow said bracket/mount to be firmly fixed in various positions to said plate. These various positions preferably include allowing the second portion of the bracket/mount to be fixed above at point along the width (X-X' direction) of the slate or tile.

Normally, said roof will be a sloping roof; however exceptionally the roof surface may lie in a generally horizontal or vertical plane.

Preferably, in use the longitudinal axis of said first arm/portion falls along one of two possible lines; either a (first) line X-X' or a (second) line Y-Y'; where the first line X- X' is generally perpendicular to the second line Y-Y'. This advantageously allows the bracket/mount of the roof item attachment apparatus to readily support roof items (such as solar panels) in landscape or portrait mode.

Preferably, the first arm portion has a longitudinal slot. This assists movement of the bracket/mount in a first direction (X-X¹) and/or a second direction (Υ-Υ'). Preferably, the first arm portion has an open-ended longitudinal slot to assist adjustable positioning prior to fixing said item to the plate.

Preferably, the end of the second portion adjoining the first portion of the bracket/mount has a notch configured such that during sliding of, or adjustment of the position of, the bracket/mount relative to the plate said notch allows the bracket/mount to slide/pass over one or more of said protuberances. This allows 3 of more protuberances to be located in a line along the width (X-X' direction) of the slate or tile and assists the positioning of the second portion of bracket/mount at any desired point above this line.

Preferably, the bracket/mount comprises two arm portions that extend in generally perpendicular directions (longitudinally).

Preferably, the protuberances comprise threaded studs/lugs that project in a direction generally perpendicular to the surface of said plate. These allow the bracket/mount to be firmly fixed to the plate using a stud/lug and typically a washer placed between the stud/lug and the first arm portion. Typically, the studs/lugs are attached to the plate by riveting or welding. However, any conventional means of attachment may be used. It is preferable not to use a bolt with a head as this would require drilling a hole through the plate and thereby provide means for water/moisture ingress. Also a bolt head on the underside of the plate would limit the position that the plate could be placed on a roof comprising beams and laths.

Preferably, the plate has at least 3 protuberances or recesses in (a first) X-X direction. More preferably, the plate has 5 to 8 protuberances/recesses in (a first) X-X direction. Preferably, the protuberances/recesses are arranged in a generally "T-shaped" or "reshaped" pattern. Preferably, the protuberances are spaced at a distance in the range 0.1W to 0.2 W; where W is the width dimension of the plate. The plate may advantageously have an angled end (elevation) profile.

In another aspect, the invention comprises a roof item attachment method, for fixing an item to a tiled or slated roof, using: a plate dimensioned to match and replace an existing slate or tile, said plate comprising an upper surface and a plurality of protuberances/recesses extending therefrom; a bracket/mount comprising two portions wherein a first arm portion of said bracket/mount is configured to engage at least two of said protuberances/recesses to allow said bracket/mount to be firmly fixed in various positions to said plate; the method comprises the following steps:

(a) removing a tile or slate from said roof and replacing said removed item with said plate;

(b) engaging said bracket/mount in a selected (one of various) position and firmly fixing said bracket/mount to said plate;

(c) attaching item to be fixed to roof (B) to a second portion of said bracket/mount using conventional attachment methods.

Preferably, the item attachment method uses apparatus according to Claim 2 and step (b) further comprises aligning the axis of the first arm portion of said bracket/mount along one of two possible lines; either a (first) line X-X' or a (second) line Y-Y'; where the first line X-X' is generally perpendicular to the second line Y-Y'.

Preferably, the item attachment method uses apparatus according to Claim 3, or Claim 2 plus Claim 3, and steps (b) and (c) further comprise sliding the bracket/mount along the line X-X' relative to the plate thereby allowing the item (B) to be firmly fixed in an any position above a line generally perpendicular to a shorter edge of the plate or parallel to the line Y-Y'.

Alternatively, the item attachment method may comprise any of the above item attachment methods using apparatus according to any of Claims 4 to 13.

BRIEF DESCRIPTION OF DRAWINGS

The invention will be described by reference to the following diagrammatic illustrations in which:

Figures la to lc show a first embodiment of the invention; Fig la and lb show plan views of this embodiment used to hold a mounting rail (B) in a first position and a second position respectively; Figure lc shows a plan view of part of the plate with the bracket removed and; Figure Id shows an end elevation when the mounting rail (B) is held in the first position;

Figure 2 shows a perspective view of a preferred embodiment of the present invention;

Figures 3a and 3b show elevations of the roof item attachment apparatus illustrated in Figure 2 in side elevation and end elevation views respectively;

Figures 4 and 5 show illustrate how apparatus according to the preferred embodiment can be used on a tiled roof to support a mounting rail (B) such that a solar panel can be supported between a pair of mounting rails (B) either in landscape or portrait position respectively; and

Figure 6 shows a side elevation section of a roof and illustrates how apparatus according to the preferred embodiment fits around existing roof tiles/slates, joists and laths.

