Abstract:
Improvements a roof tile with an integrated riser is disclosed. The roof tile with integrated riser has the shape and color to provide a similar appearance to the original tiles. The integrated riser provides a support and complete sealing to prevent intrusion from water through the riser. The riser can be formed by insert casting the riser into the roof tile, or can be bonded into a pocket in the roof tile. The composition of the roof tiles can be adjusted to reduce how brittleness of the tile. The roof tile is secured to the roof sheeting and studs. Filler material in the tile composition can also provide additional sealing capability to nails or screws that are used to secure the roof tile. The roof tile is a simpler installation that does not require removal of a large number of tiles from the existing roof.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of Provisional Application Ser. No. 62/188,304 filed Jul. 2, 2016 2015 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    Field of the invention 
         [0006]    This invention relates to improvements in a roof tile with an integrated riser. More particularly, the present roof tile with an integrated riser is a replacement tile for a roofing tile that has an integrated riser to secure solar panels or other elevated structure above the roof. 
         [0007]    Description of Related Art including information disclosed under 37 CFR 1.97 and 1.98. 
         [0008]    When solar panels or other structure is placed above an existing roof, multiple roof tiles must be removed to secure the support structure that will hold the solar panels to the roof structure. The previous tiles must then be cut to fit around the supporting structure for the solar panels. In a typical installation, nearly all of the tiles that are installed under the solar panels must be removed to secure the support structure the corners and center of the solar panels to prevent the solar panels from being lifted or moved from rain or wind that blows onto the house or building. 
         [0009]    A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below. 
         [0010]    U.S. Patent Publication Number 2013/0280448 was published on Oct. 24, 2013 to James D. Bennett discloses Solar Panel Ready Tiles. These tiles have integrated solar panels built into the tile itself. These tiles do not have a mechanism for securing a solar panel in an elevated condition above the tile. 
         [0011]    U.S. Patent Publication Number 2008/0302408 was published on Dec. 11, 2008 to Peter Bressler et al., discloses a Method of Manufacturing an Integrated Solar Roofing Tile. This method requires removal of the existing roofing tiles and replacement of the existing roofing tiles with new rodding tiles that have integrated solar panels. The method requires securing a support structure to the roof sheeting prior to installation of the solar collecting roofing tiles. 
         [0012]    U.S. Patent Publication Number 2006/0260670 was published on Nov. 23, 2006 to Miho Terunuma et al., discloses A Structure Fixing Apparatus Including Support Device. The support structure requires removal of existing tiles and then drilling through the removed existing tiles and then driving a structure through the drilled tile. The solar tile is then secured to the structure. While this patent provides a support structure for the solar panels above the roofing tiles. The tile itself does not support the solar panel. 
         [0013]    U.S. Patent Publication Number 2003/0101662 was published on Jun. 5, 2003 to Stanley A. Ullman discloses a Mounting System for Supporting Objects. The mounting system is essentially risers that are mounted to the sheet structure and then the previous roofing tiles are then trimmed and placed around the risers. While this mounting system provides a structure for securing the solar panels in an elevated configuration, the structure is not made replacement roof tiles. 
         [0014]    What is needed is a replacement roofing tile that has the same appearance as previous housing tiles, with the exception of riser integrated into the roof tile. This provides a mounting for solar panels and further keeps the roof sealed from the weather without penetrating existing roof tiles. The roof tile with an integrated riser proposed in this document provides the solution. 
       BRIEF SUMMARY OF THE INVENTION 
       [0015]    It is an object of the roof tile with an integrated riser to be a replacement for a pre-existing roof tile. The shape and color provides a similar appearance to the original tiles that were placed onto the roof. This allows the homeowner to look at the roof under the solar panel, or other item that is secured to a roof, to have a similar appearance as the previous roof tiles. The shape of the tile can be flat “S”, “W” or other shaped tile. 
         [0016]    It is an object of the roof tile with an integrated riser. The integrated riser provides a complete sealing of the roof tile to prevent intrusion from water through the riser. The riser can be formed by insert casting the riser into the roof tile, or can be bonded into a pocket in the roof tile. The composition of the roof tiles can be adjusted to reduce how brittle the tile can be. The roof tile can further include load distributing ribs that help transfer loads from the riser to the rood sheeting and studs. 
         [0017]    It is another object of the roof tile with an integrated riser to be sealed. The preferred embodiment of the roof tile does not have any openings that would allow water to pass through the tile. The roof tile is secured to the roof sheeting and studs with common securing techniques that would normally secure a roofing tile. Filler material in the tile composition can also provide additional sealing capability to nails or screws that are used to secure the roof tile. 
         [0018]    It is still another object of the roof tile with an integrated riser to be a simpler installation that does not require removal of a large number of tiles from the existing roof. Without removing a quantity of roof tiles and then modifying the existing roof tiles to provide clearance and sealing of the original roof tiles. An installer would simply remove the desired tiles and place the tiles with integrated risers. The supporting frame is aligned and then the solar panels are mounted on the frame structure to support the weight of the solar panels. 
