Abstract:
A new mounting system for elevating and supporting objects such as solar panels and satellite dishes upon a roof. The mounting base for attachment to a roof rafter incorporates a threadable elongated member or stanchion and only requires a single lag bolt which is positioned directly beneath the stanchion for fastening to a roof rafter. A guide tunnel is also provided on the roof mount for proper drill angle into the rafter.  
     The solar panel support utilizes C-shaped extruded aluminum horizontal members where, upon fastening the solar panel to the members, enhances the strength properties from a C-shape to a square structural member.  
     The disclosed design for the solar panel support and associated equipment which are attached to at least two mounting bases, permits efficient packaging, resulting in minimal packaging time and cost.

Description:
CLAIM OF PRIORITY  
       [0001]    This application claims the benefit of U.S. Provisional Application bearing Serial No. 60/176,126 filed Jan. 14, 2000. 
     
    
     
       BACKGROUND OF INVENTION  
         [0002]    The present invention relates to the building industry and specifically to mounting equipment and the method for securing this equipment to rafters. The mounting equipment, once secured to the rafters, can be used to support objects such as solar panels.  
           [0003]    The roofs of building structures have been used for placement of many objects such as air conditioning units, solar panels, satellite dishes, etc. The primary reason for location of these objects upon a roof is the lack of alternative space.  
           [0004]    Air conditioning units, because of their relative heavy weight, provide a downward force upon the roof in any weather condition. However, a problem exists for other objects such as satellite dishes and solar panels, which can, in certain windy conditions, be lifted off the roof mounting because the force of the wind applied against the surface area on the side or underside of the object creates an uplift condition which is greater than the attachment strength of the roof mount to the roof deck.  
           [0005]    Besides the need for compliance with governmental building code requirements, a more efficient method for installing a mounting system to a roof is highly desired by roof installers. A faster installation would reduce the labor costs associated with each install.  
           [0006]    One of the problems with present installations is the fact that more than one lag bolt or other type of fastening bolt is required for each mounting plate which is secured to the roof. The risk is high that some of the lag bolts will drill at an angle other than perpendicular to the roof rafter. The severity of the angle and the trajectory of the lag bolt penetration into the rafter could cause the rafter to split; further reducing the structural integrity of the mounting system.  
           [0007]    For many years, existing solar mounting systems were installed using a threaded pipe nipple that screwed into a mounting plate commonly called a “floor flange” in the trade. The threaded floor flange has been commercially available as a standard plumbing item for many years. U.S. Pat. No. 5,603,187 issued to Merrin et al. is typical of the prior art. The Merrin design, as well as all similar prior art, have a common design limitation. They all require that multiple bolts be installed offset from the threaded vertical support flange or stanchion. Also, because of the floor flange design, it would not permit industry standard flashing to install flat on the roof; primarily due to the base flashing circumference interfering with the height of the floor flange.  
           [0008]    A mounting system based upon the Merrin patent, while appropriate for roof mounting of heavy objects such as air conditioners, is not practical for use with solar panels or satellite dishes. The Merrin design precludes direct (bolted) attachment to the roof rafter by each of the mounting holes present on the base plate; primarily due to the width of the rafter in relation to the spacing of the mounting holes. Further, Merrin views rafter attachment as a limitation and therefore teaches away from using rafters for structural support. Therefore, Merrin teaches attachment to the roof decking which generally consists of only {fraction (1/21)}″ plywood or a composite sheeting; either of which do not provide the strength of a bolt mounted to a rafter in an uplift condition.  
         SUMMARY OF INVENTION  
         [0009]    This invention presents a new mounting system for elevating and supporting objects such as solar panels and satellite dishes upon a roof. The roof mount would be attached prior to installation of the roof flashing. The component parts for supporting a solar panel or satellite dish would be assembled and attached to the roof mount over the flashing. Features of the invention are as follows:  
           [0010]    1. a new roof mount having a threadable elongated member or stanchion which requires a single lag bolt positioned directly beneath the stanchion for fastening to a roof rafter. A guide tunnel is also provided on the roof mount for proper drill angle into the rafter.  
           [0011]    2. A support design comprising either a composite or aluminum extruded C-shaped horizontal members and associated equipment for attachment to a plurality of roof mounts which will support a mounted object such as a solar panel. The design, when utilized and having upon it mounted a solar panel or other structure, enhances the strength properties from that of a C-shaped horizontal member to those of a square structural member.  