DETAILED DESCRIPTION OF THE DRAWINGS

FIRST EMBODIMENT A first embodiment of the invention will now be described by reference to Figures la - Id. The roof item attachment apparatus (10) comprises a plate (12) dimensioned to match and replace an existing slate or tile. Typically, this plate will be rectangular in shape (plan view) and typically the plate (12) will have either a smooth or flat upper surface (14). The plate may be made of a wide variety of weather resistant materials including metallic material and thermoplastic resins. If heavy items are to be supported the chosen material will have to be sufficiently strong to withstand both static and wind loads. When metallic materials are selected, the plate may be anodised to provide improved weather protection. The plate may also have surface texture or colour to match an existing roof tile.

The plate will have at least three protuberances or recesses (16) located on the upper surface (14). In this case illustrated in Figure lc there is a single threaded member (protuberance 16a) and two recesses (16b). The recesses may take various shapes including holes of circular cross section (plan view) as shown in Figures la - lc or grooves/channels. Normally in any of these forms the recesses will not extend all of the way downwards through the plate; thereby preventing water/moisture ingress. At least two protuberances/recesses will be located along a first line X-X' (see Figures laic). The purpose of these protuberances/recesses (16) is to allow the plate to engage a bracket (18) or mounting member; for example using a snap-fit mechanism; an aperture and nut; or a corresponding aperture in the bracket (18) or mounting plate. Alternatively, a protuberance(s) on the underside of the bracket or mounting member may engage a corresponding recess (16b) in the plate (12).

The bracket (18) comprises a first arm portion (20) and a second portion (22); these first and second portions extending outwardly from a corner (24) along longitudinal axes that are generally perpendicular in direction. Thus, when the first arm portion (20) is fixed to the plate the second portion extends in a direction that is generally perpendicular to the upper surface (14) of the plate (12). The first arm portion has a slot (not shown) that extends part way along the length of the arm and engages the protuberance 16a. The bracket (18) further comprises a protrusion ( 19) that extends short distance downwardly in a direction perpendicular to the underside of the first arm portion (20); as shown in hidden detail in Figure Id.

During adjustment, the "L-shaped" bracket (18) can be pivoted about protuberance 16a so that the protrusion (19) on underside of the bracket (18) engages either recess 16b or recess 16c; thus allowing adjustment of bracket so that longitudinal axis of first arm portion (20) is in either the X-X' or the Y-Y' direction. It is locked in place using a washer (not shown) and nut (34) placed around the threaded protuberance 16a. In use, an item such as a mounting rail (B) may be fixed to the second portion (22) of the bracket (18) by means of a bolt (36).

The bracket (18) can be replaced by a mounting member that serves the same general function by providing a flat face (first portion) that abuts against the surface (14) of the plate (12) and may engage the plate as described above (for a bracket); said mounting member having a second portion that extends away from the plate surface and is configured to allow an item such as a mounting rail (B) to be fixed thereto.

PREFERRED EMBODIMENT A preferred embodiment of the invention will now be described by reference to Figures 2 and 3. The roof item attachment apparatus (1 10) comprises a plate (1 12) dimensioned to match and replace an existing slate or tile. Typically, this plate will be rectangular in shape (plan view) and typically the plate (1 12) will have either a smooth or flat upper surface (1 14). The plate may be made of a wide variety of weather resistant materials as described above for the first embodiment. The plate preferably has six protuberances (1 16, 1 17) located on the upper surface (1 14). These protuberances comprise studs that extend longitudinally in a direction perpendicular to the plate surface (1 14). Five of the protuberances (1 16) are equally spaced along a first line X-X' and the remaining protuberance (1 17) is located along centre line Y-Y' such that the protuberances are arranged in a generally "T-shaped" (illustrated) or "L-shaped" (not illustrated) pattern. Preferably, the spacing between the five studs (1 16) is between 0.16W and 0.20W; where W is the width dimension of the plate (1 12). Spacing of protuberances (116) in this manner allows optimal flexibility in selecting the best position for the bracket (1 18) relative to the plate (1 12) before fixing in place. Typically, the studs/lugs (1 16, 1 17) are attached to plate by riveting or welding.

