Abstract:
A method and apparatus for installing a stanchion on a tile roof includes a tile which has an aperture and a stanchion which fits through the aperture. An existing roof tile is removed and the stanchion is connected to the roof sheathing at the place of removal. The tile is then placed over the stanchion so that the stanchion project through the aperture. In an embodiment of the invention, a sleeve surrounds the aperture and a seal provides a weather proof seal between the stanchion and the sleeve.

Description:
TECHNICAL FIELD 
     The present invention pertains generally to roofs, and more particularly to a method and system for installing a stanchion on a tile roof while maintaining waterproof integrity. 
     BACKGROUND OF THE INVENTION 
     Many roofs comprise a plurality of individual overlapping roof tiles which are installed over a roof sheathing. With such tile roofs it is troublesome to install stanchions to support roof fixtures such as solar panel structures. The current method of adding a stanchion comprises removing several tiles, attaching a stanchion to the roof, waterproofing the stanchion at the subroof (sheathing), reinstalling the tile around the mount by cutting away the one or two tiles around the stanchion, and flashing the hole around the stanchion with metal flashing. An installation of a solar system usually requires multiple points of contact to comply with building codes. In many instances, it is easier and less expensive to actually remove an entire section of roof, and then reinstall the roof with flashings after the stanchions are in place. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed to a method and system for installing a stanchion on a tile roof. The system includes a replacement tile which has an aperture and a stanchion which is shaped and dimensioned to be received by the aperture. An existing roof tile is removed and the stanchion is connected to the roof sheathing exposed by the removed existing tile. The tile of the present invention is then placed over the stanchion at the location of the removed existing tile. The stanchion projects up through the tile and is therefore available for connecting a roof fixture. The principles of the present invention may be applied to both flat and curved tiles. 
     In accordance with a preferred embodiment of the invention, a system for installing a stanchion on a roof having tiles disposed on top of roof sheathing includes a tile having an aperture. A stanchion is shaped and dimensioned to be received by the aperture, and is connectable to the roof sheathing. 
     In accordance with an aspect of the invention, the tile is disposable over the stanchion so that the stanchion projects through the aperture. 
     In accordance with another aspect of the invention, the stanchion includes a flange for connecting the stanchion to the roof sheathing. 
     In accordance with another aspect of the invention, the tile has a top surface and an opposite bottom surface. The tile includes a sleeve which connected to the top surface of the tile and surrounds the aperture. The tile is disposable over the stanchion so that the stanchion projects through the sleeve. 
     In accordance with another aspect of the invention, the roof sheathing defines a roof plane, and the top surface of the tile defines a tile plane. When the tile is installed on the roof, the tile plane forms an angle A with the roof plane. The sleeve has a central axis, and when the tile is viewed from the side, the central axis forms an acute angle B with the tile plane, wherein angle B is approximately equal to 90° minus angle A. In accordance with another aspect of the invention, angle B is about 84°. 
     In accordance with another aspect of the invention, the sleeve has a top surface. The top surface of the sleeve forms an angle C with the tile plane, wherein angle C is approximately equal to angle A. 
     In accordance with another aspect of the invention, a seal is provided for sealing a space between the stanchion and the sleeve. 
     In accordance with another aspect of the invention, the roof sheathing defines a roof plane, and the tile has a central longitudinal axis. When the tile is installed on the roof, the central axis of the tile forms an angle A with the roof plane. The sleeve has a central axis, and when the tile is viewed from the side, the central axis of the sleeve forms an acute angle B with the central axis of the tile, wherein angle B is approximately equal to 90° minus angle A. 
     In accordance with another aspect of the invention, the sleeve has a top surface. The top surface of the sleeve forms an angle C with the central axis of the tile, wherein angle C is approximately equal to angle A. 