         [0019]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0020]      FIG. 1  shows an “S” roof tile with an integrated riser. 
           [0021]      FIG. 2  shows a top view of an “S” roof tile with an integrated riser. 
           [0022]      FIG. 3  is a cross-section of the roof tile from  FIG. 2  cut through lines  3 - 3 . 
           [0023]      FIG. 4  shows a rail for a solar panel array using the roof tiles with integrated risers. 
           [0024]      FIG. 5  shows a top perspective view of a flat roof tile with an integrated riser. 
           [0025]      FIG. 6  is the underside of the flat roof tile from  FIG. 5 . 
           [0026]      FIG. 7  shows a formed metal roof tile with an integrated riser. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]      FIG. 1  shows an “S” roof tile  21  with an integrated riser  22 . From the perspective of a person looking at the “S” roof tile  21 , the roof tile appears like other “S” roof tiles  19  with the exception of the riser  22 . The “S” roof tile  21  is installed onto the roof  20  by removing an existing roof tile and then installing the “S” roof tile  21  onto the roof sheeting with nails, screws or the like. Once one or multiple “S” roof tiles  21  are installed the railings can be installed on the riser  22 . The “S” roof tile  21  has a central hole  23  for securing a fastener into the riser. The riser  22  can have a threaded stud that extend out the top  25  of the riser  22  for securing a railing system. It is contemplated that the hole  23  can be a blind hole wherein an installer can bond a stud or drill through the blind hole  23  to install or bond a fastener. It is also contemplated that the hole can include a threaded nut or other fastener. 
         [0028]    The riser  22  has a plurality of ribs  24  that extend from the top “S” body of the tile to the side of the riser  22 . In this embodiment, four ribs, but more or less than four ribs are contemplated. Other rib shapes such as fillets or radius or rounds are contemplated that provide structural strength to the riser  22  to support the railing and the solar panels that will be secured to the riser. 
         [0029]    Most roof securing structures are made from ductile metals that can flex under temperature, weather, environmental condition and compression loads. The bonding agent can be recycled tires, epoxy or silicon. This is somewhat in contrast to standard “S” roof tiles  21  that are made from cast cement or concrete. To allow the “S” roof tile  21  with an integrated riser  22  to have longevity on a roof with the “S” roof tile  21  is formed with an embedded wire mesh and or the aggregate that the “S” roof tile  21  is made from steel or a composite of material that may include plastic, clay, sand, concrete, cement, rubbers or recycled tires. These materials make the “S” roof tile  21  less brittle and able to operate as equivalent to a metal riser. The “S” roof tile  21  provides a flexible post for securing a rail system for securing solar panels. In this figure a threaded rod  40  or similar member is shown extending through a central hole  23  from the top of the riser  22 . Rails can be secured to the rod  40  and solar panels can then be secured to the rod  40   
         [0030]      FIG. 2  shows a top view of an “S” roof tile  21  with an integrated riser, and  FIG. 3  is a cross-section of the roof tile from  FIG. 2  cut through lines  3 - 3 . The top view shows the riser and ribs  24  that support the riser. The central hole  23  in this embodiment has an open bottom hole  30  with a skin  33  between the upper hole  23  and the lower hole  33 . This would allow a stud to be bonded into the upper hole  23 . The tile  21  can be formed without the skin  33  and a stud  40  integrated into the tile  21 , because the hole is filled with an insert material can&#39;t pass through the hole when the solar panel and railing system is secured to top surface  25 , of the roof tile  21 . The top surface of the tile  21  is cosmetic, while the underside includes one or more structural ribs  27  or details. 
         [0031]    The underside of the S roof tile also has a plurality of ribs  28  that displace loads on the riser. The loads on the riser  25  are distributed down the riser through the upper wall of the tile and into the rib structure under the “S” wall. The distribution of the loads from the riser to the roof sheeting prevents damages of loads on the riser from fracturing the area where the riser joins the top surface of the tile  21 . The ribs  28  on the underside also have clearance areas  29  that both allow for drainage and lighten the tile  21 . Ribs  28  and  27  lift the surface of the tile above the roof to allow for some natural air circulation. The edges of the tile have surfaces  31  and  32  that allow for interconnection of adjacent tiles to nest. One or a plurality of holes  26  allow for securing the tile  21  to the roof sheeting, rafters or studs. It is further contemplated that additional blind holes  34 , passageways or indentations can be located in the ribs to further secure the tile. These holes  34  or recesses are “blind” until they are penetrated. The holes are blind to prevent water penetration, but provide a starting location for drilling and/or insertion of a fastener. These features can be caulked to seal the openings. 