The apparatus (1 10) further comprises a bracket (1 18) having a first arm portion (120) and a second portion (122); these first and second portions extending outwardly from a corner (124) along longitudinal axes that are generally perpendicular in direction. Thus, when the first arm portion (120) is fixed to the plate the second portion extends in a direction that is generally perpendicular to the upper surface (1 14) of the plate (1 12). The first arm portion has an open-ended slot (126) that extends the entire length of the arm and at the corner (124) adjoins a notch (128) that extends part way along a longitudinal axis of the second portion (122) of the bracket (1 18). The notch (128) is located within the second portion (122) near the corner (124) of the bracket (1 18) such that it adjoins the open-ended slot (126); and is sized to allow the bracket (during adjustment and before fixing) to slide over any protuberances (1 16). The combination of this open ended slot (126) and adjoining notch (128) allows the bracket to be adjusted so that the second portion (122) [and also in use a mounting rail (B) fixed thereto] may be attached in any position above any point along the line X-X' (width direction) of the plate (1 12).

The bracket (1 18) is configured to engage at least two of said protuberances; in this case threaded studs (1 16, 1 17) to allow said bracket (1 18) to be firmly fixed in various positions to said plate (1 12) using washers (not shown) and nuts. METHOD OF THE INVENTION

The apparatus of the present invention (as described above) allows support items (B); panels etc., to be efficiently securely fixed to a roof; and also to avoid subsequent water moisture ingress that might otherwise result from such work.

Figures 4 to 6 illustrate how the apparatus (10, 1 10) of the present invention can be used to support a solar panel (not shown) in either landscape or portrait mode. If the apparatus (10, 1 10) is being used to fix a solar panel to a roof (R) then, typically, four existing tiles/slates (T) are removed from the roof and each of these tiles/slates (T) are replaced by roof attachment apparatus (10, 1 10) according to the invention (see Figures 4 and 5).

Figure 4 shows a support mounting rail (B) horizontally attached to the brackets associated with the upper pair (1 10). A similar mounting rail (not shown) can be attached to the lower pair of plates (1 12). A solar panel can then be fixed (by conventional means) in landscape mode between the mounting rails (B).

Figure 5 shows a mounting rail (B) vertically attached to the brackets associated with the right-hand pair ( 10). A similar mounting rail (not shown) can be attached to the left-hand pair of plates (1 12). A solar panel can then be fixed (by conventional means) in portrait mode between the mounting rails (B).

The bracket (1 18) can easily be moved from the position shown in Figure 4 to that shown in Figure 5; merely by removing the washers and nuts (not shown) and then engaging either a pair of the five linearly arranged protuberances ( 16) or engaging one of these protuberances (1 16) and the remaining protuberance (1 17).

Figure 6 illustrates a sectioned (along line A-A') side elevation of part of the roof shown in Figure 4 and shows how roof item attachment apparatus (10, 1 10) according to the present invention is positioned between and under/over existing tiles/slates (T) supported by roof laths (L). The mounting rail (B) is secured to the bracket (1 18) by conventional means (not shown). Normally, at least one substantial pin/nail (N) is used to secure the plate (1 12) to a main structural roof joist (J) to ensure that the roof attachment apparatus (10, 1 10) can bear any imposed static and wind loads. During securing the plates (12, 112) to the roof members suitably positioned holes (not shown) are drilled through the plates (12, 1 12). Preferably, two such (spaced) pins/nails (N) are used. Once the tiles/slates (T) are positioned around/over the attachment apparatus (10, 1 10), as shown in Figure 6, water ingress cannot take place as these pins/nails (N) are covered by a normal tile/slate.

Thus, in outline, the method comprises the following basic steps:

(a) removing tiles (T) or slates from said roof and replacing said removed items with said plate (12, 1 12);

(b) engaging said bracket/mounting-member (18, 1 18) in a selected (one of various) position and firmly fixing said bracket/mounting-member (18, 1 18) to said plate (12, 1 12);

(c) attaching item to be fixed to roof (B) to second portion (22, 122) of said bracket/mounting-member using conventional attachment methods. Referring to Figure 5; the position of individual brackets (1 18) can be adjusted (prior to fixing firmly in place) so that they lie over roof structural support members (for example: joists - J). Such flexibility in lateral (X-X' direction) movement is made possible by the line of protuberances (1 16) combined with the combination of the open slot (126) and notch (128) in the bracket (1 18), as described above.

The apparatus and method according to the present invention avoids forming any additional apertures (to those normally used to retain the tiles/slates) and so eliminates the possibility of water ingress that may otherwise occur. The plates (12, 12) are fixed to roof joists, laths etc. in the same way as the tile/slate that they replace; typically using nails and pre-formed holes (not shown) in the upper portion of the plate (12, 112).