     Other aspects of the present invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a fragmented perspective view of a prior art tile roof; 
         FIG. 2  is an enlarged exploded perspective view of a system for installing a stanchion on a roof having tiles disposed on top of roof sheathing in accordance with the present invention; 
         FIG. 3  is an enlarged top plan view of a tile in accordance with the present invention; 
         FIG. 4  is an enlarged side elevation view of the tile; 
         FIG. 5  is an enlarged bottom plan view of the tile; 
         FIG. 6  is an enlarged top perspective view of the tile; 
         FIG. 7  is and enlarged bottom perspective view of the tile; 
         FIG. 8  is an enlarged top plan view of a stanchion; 
         FIG. 9  is an enlarged side elevation view of the stanchion; 
         FIG. 10  is an enlarged top plan view of a seal; 
         FIG. 11  is an enlarged side elevation view of the seal; 
         FIG. 12  is a fragmented perspective view of the prior art roof with one of the existing tiles removed; 
         FIG. 13  is a fragmented perspective view of the stanchion installed on the roof sheathing; 
         FIG. 14  is a fragmented perspective view of a tile installed over the stanchion; 
         FIG. 15  is a fragmented perspective view of the seal installed on the stanchion and tile; 
         FIG. 16  is a cross sectional view along the line  16 - 16  of  FIG. 15 ; 
         FIG. 17  is an enlarged side elevation view of a second embodiment of the tile; 
         FIG. 18  is an enlarged top perspective view of a second embodiment tile; 
         FIG. 19  is an enlarged top plan view of the second embodiment tile; 
         FIG. 20  is an enlarged side elevation view of the second embodiment tile; and, 
         FIG. 21  is an enlarged top perspective view of a third embodiment tile. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIG. 1 , there is illustrated a fragmented perspective view of a prior art tile roof, generally designated as  500 . Tile roof  500  (also known as a tile roof system) includes a plurality of existing tiles  502  disposed on top of roof sheathing  504  (refer to  FIGS. 2 and 16 ). Tiles  502  are typically fabricated from concrete, ceramic, or a polymer. In the shown embodiment tiles  502  have interlocking edges  506 , however non-interlocking tiles  502  can also be used in conjunction with the present invention. Roof sheathing  504  (also known as sub-roofing) typically comprises sheets of planar material such as plywood which are placed on top of the rafters of a building to serve as the support for tiles  502 . Referring also to  FIG. 16 , roof sheathing  504  defines a roof plane R. 
     Now referring to  FIG. 2 , there is illustrated an enlarged exploded perspective view of a system for installing a stanchion on a roof having tiles  502  disposed on top of roof sheathing  504  in accordance with the present invention, generally designated as  20 . System  20  includes a tile  22  having an aperture  24  (also refer to  FIG. 3 ). System  20  further includes a stanchion  26  which is shaped and dimensioned to be received by aperture  24  in tile  22  (also refer to  FIGS. 14 and 16 ). Tile  22  is disposable over stanchion  26  so that stanchion  26  projects through aperture  24  (also refer to  FIGS. 14 and 16 ). In the shown embodiment, stanchion  26  includes an upstanding post  28  which is received by and projects through aperture  24  (also refer to  FIG. 14 ). Post  28  has a threaded portion  30  for connecting solar panels or other roof fixtures  600  (also refer to  FIG. 16 ). Stanchion  26  also includes a flange  32  for connecting stanchion  26  to the roof sheathing  504  with bolts or screws (refer to  FIG. 13 ). 
     Tile  22  includes a top surface  34  and an opposite bottom surface  36  (refer also to  FIG. 5 ). Tile  22  includes a sleeve  38  which is connected to top surface  34  of tile  22  and surrounds aperture  24 . In the shown embodiment sleeve  38  is an integral portion of tile  22 . Tile  22  is disposable over stanchion  26  so that stanchion  26  projects through sleeve  38  (refer also to  FIGS. 14 and 16 ). It is noted that it is post  28  of stanchion  26  which projects through aperture  24  and sleeve  38 . 
     System  20  also includes a weatherproofing seal  40  for sealing the space between stanchion  26  and sleeve  38  (also refer to  FIGS. 15 and 16 ). In the shown embodiment, seal  40  is a collar fabricated from a resilient material such as rubber which tightly fits over post  28  of stanchion  26  and sleeve  38  to effect a water tight seal between post  28  and sleeve  38 . 
