Abstract:
The present application presents a height adjustable mount for attaching an article to a roof. This mount improves upon existing mounts by allowing a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article to be mounted. The heights may be independently selected, thereby allowing adjustability to compensate for the uneven nature of many roofs.

Description:
BACKGROUND 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates generally to attaching articles to the roof of a structure, and more particularly to a height adjustable mount for attaching articles to the roof of a structure. 
         [0003]    2. Background of the Invention 
         [0004]    There are many situations in which it is necessary or desirable to attach articles to the roof of a structure. These articles may be photovoltaic (a.k.a. solar) panels, photothermal panels, heating equipment, air conditioners, satellite dishes, and so on. Attachment is commonly accomplished by the use of one or more mounts which attach to the roof, and either provide mounting hardware for the article(s) or accept mounting hardware for the article(s). These mounts are usually designed so as to minimize leakage of water or other elements through the roof. 
         [0005]    One issue encountered when mounting an article or articles on a roof is alignment. Most roofs or other structures are not truly flat or straight, whether by design or by imperfections, warping, or simple wear and tear. It is frequently desirable to attach articles to a roof such that they lay flat, and the unevenness common to roofs makes this challenging. Most mounts do not easily adjust the height between the article and the roof and thus do not solve this problem. Additionally, it may be desirable to mount articles at different heights even if the roof is flat or straight. Most mounts do not allow the article(s) to be mounted at various heights as may be advantageous for a specific installation of articles. 
         [0006]    Another issue encountered when mounting an article or articles on a roof is the need to use a standard rack in addition to whatever mounts have been chosen for the particular installation. That is to say that usually when one installs articles on a roof the articles themselves must be installed in a rack/frame and this rack/frame is then attached to the roof via the mounts. 
         [0007]    It is thus a first object of the present application to provide a height adjustable mount for attaching an article or articles to a roof structure. 
         [0008]    It is a further object of the present application to provide a mount which provides a plurality of discrete heights between the roof and the article. 
         [0009]    It is a further object of the present application to provide a mount which provides easy and repeatable selection of a specific height between the roof and the article. 
         [0010]    It is a further object of the present application to provide a mount which includes built in cable guides. 
         [0011]    It is a further object of the present application to provide a mount which does not require the use of a standard rack but instead employs the edge of the article as the structural element that is attached to the mount. 
         [0012]    It is a further object of the present application to provide a mount that allows simple and easy height adjustment such that an installation of an article or articles may be quickly and easily adjusted/aligned for ascetics. 
         [0013]    It is a final object of the present application to provide a mount for attaching an article or articles to a roof structure, which minimizes potential leakage through the roof. 
         [0014]    These and other objectives, advantages, features, and aspects of the present invention will become apparent as the following description proceeds. To the accomplishment of the foregoing and related ends, the invention, then, comprises the features hereinafter more fully described and particularly pointed out in the claims, the following description and the annexed drawings setting forth in detail certain illustrative embodiments of the invention, these being indicative, however, of but several of the various ways in which the principles of the invention may be employed. 