           [0012]    3. The support design permits efficient packaging, resulting in minimal packaging time and cost.  
           [0013]    Roof Mount  
           [0014]    In order to utilize my mounting system, a roof mount must first be secured to a rafter. The roof mount is preferably machined from aluminum and comprises a threaded cavity with an insertion opening for threadably receiving a vertical stanchion. Directly below the cavity is an aperture for insertion of a lag bolt for attachment to the rafter. This is a unique feature of my support base. Only one lag bolt or other type of fastening bolt is required. For a one bolt design, having the attachment force positioned directly beneath the stanchion provides the highest level of attachment strength.  
           [0015]    Additionally, a special hollow can be machined at the base of the channel to allow clearance for the bolt head when installed so that it does not contact the bottom surface area of the stanchion. This permits maximum threadable engagement of the stanchion to the base.  
           [0016]    The base section of the roof mount comprises a base for direct contact with the decking surface of a roof and a vertically extending cylindrical member having the threaded cavity and an offset wall having a guide tunnel. It is not necessary that the guide tunnel be part of the cylindrical member. It is however, preferable to maintain a minimum distance between channel and guide tunnel so that it is easy to use the guide tunnel to drill a pilot hole into a rafter and to thereafter align the pilot hole with the aperture by sliding the base section a minimal distance.  
           [0017]    The distance between the cavity and guide tunnel however, must be sufficient so as not to compromise the overall structural integrity of the base section.  
           [0018]    In an alternative design, the guide tunnel is not used and the roof mount base section simply incorporates my single bolt design described above which includes a base and a vertically extending cylindrical member having the threaded cavity.  
           [0019]    The base can be of any geometrical shape such as circular, rectangle or square. All that is required is that the geometrical shape be sized accordingly so that it does not interfere with the alignment or use of commercially available flashing to the roof.  
           [0020]    Once the lag bolt is secured to the rafter, one end of the stanchion is inserted and secured within the threaded cavity and the roof flashing is thereafter installed. For purposes of this specification, the base section and the stanchion/elongated member are collectively referred to as the roof mount. Although the mounting equipment may be installed days later, it is preferable to install the roof mount at this point.  
           [0021]    Solar Panel Support and Installation  
           [0022]    A pair of C-shaped horizontal members are provided for attachment to roof mounts and support an object, such as a solar panel, above the roof. Each horizontal member is preferably made from extruded aluminum and can be manufactured to any length. Each horizontal member has a track which can be used by slidable inserts which have been designed to fit within and slide along this track. These slidable inserts have a female threaded hole for receiving a fastening bolt; the use of which will be described later.  
           [0023]    A clamp having a hole is provided for each slidable insert. The clamp hole is positioned so that a fastening bolt can be inserted through and secured to the threaded hole of the threadable insert. There are two types of clamps available: end clamps and bi-module clamps.  
           [0024]    Bi-module clamps are primarily used for securement of the sides of two solar panel modules. A module is a set of photovoltaic cells while a solar panel is a plurality of modules. End clamps would secure the sides of a solar panel. In any case, bi-module clamps are used to secure the sides of two adjoining solar modules to the horizontal member.  
           [0025]    Each horizontal member has a pair of end clamps for securement of a solar panel. Each end clamp has a slight rise or heel on its bottom surface distally positioned from its clamping surface. This slight rise provides a pair of advantages when attaching solar modules. First, the slight rise prevents twisting of the clamp while it is being bolted into position on the horizontal member. Second, when the end clamp is engaged to a solar module frame, the rise forces the clamp inward at 90 degrees to fully engage a module frame. This design prevents the end clamp from inadvertently separating the module frame from its glass. Also, the rise provides spring tension against the module frame, providing full engagement as the module laminate glass and frame flex under extreme stresses caused by weather conditions such as high wind and snow.  
           [0026]    The solar panel support includes the horizontal members, slidable inserts, end clamps, bi-module clamps and the attachment means to a roof mount. The roof mount can be the one described as part of this invention or it can be one already available in the prior art. The attachment means would comprise holes drilled in the horizontal members which are aligned with and mounted to the already installed roof mounts. A mounting bolt or the like would be used to attach the horizontal members to the roof mount.  
           [0027]    Alternatively, it is possible to use composite material instead of aluminum for the solar panel support and roof mount.  