         [0032]      FIG. 4  shows a rail for a solar panel array using the roof tiles  19  and roof tiles  21  with integrated risers. This figure is the typical view of a roof  20  that would include multiple risers that have the supporting rails  50  secured to the top risers on studs  40  that would be secured with a nut  51  or other hardware. Additional structure is secured to the rails  50  and the solar panels are then secured to the railing system. The solar panels are then electrically connected from the solar panels to inverters and then to the house wiring or batteries. The roofing tiles  19  and  21  are secured to the roof sheeting and rafters and supply sufficient structural strength to keep the solar panels secured through weather conditions. 
         [0033]    There are essentially three basic types of popular roofing tiles. The most common types are the previously disclosed “S” tiles the flat version shown in  FIG. 5  as a perspective view of a flat roof tile with an integrated riser and “W” style roofing tiles. 
         [0034]      FIG. 5  shows a top perspective view of a flat roof tile with an integrated riser and  FIG. 6  is the underside of the flat roof tile from  FIG. 5 . This roof tile is essentially flat or parallel between the top and bottom surface, on the riser has supporting ribs  64  that extend from the riser to the top surface of the roof tile. The underside of this tile has a number of parallel ribs  67  that support the tile on a roof and also reduce the amount of material that is being used and the therefore also reduces the weight of each flat roof tile. 
         [0035]    The riser  62  has a plurality of ribs  64  that extend from the top of the tile  61  to the side of the riser  62 . In this embodiment, four ribs, but more or less than four ribs are contemplated. Other rib shapes such as fillets or radius or rounds are contemplated that provide structural strength to the riser  62  to support the railing and the solar panels that will be secured to the riser. The top surface of the tile  61  is cosmetic, while the underside includes one or more structural ribs  67  or details. 
         [0036]    Most roof securing structures are made from ductile metals that can flex under temperature, weather, environmental condition and compression loads. This is somewhat in contrast to standard flat roof tile that are made from cast cement or concrete. The tile body may be made up of any of the commercially available materials (such as clay, plastic or glass) and may be with industry standard specifications. It is also contemplated that the tile can be formed from steel or aluminum metal. In other words, each of the dimensional specifications (such as length, width, height and curvatures, externally and internal) of the tile body may be set as an industry standard and is manufactured according to these standard dimensions. Some of the tile bodies that fit into the edges of the roof or on the top most edge of the roof may have slightly different designs from the one illustrated. 
         [0037]    To allow roof tile  61  with an integrated riser  62  to have longevity on a roof, the roof tile  61  can be formed with an embedded wire mesh and or the aggregate that roof tile  61  is made from a composite of material that may include clay, sand, plastic, rubbers or recycled tires. These materials make the roof tile  61  less brittle. The tile can also be formed from sheet metal or cast. The roof tile  61  provides a flexible post for securing a rail system for securing solar panels. A threaded rod or other securing member can be bonded or integrated into the central hole  63 . The hole can extend partially or completely through the roof tile  61 . Rails can be secured to the threaded rod or other securing member and solar panels can then be secured onto the top surface  65  of the riser  62 . 
         [0038]    The edges or side areas  66 ,  71  of the tile  61  allow for joining or interconnection with other tiles. A supporting rib  68  is located under the riser to support weight placed on the riser  62 . It is contemplated that one or more slots can be placed in this rib to promote air circulation and or drainage under the tile. Hole  69  allow for the tile  61  to be secured to the roof sheeting, rafters or studs. It is further contemplated that additional holes  72 , passageways or indentations  73  can be located in the ribs to further secure the tile. These holes  72  or recesses are “blind” until they are penetrated. The holes are blind to prevent water penetration, but provide a starting location for drilling and/or insertion of a fastener. These features can be caulked to seal the openings. 
         [0039]    The tile roof institute has installation of theses such roofing products to have base flashing in to tar paper to ensure the penetration is water proof under the tile. The roofing tile with integrated riser has an outer seal and an inner seal that compresses when the roofing tile is secured to the roof deck to seal the roof tile with integrated riser to pre-existing tar paper thereby eliminating the need to sub-flash the roofing and to make the tile a replacement tile with a built-in riser mount. 
         [0040]      FIG. 7  shows a formed metal roof tile with an integrated riser. This embodiment uses metal formed tile  80  where the formed tile is made from steel or aluminum. The forming of the tile allows the tile to be nested with adjacent existing roof tiles  19 . The formed tile  80  has an integrated solid base  84  that fills the void under the formed tile  80 . The riser area  81  elevates the stud above the tile face. The riser  81  is shown with an angle bracket  82  that is secured with a fastener  83 . Alternative brackets  82  can be used depending upon the needs of the installation. The formed tile  80  is mounted to roof sheeting  89  in a manner that is consistent with roof tile mounting. 
         [0041]    Thus, specific embodiments of a roof tile with an integrated riser have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.