       SUMMARY OF THE INVENTION 
       [0015]    The present application presents a height adjustable mount for attaching an article to a roof. This mount improves upon existing mounts by allowing a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article to be mounted. The heights may be independently selected, thereby allowing adjustability to compensate for the uneven nature of many roofs. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The foregoing aspects and many of the attendant advantages of the invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description, when taken in conjunction with the attached charts and figures, wherein: 
           [0017]      FIG. 1  is a perspective view of a preferred embodiment of the mount; 
           [0018]      FIG. 2  is a side view of a preferred embodiment of the mount; 
           [0019]      FIG. 3  is a perspective view of the top portion of a preferred embodiment of the mount; 
           [0020]      FIG. 4  is a side view of the top portion of a preferred embodiment of the mount; 
           [0021]      FIG. 5  is a side view of the top portion of a preferred embodiment of the mount; 
           [0022]      FIG. 6  is a perspective view of a preferred embodiment of the base of the mount; 
           [0023]      FIG. 7  is a top view of a preferred embodiment of the base of the mount; 
           [0024]      FIG. 8  is a side view of a preferred embodiment of the base of the mount along cut-line A-A of  FIG. 7 ; 
           [0025]      FIG. 9  is a series of side views of the mount; 
           [0026]      FIG. 10  is a perspective view of an alternative embodiment of the base of the mount; 
           [0027]      FIG. 11  is a top view of an alternative embodiment of the base of the mount; 
           [0028]      FIG. 12  is a side view of an alternative embodiment of the base of the mount along cut-line A-A of  FIG. 11 ; 
           [0029]      FIG. 13  is a side view of a preferred embodiment of the mount including an embodiment of article attachment hardware; 
           [0030]      FIG. 14  is a side view of a preferred embodiment of the mount including an embodiment of article attachment hardware; 
           [0031]      FIG. 15  is an exploded side view of a preferred embodiment of the mount including an embodiment of article attachment hardware; 
           [0032]      FIG. 16  is a perspective view of an alternative embodiment of the base; 
           [0033]      FIG. 17  is a side view of the alternative embodiment of the base shown in  FIG. 16 ; 
           [0034]      FIG. 17   b  is a side view of the alternative embodiment of the base shown in  FIG. 16 ; 
           [0035]    wherein the alternative embodiment is attached to a post in partial view; 
           [0036]      FIG. 17   c  is a side view of the alternative embodiment of the base shown in  FIG. 16 ; wherein the alternative embodiment is attached to a post; 
           [0037]      FIG. 18  is a perspective view of an alternative embodiment of the base; 
           [0038]      FIG. 19  is a perspective view of an alternative embodiment of the base; 
           [0039]      FIG. 20  is a perspective view of an alternative embodiment of the mount shown attached to a tile roof and holding an article; 
           [0040]      FIG. 21  is a perspective view of a preferred embodiment of the mount shown attached to a shingled roof and holding an article; 
           [0041]      FIG. 22  is a perspective view of a plurality of a preferred embodiment of the mount shown attached to a shingled roof and holding two articles; 
           [0042]      FIG. 23  is a perspective view of an alternative embodiment of the mount; 
           [0043]      FIG. 24  is a side view of an alternative embodiment of the mount; 
           [0044]      FIG. 25  is a top view of an alternative embodiment of the mount; 
           [0045]      FIG. 26  is a perspective view of an alternative embodiment of the mount which includes an integrated cable guide; 
           [0046]      FIG. 27  is a top view of an alternative embodiment of the mount which includes an integrated cable guide; 
           [0047]      FIG. 28  is a side view of an alternative embodiment of the mount which includes an integrated cable guide; 
           [0048]      FIG. 29  is a side view of an alternative embodiment of the mount which includes an integrated cable guide; 
           [0049]      FIG. 30  is a perspective view of an alternative embodiment of the mount; 
           [0050]      FIG. 31  is a perspective view of an alternative embodiment of the base; 
           [0051]      FIG. 32  is a top view of the alternative embodiment of the base first shown in  FIG. 31 ; 
           [0052]      FIG. 33  is a side view of the alternative embodiment of the base first shown in  FIG. 31 ; 
           [0053]      FIG. 34  is a side view of the alternative embodiment of the base first shown in  FIG. 31 ; 
           [0054]      FIG. 35  is a side view of an alternative embodiment of the base; 
           [0055]      FIG. 36  is a perspective side view of the alternative embodiment of the base first shown in  FIG. 35 ; 
           [0056]      FIG. 37  is a side view of the alternative embodiment of the base first shown in  FIG. 35 ; and 
           [0057]      FIG. 38  is a perspective view of the alternative embodiment of the base first shown in  FIG. 35 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0058]    The following description is presented to enable a person of ordinary skill in the art to make and use various aspects and examples of the present invention. Descriptions of specific materials, techniques, and applications are provided only as examples. Various modifications to the examples described herein will be readily apparent to those of ordinary skill in the art, and the general principles defined herein may be applied to other examples and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the examples described and shown, but is to be accorded the scope consistent with the appended claims. 