           [0028]    Packaging  
           [0029]    The horizontal members and associated mounting equipment described in the preceding section have been designed so that they can be packaged quickly; resulting in minimal labor cost associated with packaging as well as reduced packing material cost. The design prevents damage to the mounting equipment by effectively enclosing the clamps and inserts between the C-shaped horizontal members. With the open side of the C-shaped horizontal members facing each other, an elongated tubular square member is formed and all that is necessary from a packaging standpoint, is sealing the ends of the tubular member. Horizontal ridges are formed into the end surface of the open sides. The engagement of these ridges from facing C-shaped horizontal members mate or interlock. This maintains the elongated tubular configuration and facilitates product packaging. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0030]    [0030]FIG. 1 is a perspective view and illustrates the position of the base section of the roof mount above a rafter and a drill positioned for drilling a pilot hole.  
         [0031]    [0031]FIG. 2 is a view taken along line  2 - 2  of FIG. 1 and which shows a drilled pilot hole.  
         [0032]    [0032]FIG. 3 indicates the roof mount displaced so that the pilot hole is in alignment with the support channel.  
         [0033]    [0033]FIG. 4 is an exploded view showing the lag bolt and stanchion relationship to the roof mount.  
         [0034]    [0034]FIG. 5 is a perspective view when the lag bolt and stanchion are assembled to the roof mount.  
         [0035]    [0035]FIG. 6 is a view taken along line  6 - 6  of FIG. 5.  
         [0036]    [0036]FIG. 7 is a perspective view illustrating the relationship of the assembled roof mount to flashing material.  
         [0037]    [0037]FIG. 8 is a perspective view of the package comprising a pair of elongated C-shaped members and associated equipment.  
         [0038]    [0038]FIG. 9 is a view taken along line  9 - 9  of FIG. 8.  
         [0039]    [0039]FIG. 9 a  is a end view of an elongated U-shape member depicting a linear positioning groove for a drill bit to make a hole.  
         [0040]    [0040]FIG. 10 is a perspective view illustrating the attachment of an elongated C-shaped member to a plurality of stanchions.  
         [0041]    [0041]FIG. 11 is a perspective view illustrating the slidable relationship of clamps relative to the C-shaped member and the positioning of a solar module.  
         [0042]    [0042]FIG. 12 is an exploded view of the relationship of an end clamp to a slidable insert.  
         [0043]    [0043]FIG. 13 is an exploded view of the relationship of a bi-module clamp to a slidable insert.  
         [0044]    [0044]FIG. 14 is a perspective view of an assembled solar panel having  4  modules.  
         [0045]    [0045]FIG. 15 is a side view showing a secured end clamp in relationship to the side of a solar panel.  
         [0046]    [0046]FIG. 16 is a view taken along line  16 - 16  of FIG. 15.  
         [0047]    [0047]FIG. 17 is a side view showing a secured bi-module clamp in relationship to the adjacent sides of two solar modules.  
         [0048]    [0048]FIG. 18 is a view taken along line  18 - 18  of FIG. 17. 
     
    
     DETAILED DESCRIPTION  
       [0049]    [0049]FIG. 1 through FIG. 6 illustrate the sequence for installing my roof mount to a rafter.  
         [0050]    [0050]FIG. 1 illustrates the general relationship of base section  17  to a roof having decking  12  and rafter  14 .  
         [0051]    Base section  17  comprises a base  16  and a cylindrical member  18  integral with and extending away from base  16 . Cylindrical member  18  has an offset wall area.  
         [0052]    As illustrated in FIG. 2, base section  17  has a guide tunnel  20  which extends from the top of cylindrical member  18  to the bottom of base  16 . The purpose of guide tunnel  20  is to provide perpendicular alignment of drill bit  24  to rafter  14  for the drilling of pilot hole  26 . Perpendicular alignment is important because it minimizes the probability of rafter splits, as can occur when a pilot hole is drilled which is not in perpendicular alignment to the rafter.  
         [0053]    Cylindrical member  18  further has a cavity  22 , the top of cavity  22  defining an insertion opening  28 . The walls of cavity  22  are threaded for engaging a stanchion  42  as will be discussed later.  
         [0054]    Defining the bottom of cavity  22  is top surface  30 . A hole  32  extends from top surface  30  through base  16 . Hole  32  has a common axis of symmetry with cavity  22  and is designed to accept the stem  36  of a fastening bolt  34  as shown in FIG. 4.  