Claims

1. Roof item attachment apparatus (10), for fixing an item to a tiled or slated roof, comprising: a plate (12) dimensioned to match and replace an existing slate or tile; said plate (12) having an upper surface (14) with a plurality of protuberances/recesses (16); a bracket/mount (18) comprising two portions (20, 22) wherein a first arm portion (20) of said bracket/mount (18) is configured to engage at least two of said protuberances/recesses (16) to allow said bracket/mount (18) to be firmly fixed in various positions to said plate (12).

2. Roof item attachment apparatus (10) according to Claim 1 wherein in use the longitudinal axis of said first arm/portion (20) falls along one of two possible lines; either a (first) line X-X' or a (second) line Y-Y'; where the first line X-X' is generally perpendicular to the second line Y-Y'.

3. Roof item attachment apparatus (10) according to any preceding claim wherein said first arm portion (20, 120) has a longitudinal slot (126).

4. Roof item attachment apparatus (10) according to any preceding claim wherein said first arm portion (20, 120) has an open ended longitudinal slot ( 126) to assist fixing said item (B).

5. Roof item attachment apparatus (10) according to any preceding claim wherein the end of the second arm portion (22) adjoining the first arm portion (20, 120) of the bracket (18, 118) has a notch (124) that during sliding of, or adjustment of the position of, the bracket/mount (18) relative to the plate (12) allows the bracket to slide/pass over one or more of said protuberances (16).

6. Roof item attachment apparatus (10) according to Claim 3 or 4 wherein the end of the second portion (22) adjoining the first arm portion (20, 120) of the bracket (18, 118) has a notch (124) that adjoins said slot (126) so that during sliding of (or adjustment of the position of) the bracket/mount (18) relative to the plate (12); said notch (124) allows the bracket to slide/pass over one or more of said protuberances . (16).

S

7. Roof item attachment apparatus (10) according to any preceding claim wherein said two portions (20, 22) of the bracket (18) comprise arms that extend in generally perpendicular directions (longitudinally). 0

8. Roof item attachment apparatus (10) according to any preceding claim wherein said protuberances comprise threaded studs/lugs that project in a direction generally perpendicular to the surface of said plate (12).

9. Roof item attachment apparatus (10) according to Claim 8 wherein the5 studs/lugs are attached to plate by riveting, welding or clinching.

10. Roof item attachment apparatus (10) according to any preceding claim comprising at least 3 protuberances/recesses in (a first) X-X direction or 5 to 8 protuberances/recesses in (a first) X-X direction.

1 1. Roof item attachment apparatus (10) according to any preceding claim wherein said protuberances/recesses are arranged in a generally "T-shaped" or "L-shaped" pattern.

12. Roof item attachment apparatus (10) according to Claim 1 1 wherein the protuberances are spaced at a distance in the range 0.1 W to 0.2W; where W is the width dimension of the plate (12).

13. Roof item attachment apparatus (10) according to any preceding claim wherein said plate (12) has an angled end (elevation) profile. a plate (12) dimensioned to match and replace an existing slate or tile, said plate (12) comprising an upper surface

(14) with a plurality of protuberances/recesses (16); a bracket/mount (18) comprising two portions (20, 22) wherein a first arm portion (20) of said bracket/mount (18) is configured to engage at least two of said protuberances/recesses (16) to allow said bracket/mount (18) to be firmly fixed in various positions to said plate (12); the method comprises the following steps: (a) removing tile or slate from said roof and replacing said removed item with said plate (12);

(b) engaging said bracket/mount (18) in a selected (one of various) position and firmly fixing said bracket/mount (18) to said plate (12);

(c) attaching item to be fixed to roof (B) to second portion (22) of said bracket using conventional attachment methods.

15. Roof item attachment method according to Claim 14 using apparatus according to Claim 2 wherein step (b) further comprises aligning the axis of the first arm portion (20) of said bracket/mount (18) along one of two possible lines; either a (first) line X- X' or a (second) line Y-Y'; where the first line X-X' is generally perpendicular to the second line Y-Y'.

16. Roof item attachment method according to Claim 14 using apparatus according to Claim 3 wherein steps (b) and (c) further comprise sliding the bracket/mount (18) along the line X-X' relative to the plate (12) thereby allowing the item (B) to be firmly fixed in an any position above a line generally parallel to a shorter edge of the plate (12) or parallel to the line X-X'.

17. Roof item attachment method according to any of Claims 1 to 16 using apparatus according to any of Claims 4 to 13.