         [0059]    The present application presents a height adjustable mount for attaching an article to a roof. This mount allows a user to easily and repeatedly choose one of a plurality of discrete heights between a roof and the article mounted thereto. 
         [0060]    Turning first to  FIG. 1 , a perspective view of a preferred embodiment is shown. The preferred embodiment mount  1  comprises a base  100  and a top portion  200 , which interlock at a plurality of discrete heights. In a preferred embodiment the top portion  200  is between six and eleven inches long, however, in alternative embodiments the top portion may longer than eleven inches or shorter than six inches. As will be clear from the following figures and description, the top portion slides over the base via interlocking components, preferably protrusions and/or recesses. After the top portion has been slidingly interlocked with the base as shown in  FIG. 1 , the top portion may be secured in place by use of a bolt (not shown) placed through bolt hole  201 . In a preferred embodiment bolt hole  201  is a clearance hole on one side and a ¼×20 tap on the other. In alternative embodiments the bolt hole may be clearance on both sides, or may take any suitable form known in the art which will accept a bolt or other fastening member. The upstanding member  101  of the base has a corresponding blot slot  103  (see briefly,  FIG. 6 ) to allow the bolt to secure the base and the top portion together. In an alternative embodiment a wire guide may also be attached to the mount via the bolt and bolt hole, such an embodiment is shown in  FIGS. 26-29 . For the purposes of this application, the upstanding member is generally planer in shape and in a preferred embodiment projects substantially vertically from the base, substantially vertically meaning for the purposes of this application with fifteen degrees of vertical. In alternative embodiments the upstanding member need not project substantially vertically, but may instead project at other angles. For the purposes of this application generally planer is taken to mean that the object in question is substantially longer and/or wider than it is thick. 
         [0061]    Returning to  FIG. 1 , in most embodiments, base  100  comprises an attachment portion  120 . In a preferred embodiment the attachment is a roof attachment portion  120  as shown, and which is configured to attach to a roof with one or more fasteners. In other embodiments the attachment may be accomplished by other structures. Also shown in  FIG. 1  is cover  121 , which in a preferred embodiment slides over the roof attachment portion  120  of the base  100 . In other embodiments, the cover may take any form known in the art such as but not limited to plugs. In yet other embodiment no cover is present at all. In the preferred embodiment the base attached to a roof with a flashing  600  (not shown in  FIG. 1 ). 
         [0062]    In a preferred embodiment the base and the top portion are made of a metal, and more particularly aluminum. In other embodiments the base and top portion may be made of any suitable material known in the art including but not limited to metal, plastic, ceramic, and composite. The base and top may be made of different materials. 
         [0063]    Turning now to  FIG. 2 , a side view of a preferred embodiment is shown. As may be seen clearly in this view, the upstanding portion  101  comprises a plurality of height adjustment protrusions  102  and/or height adjustment recesses (not labeled). In a preferred embodiment these height adjustment protrusions and/or recesses are of a regular ridge and recess form as shown in  FIG. 2 . In alternative embodiments the height adjustment protrusions/recesses may take any form known in the art, provided it allows the base and top portion to interlock at one of a plurality of heights. 
         [0064]    In a preferred embodiment, the top portion comprises a vertical channel  202 , each side of which comprises height adjustment protrusions and/or recesses  203  configured to interlock with the height adjustment protrusions and/or recesses  102  of the upstanding member  101  at a plurality of discrete positions achieving varying heights between the base and the top portion, and thereby varying heights between the roof and the article. It is noted, and will be further illustrated below, that the top portion may interlock in two orientations with the base. In other words the upstanding member  101  can flip-flop and attach either direction. Note that the upstanding member may be thought of as a base height adjustable interlocking means. 
         [0065]    It is important to note that in the preferred embodiment the recesses may be conceptualized as the space between the protrusions. In an alternative embodiment the protrusions may be thought of as the portions of material between the recesses. The terminology is effectively interchangeable, but one terminology may be preferable over the other depending upon the manufacturing process employed to create the base and top portion. 
         [0066]    In a preferred embodiment, in order to allow the top portion to slide and interlock with the upstanding member in either of two orientations the height adjustment protrusions/recesses disposed on the upstanding member are configured such that each protrusion on one side of the upstanding member is vertically aligned with a recess on the opposite side of the upstanding member, and visa-versa. 
         [0067]    At the upper end of top potion  200  is a receiver track  204  for receiving an inverted bolt and thereby the article attachment hardware. In a preferred embodiment the receiver track  204  is sized to receive a 5/16 inch inverted bolt, however, it should be readily understood that the receiver track may be sized to receive a different size bolt, or may be replaced entirely with any structure known in the art and which is capable of receiving article attachment hardware, or of directly mounting an article. Also at the upper end of top portion  200  is a screw race  205  configured to accept accessories such as but not limited to a ground clip or a cap. 
         [0068]    Turning to  FIGS. 3 ,  4 , and  5 , a perspective view, and two side views of the top portion  200  of a preferred embodiment is shown. In this preferred embodiment the upper end of top portion  200  comprises friction ridges  206  running longitudinally on top of the receiver track  204  shown best in  FIG. 2 . These friction ridges  206  aid in securing an article to the top portion. In alternative embodiments these friction ridges may take any form known in the art such as ridges running perpendicular to those shown in the  FIG. 3 , surface texture, or may be omitted entirely. 
         [0069]    Turning to  FIGS. 6 ,  7 , and  8 , a perspective view, and two side views of the base of a preferred embodiment is shown. It is noted that  FIG. 8  shows a side view along cut line A-A in  FIG. 7 . The base comprises bolt slot  103 , which corresponds to bolt hole  201  in the top portion. As may be seen the bolt slot  103  extends vertically through most of the upstanding member  101  and allows the top portion and the base to be secured together at one of a plurality of heights after the top portion is slid over and interlocked with the upstanding member at one of a plurality of discrete positions. In this preferred embodiment the attachment portion  120  comprises two roof attachment holes  122 , which in this preferred embodiment are dimensioned to be coupled with a flashing (not shown) and to then accept one screw driven into the roof (one screw per hole). These screws anchor the base to the roof, and the flashing ensures that water doesn&#39;t leak through the roof. After the base is anchored to the roof, the cover  121  (see  FIG. 1 ) is slid over the attachment portion  120  to further prevent water from leaking through the roof. In alternative embodiments there may be only a single roof attachment hole  122 , or the roof attachment holes may be replaced with any structure known in the art which would serve to anchor the base to the roof. Similarly, the screws may be replaced with any fastener known in the art such as but not limited to bolts. 
         [0070]    Turning to  FIG. 9 , a series of side views of the mount are shown. These side views illustrate how the top portion  200  and the base  100  (not labeled in this Fig.) may be slid together and interlocked at a plurality of discrete heights. Note that the top portion may be slid together and interlocked with the base in one of two orientations, and each of the two orientations allows for different discrete heights to be achieved. In all embodiments the top portion and the base may be slid together and interlocked at a minimum height, at a maximum height, and at a plurality of discrete heights between the minimum and maximum height. In all embodiments the maximum height is less than twice the minimum height. In all embodiments the maximum height is technically achieved when the top portion is interlocking with one of the upstanding member&#39;s protrusions, however, due to stability concerns the preferred minimum number of upstanding member protrusions interlocked is 3, as shown in Position 6.0. 
         [0071]    Another way to conceptualize the various heights between the roof and the top of the receiving track sets a minimum height as H=1 unit height. The mount may then be configured at any of a plurality of discrete heights H n  where 1≦H n &lt;2. Here, and in practice, the number of discrete configurations has no upper limit. 
         [0072]    Turning to  FIGS. 10 ,  11 , and  12 , a perspective view, and two side views of the base of an alternative embodiment is shown. Note that  FIG. 12  shows a side view along cut-line A-A of  FIG. 11 . As may be seen, this alternative embodiment of the base differs in that it includes a single roof attachment hole. 
         [0073]    Turning to  FIG. 13 , a side view of a preferred embodiment of the base  100 , top section  200 , and a first embodiment of article attachment hardware  300  is shown. As may be seen an inverted bolt (not labeled) has been slid into receiver track  204  (not labeled), and article attachment hardware  300  has been secured to the bolt and the top section by a nut. 
         [0074]    Turning to  FIG. 14 , a side view of a preferred embodiment of the base  100 , top section  200 , and a first embodiment of article attachment hardware  300  is shown. Article attachment hardware comprises a lower section  302  and an upper section  301 . Lower section is secured to the top portion  200  by the bolt passing through lower section  301  and a nut on the bolt. Lower section and upper section interlock at one a plurality of discrete heights by use of periodic protuberances/recesses disposed on a surface of the lower section and corresponding periodic protuberances/recesses disposed on a surface of the upper section configured to interlock with those on the lower section. These protuberances/recesses may take any form known in the art such as but not limited to a comb, dovetail design, or more creative jigsaw puzzle-type shapes. The lower and upper sections  302  and  301  may attach to each other by any other means known in the art such as but not limited to fasteners and adhesives. In alternative embodiments the upper and lower sections  302  and  301  may be replaced with a single piece article attachment hardware. 
         [0075]    In this first embodiment article attachment hardware  300  comprises a clamping portion  303  configured to overlay and exert pressure towards the top portion  200  on an article  500 . The pressure exerted by the clamping portion  303  on the article  500  is sufficient to securely hold the article to the top portion  200 , and thereby attach the article to the mount, and thereby to the roof. This first embodiment of article attachment hardware is suitable to attach a top portion to a single article. 
         [0076]    Turning to  FIG. 15 , an exploded side view of a preferred embodiment of the base  100 , top section  200 , and a second embodiment of article attachment hardware  400  is shown. In this embodiment the article attachment hardware  400  comprises a securing piece  401 , which has a hole to slide onto the bolt, and is then secured with a nut. Fully assembled, the bolt will be slid into the receiving track as shown in  FIGS. 13-14 , and the nut will be tightened urging the securing piece  401  towards the top portion  200 . This embodiment of article attachment hardware is suitable for attaching a top portion to two articles. Each side of the securing piece  401  will exert pressure on an article and thereby secure it to the top portion, and thereby to the mount and roof. 
         [0077]    It is to be appreciated that the first and second embodiments of article attachment hardware are but two of many possible embodiments, and that the articles may be secured to the top portion by any means known in the art such as but not limited to directly bolting the articles to the top portion. 
         [0078]    Turning to  FIGS. 16 and 17 , a side view and a perspective view of an alternative embodiment of the base is shown. This embodiment allows the base to be mounted onto the top of a post while adding little height to the overall mounting system.  FIGS. 17   b  and  17   c  expand on this embodiment by showing depicting said attachment to a post (not labeled). 
         [0079]    Turning to  FIG. 18 , a perspective view of an alternative embodiment of the base  100  is shown. In this embodiment the roof attachment portion has been removed and instead the base includes a simple bolt slot through which any appropriate fastener (such as but not limited to screws and bolts) may be driven to attach the base to a roof. 
         [0080]    Turning to  FIG. 19 , a perspective view of an alternative embodiment of the base is shown. In this embodiment the upstanding member has been incorporated onto a roof mounting hook which is commonly used worldwide. The upstanding member may be attached to nearly any standard mount or hook to allow for height adjustable mounting of an article(s). 