         [0055]    With the alignment as shown in FIG. 1, drill bit  24  is inserted into guide tunnel  20  and a pilot hole  26  is drilled into rafter  14  as shown in FIG. 2.  
         [0056]    Base section  17  is then displaced along decking  12  until pilot hole  26  is aligned with hole  32  as shown in FIG. 3.  
         [0057]    [0057]FIG. 4 illustrates the relationship of fastening bolt  34  and stanchion  42  to base section  17 . Once hole  32  is aligned with pilot hole  26 , fastening bolt  34  is inserted through washer  40  and screwed into rafter  14 . Fastening bolt head  38  remains within cavity  22 . Stanchion  42  has a male threaded end  44  and is inserted through insertion opening  28  for threadable engagement within cavity  22 .  
         [0058]    Distal from threaded end  44  is female threaded end  46  for frictional engagement of mounting bolt  48  and washer  50 . FIG. 5 and FIG. 6 illustrate the assembled roof mount  10  fastened to rafter  14 . Roof mount  10  comprises base section  17 , stanchion  42  along with threadably connected mounting bolt  40  and washer  50 .  
         [0059]    In practice, the rafters  14  and decking  12  will be installed prior to the installation of roof mount  10 . A single pilot hole  26  is drilled for each roof mount which, due to my design, will be perpendicular to the roof rafter and minimize the risk of rafter split. The number of roof mounts used will be determined by the size of the object to be mounted.  
         [0060]    Once the pilot hole is drilled, base section  17  is slid a short distance and fastening bolt  34  is inserted to fasten base section to rafter  14 . Again, because only one hole is drilled into the rafter for each roof mount  10 , less labor time is required than with typical floor flanges.  
         [0061]    Once all roof mounts  10  have been fastened to their respective rafters, flashing  52  must be installed to protect the roof from the risk of future water damage. FIG. 7 illustrates the arrangement of multiple flashings  52  over a plurality of roof mounts  10 . Following flashing installation, the decking  12  is typically layered with roofing material (not shown).  
         [0062]    Although my mounting system can be utilized for a variety of objects to be mounted above a roof, the following procedure will address installation of a solar panel having multiple modules.  
         [0063]    Once the roof is in a condition for installing a solar panel, a pair of C-shaped elongated horizontal members  54  are provided. Each horizontal member  54  has a base wall  56  and a pair of side walls  58  and  60 . A linear groove  62  runs along the bottom surface of base wall  56  as can be seen in FIG. 9 a  and FIG. 10.  
         [0064]    [0064]FIG. 9 a  also illustrates a pair of horizontal ledges  64  and  66  extending inward from sidewalls  58  and  60  toward each other. These ledges extend the length of sidewalls  58  and  60 . A pair of protruding lips  68  and  70  extend inward from the distal end of sidewalls  58  and  60  relative to base wall  56 . A track area is defined by the surface area of ledges  64  and  66  which face lips  68  and  70  respectively. The purpose of the track will be discussed below.  
         [0065]    [0065]FIG. 10 illustrates the attachment of horizontal members  54  to roof mounts  10 . Initially, mounting bolts  48  and washers  50  are removed from stanchions  42 . Horizontal member  54  is positioned along each flashing cone. As shown in FIG. 9 a,  a drill is used to drill mounting holes  72  along groove  62  on base wall  56  for each roof mount. Once the first mounting hole  72  is drilled, additional mounting holes can be drilled by simply measuring the distance from the last hole drilled when the spacing between the rafters is known.  
         [0066]    Once all mounting holes  72  have been drilled, horizontal member  54 , is positioned the above flashing cones with mounting holes  72  aligned with female threaded end  46 . Mounting bolts  48  and washers  50  are then used to frictionally engage horizontal members  54  to respective roof mounts  10 . FIG. 11 shows horizontal members  54  assembled to roof mounts  10 .  
         [0067]    At least two slidable inserts  74  are provided for each horizontal member  54  and a general configuration is illustrated in FIG. 12 and FIG. 13. Insert  74  has a female threaded hole  80 . The outer configuration of insert  74  is designed to be slidably received within track area of horizontal member  54 . The required number of inserts  74  is dependent upon the number of clamps needed to secure the solar panel. There are two types of clamps available: end clamps  76  and bi-module clamps  78 .  