       FIGS. 3 through 7  are enlarged top plan, side elevation, bottom plan, top perspective, and bottom perspective views respectively of tile  22 , showing aperture  24 , sleeve  38 , and top surface  34 . Referring to  FIG. 4 , top surface  34  of tile  22  defines a tile plane (viewed on edge) Referring to  FIGS. 4 and 16 , when tile  22  is installed on roof  500 , tile plane T forms an angle A with roof plane R (viewed on edge, refer also to  FIG. 16 ). Sleeve  38  has a central axis  42 . Central axis  42  forms an acute angle B with tile plane T, wherein angle B is approximately equal to 90° minus angle A. In an embodiment of the invention, angle B is about 84°. Sleeve  38  also has a top surface  44  which forms an angle C with tile plane T. Angle C is approximately equal to angle A. As is shown in  FIGS. 6 and 7 , tile  22  includes interlocking edges  25  which are interlockable with interlocking edges  506  of adjacent existing tiles  502  as is shown in  14 , and  15  (refer also to  FIG. 1 ). Also, as shown in  FIG. 7 , a transverse lip  37  is disposed on the bottom of tile  22  (also refer to  FIG. 17 ). 
       FIGS. 8 and 9  are enlarged top plan and side elevation views respectively of stanchion  26  showing post  28 , threaded portion  30 , and holes  48  for connecting stanchion  26  to roof sheathing  504  (refer also to  FIG. 13 ). In an embodiment of the invention, the bottom of flange  32  includes double sided tape  46  to mechanically strengthen the connection to roof sheathing  504 . 
       FIGS. 10 and 11  are enlarged top plan and side elevation views respectively of seal  40 . Referring also to  FIG. 15 , seal  40  snuggly fits over post  28  of stanchion  26  to provide a weatherproof seal between post  28  and sleeve  38 . 
       FIG. 12  is a fragmented perspective view of prior art roof  500  with one of the existing tiles  502  removed thereby exposing roof sheathing  504 . 
       FIG. 13  is a fragmented perspective view of stanchion  26  installed on a roof sheathing  504  showing post  28  threaded portion  30  and flange  32 . Before stanchion  26  is connected to roof sheathing  504 , its position is defined (measured) so that stanchion  26  is in the correct location to be received by sleeve  38  of tile  22  when tile  22  is placed over stanchion  26  to replace the existing tile  502  (refer to  FIG. 14 ). If roof sheathing  504  is covered with tar paper or other material, that material is removed prior to installing stanchion  26 . 
       FIG. 14  is a fragmented perspective view of tile  22  installed over stanchion  26  showing aperture  24 , sleeve  38 , and post  28 . Tile  22  has been placed in the previous location of removed existing tile  502  (refer to  FIG. 12 ) so that post  28  of stanchion  26  projects through aperture  24  and sleeve  38 . In this position, stanchion  26  is now available for connecting solar panels or other roof fixtures  600  (also refer to  FIG. 16 ). 
       FIG. 15  is a fragmented perspective view of seal  40  installed stanchion  26  and tile  22 . Seal  40  ensures a watertight connection between post  28  of stanchion  26  and sleeve  38  of tile  22 . 
       FIG. 16  is a cross sectional view along the line  16 - 16  of  FIG. 15  showing roof sheathing  504 , tile  22 , aperture  24 , sleeve  38 , stanchion  26 , post  28 , flange  32 , and seal  40 . Angle A is the angle between tile plane T and roof plane R. A roof fixture  600  is connected to post  28  of stanchion  26 . 
       FIG. 17  is an enlarged side elevation view of a second embodiment of tile  22 . In this embodiment central axis  42  of sleeve  38  does not form an acute angle B with tile plane T as in  FIG. 4 , but is rather substantially perpendicular to tile plane T. The top surface  44  of sleeve  38  is inclined so that it forms an angle A with tile plane T. This facilitates the installation of seal  40 . 
       FIGS. 18-20  are enlarged top perspective, enlarged top plan, and enlarged side elevation views respectively of a second embodiment tile, generally designated  122 . Tile  122  has a double curve as opposed to the flat tile of tile  22 . As with tile  22 , tile  122  includes an aperture  124 , a sleeve  138  which surrounds aperture  124  and which has a top surface  144  and a central axis  142 . Tile  122  also includes a central longitudinal axis  150 . When tile  122  is installed on roof  500 , central axis  142  of tile  122  forms an angle A with roof plane  504 . When tile  122  is viewed from the side ( FIG. 20 ), central axis  142  of sleeve  138  forms an acute angle B with central axis  150  of tile  122 , wherein angle B is approximately equal to 90° minus angle A. In an embodiment of the invention, angle B is about 84°. Sleeve  138  has a top surface  144 . Top surface  144  forms an angle C with central axis  142  of tile  138 , wherein angle C is approximately equal to angle A. It is noted that, tile  122  cooperates with stanchion  26  and seal  40  in the same manner as is described above for tile  22 . That is, post  28  of stanchion  26  projects through aperture  124  and sleeve  138 , and seal  40  seals the space between stanchion  26  and sleeve  138 . 