         [0081]    Turning to  FIG. 20 , a perspective view of an alternative embodiment of the mount is shown attached to a tile roof and holding an article. In this embodiment the upstanding member is attached to a base configured to slide up and under a roof tile. As may be seen in this figure, each base/top portion pair has been slid together and interlocked at a different height so as to account for roof unevenness. Note that while only single article is shown for clarity, the article attachment hardware as shown is configured to hold two articles, one as shown, and one extending towards the bottom of the figure. 
         [0082]    Turning to  FIG. 21 , a perspective view of a preferred embodiment of the mount is shown attached to a shingled roof and holding an article. In this embodiment each base is attached to the roof with a flashing  600  intermediate the base and the roof. The flashing slides up and under the shingles on the roof and prevents leakage of water through the roof. As may be seen in this figure, each base/top portion pair has been slid together and interlocked at a different height so as to account for roof unevenness. Note that while only a single article is shown for clarity, the article attachment hardware as shown is configured to hold two articles, one as shown, and one extending towards the bottom of the figure. 
         [0083]    Turning to  FIG. 22 , a perspective view of a plurality of a preferred embodiment of the mount is shown attached to a shingled roof and holding two articles. In this embodiment each base is attached to the roof with a flashing  600  intermediate the base and the roof. The flashing slides up and under the shingles on the roof and prevents leakage of water through the roof. 
         [0084]    One feature of the mount which is shown clearly in  FIGS. 20-22  is that the article(s), in this case solar panels, are attached directly to the mount and do not require a standard rack. The mount simply attaches directly to the edge of the article(s), and that edge acts as the structural member. This feature of the mount saves time and money when installing an article or articles on a roof as a standard rack need not be purchased or installed. 
         [0085]    Turning to  FIGS. 23-25 , a perspective view, a top view, and a side view of an alternative embodiment of the mount is shown. This embodiment differs from the above-disclosed embodiments in that the upstanding member has height adjustment protrusions and/or height adjustment recesses on only a single side of the upstanding member. This embodiment also differs from the above-disclosed embodiments in that the top portion comprises a single vertical surface configured to slide and interlock with the upstanding portion of the base. This single surface comprises height adjustment protrusions and/or height adjustment recesses configured to interlock with those on the upstanding portion of the base. The top portion also comprises a bolt hole as disclosed above to secure the top portion to the base after they have been interlocked. 
         [0086]    Turning to  FIGS. 26-29 , a perspective view, a top view, and two side views of an additional alternative embodiment of the mount is shown. This embodiment differs from the above disclosed embodiments in that the mount further comprises a wire guide attached to the base via the bolt and bolt hole. The wire guide may comprise a conduit, channel, or other suitable structure for securing and organizing wires. 
         [0087]    Turning to  FIG. 30  a perspective view of an alternative embodiment of the mount is shown. This embodiment differs from the above-disclosed embodiments in that the two roof attachment holes have been reoriented such that the mount would attach to the rafter of a roof 90 degrees offset from the above-disclosed embodiments. This may be desirable depending upon the design of the roof the mount and the article(s) are being attached to. 
         [0088]    Turning to  FIGS. 31-34 , a perspective view, a top view, and two side views of an alternative embodiment of the base is shown. This embodiment differs from the above-disclosed embodiments in that the roof attachment holes configured to accept screws driven into a roof have been removed and replaced with a single attachment hole configured to accept a screw driven into the side of a structure. This base could be used for example if it was advantageous to attach the base to the edge of a roof. 
         [0089]    Another embodiment similar to the embodiment shown above is depicted in  FIGS. 35-38 . In this embodiment the base is replaced with an alternative base that allows for tilting adjustments to be made to the upstanding portion. 
         [0090]    Although the invention has been shown and described with respect to certain embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of the specification. In particular, with regard to the various functions performed by the above-described components, the terms (including any reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent) even though not structurally equivalent to the disclosed component which performs the functions in the herein exemplary embodiments of the invention. In addition, while a particular feature of the invention may have been disclosed with respect to only one embodiment, such feature may be combined with one or more other features of other embodiments as may be desired or advantageous for any given or particular application.