         [0068]    End clamp  76  is illustrated in FIG. 12 and has a hole  82  for alignment with threaded hole  80  on insert  74 . End clamp  76  has a notched surface  84  for frictionally engaging the solar panel and securing it between notched surface  84  and horizontal member  54  when end clamp bolt  86  has its threaded stem  88  passed through washer  90  and hole  82  for engagement with threaded hole  80  on insert  74 . FIG. 15 and FIG. 16 show the solar panel in frictional engagement between notched surface  84  and horizontal member  54 .  
         [0069]    Two end clamps  76  are used to secure a solar panel therebetween and along each horizontal member  54  when each end clamp  76  is threadably fastened to insert  74  using bolt  86 . A solar panel is defined as at least one solar module and can be a number of modules in series as illustrated in FIG. 14. Therefore, four end clamps  76  are used to secure a solar panel to two horizontal members  54 .  
         [0070]    A bi-module clamp  78  is illustrated FIG. 13. They are used to secure the sides of two adjoining solar panel modules and to a horizontal member  54  when bi-module clamp  78  is threadably fastened to insert  74  using a bolt  104 . The use of bi-module clamps  78  and end clamps  76  in my mounting system is best illustrated in FIG. 14.  
         [0071]    The number of bi-module clamps required for each horizontal member  54  is determined by the formula: 
         number of bi-module clamps=(number of modules−1). 
         [0072]    Each bi-module clamp  78  has a top side  92 , a bottom side  94 , a pair of side walls  96 . Holes  98  located on top side  92  and bottom side  94  have a common axis of symmetry and are for alignment with threaded hole  80  on insert  74 . Top side  92  extends perpendicularly away from side walls  96  in either direction forming overhangs  100  having notched surfaces  102 . Notched surfaces  102  are for frictionally engaging the solar module and securing it between notched surface  102  and horizontal member  54  when bolt  104  has its threaded stem  106  passed through washer  90  and holes  98  for engagement with threaded hole  80  on insert  74 . FIG. 17 and FIG. 18 show a pair of solar modules in frictional engagement between notched surfaces  102  and horizontal member  54 .  
         [0073]    As a slidable insert  74  is threadably engaged and frictionally positions either bi-module clamp  78  or end clamp  76  along member  54 , insert  74  also frictionally engages an area of member  54 . This relationship is illustrated in FIG. 16 and FIG. 18. This engagement changes the structural properties of member  54  to that of a structural square for enhanced strength. In addition, when engaged to the module or solar panel frame, the structural properties of the module frame combine with horizontal member  54  and form a rigid inter-locking trussed cross-section.  
         [0074]    Each end clamp  76  has a slight rise  108  on its bottom surface distally positioned from its clamping surface and is illustrated in FIG. 12 and FIG. 15. Rise  108  prevents end clamp  76  from twisting while fastening bolt  86  to insert  74 .  
         [0075]    As best illustrated in FIG. 14, horizontal members  54  along with the associated component parts, namely slidable inserts  74 , end clamps  76  and bi-module clamps  78  and the attachment means to roof mount  10  comprise a solar panel support structure.  
         [0076]    [0076]FIG. 8 illustrates the unitized packaging for the mounting components, namely a pair of horizontal members  54  and the associated number of inserts  74 , bi-module clamps  78 , and a pair of end clamps  76 . The ends of the horizontal members  54  are secured by tape or other packaging material  110 . Packaging material  110  not only maintains the relationship of horizontal members  54  to one another, it also prevents the inserts and clamps from escaping.  
         [0077]    As can be best seen in FIG. 9 a,  the outward facing surface  112  of the open side of horizontal member  54  has ridges. These ridges extend the length of each member  54  and form mating or interlocking surfaces when the open sides of two horizontal members  54  are aligned and contacted with one another. FIG. 9 illustrates two horizontal members  54  mated to one another and show a bi-module clamp  78  and an end clamp  76  in view.  
         [0078]    During assembly, the inserts and clamps are placed into a horizontal member  54 . Packing such as paper (not shown) is also inserted to prevent the inserts and clamps from excessive movement and potential wear and damage. The second horizontal member  54  is thereafter mated to the other member by cooperatively engaging along surfaces  112 . Outside packaging is thereafter used to seal the open ends.