       FIG. 21  is an enlarged top perspective view of a third embodiment tile, generally designated as  222 . Tile  222  is a variation of tile  122  which has only one curve. Tile  222  includes sleeve  238  having a top surface  244 , an aperture  224 , and a central longitudinal axis  250 . The angular relationships discussed above for tile  122  also apply to tile  222 . Tile  222  cooperates with stanchion  26  and seal  40  in the same manner as is described above for tile  22 . 
     In terms of use, a method for installing a stanchion  26  on a roof  500  includes: 
     (a) providing a roof  500  having a plurality of existing tiles  502  disposed on top of roof sheathing  504 ; 
     (b) providing a system  20  for installing a stanchion  26  on roof  500  including:
         a tile  22  having an aperture  24 ;   a stanchion  26  shaped and dimensioned to be received by aperture  24 ;       

     (c) removing one of the existing tiles  502 : 
     (d) defining a position where stanchion  26  is to be connected to roof sheathing  504 ; 
     (e) connecting stanchion  26  to roof sheathing  504  at the position of step (d); and, 
     (f) placing tile  22  at the previous location of the removed existing tile  502  of step (c) and over stanchion  26  so that stanchion  26  projects through aperture  24 . 
     The method further including: 
     in step (b), stanchion  26  including a flange  32  for connecting stanchion  26  to roof sheathing  504 ; and, 
     in step (e), using flange  32  to connect stanchion  26  to roof sheathing  504 . 
     The method further including: 
     in step (b), tile  22  having a top surface  34  and an opposite bottom surface  36 ; 
     tile  22  has a sleeve  38  connected to top surface  34  of tile  22  and surrounding aperture  38 ; and, 
     in step (f), stanchion  26  projecting through sleeve  38 . 
     The method further including: 
     in step (a), roof sheathing  504  defining a roof plane R; 
     in step (b), top surface  34  of tile  22  defining a tile plane T; 
     in step (f), tile plane T forming an angle A with roof plane R; 
     in step (b), sleeve  38  having a central axis  42 ; and, 
     in step (b), when tile  22  is viewed from the side, central axis  42  forming an acute angle B with tile plane T, wherein angle B is approximately equal to 90° minus angle A. 
     The method further including: 
     in step (b), angle B being about 84°. 
     The method further including: 
     in step (b), sleeve  38  having a top surface  44 ; and, 
     in step (b), top surface  44  of sleeve  38  forming an angle C with tile plane T, wherein angle C is approximately equal to A. 
     The method further including: 
     in step (b), a seal  40  for sealing a space between stanchion  26  and sleeve  38 ; and, 
     after step (f), installing seal  40  over stanchion  26 . 
     The method further including: 
     in step (a), roof sheathing  504  defining a roof plane R; 
     in step (b), tile  122  (or  222 ) having a central axis  150  (or  250 ); 
     in step (f), central axis  150  (or  250 ) of tile  122  (or  222 ) forming an angle A with roof plane R; 
     in step (b), sleeve  138  (or  238 ) has a central axis  142  (or  242 ); and, 
     in step (b), when tile  122  (or  222 ) is viewed from the side, central axis  142  (or  242 ) of sleeve  138  (or  238 ) forms an acute angle B with central axis  142  (or  242 ) of tile  122  (or  222 ), wherein angle B is approximately equal to 90° minus angle A. 
     The method further including: 
     in step (b), angle B being about 84°. 
     The method further including: 
     in step (b), sleeve  138  (or  238 ) having a top surface  144  (or  244 ); and, 
     in step (b), top surface  144  (or  244 ) of sleeve  138  (or  238 ) forming an angle C with central axis  142  (or  242 ) of tile  122  (or  222 ), wherein angle C is approximately equal to A. 
     The preferred embodiments of the invention described herein are exemplary and numerous modifications, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims.