Abstract:
A bracket for installing photovoltaic modules on a tile roof. The bracket can have a base portion adapted to sit on a flat roof surface below a tile. A pair of curved portions above the base portion can be supported by a pair of vertical portions. A riser portion can be connected to the pair of curved portion and rising in a direction perpendicular to a roof surface. A flange can be connected to and be perpendicular to the riser portion and parallel to the base.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/063,266, filed on Oct. 13, 2014, which is incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The instant invention relates generally to photovoltaic systems (“PV” or “solar”) and in particular to PV mounting systems for tiled roofs. 
         [0003]    There are many systems available for mounting photovoltaic (PV) modules to building structures, such as a roof. These systems serve as a rigid interconnection element between a roof and a PV module to hold the modules in place and resist the forces of gravity and wind. 
         [0004]    Tile roofs (e.g., concrete, ceramic, etc.) present a unique challenge for installing photovoltaic panels as compared to shingled or composite roofs. This is primarily due to the fact that tiles are rigid, brittle, cannot simply be drilled/nailed/screwed through, and in some cases because they are curved. In order to provide the requisite stability and resistance to wind, photovoltaic arrays must be directly or indirectly attached to underlying roof surface and into the supporting roof rafters. In order to accomplish this on a tile roof, it is typically necessary to remove one or more tiles to expose the roof surface so that base mounting hardware can be securely attached to the roof deck. Therefore, known solutions for mounting PV panels onto tiled roofs are often relatively more expensive to manufacture as well as potentially far more time consuming compared to the systems used on composite shingle roofs. 
         [0005]    One solution to this problem has been a hook that attaches to roof surface, between upper and lower tiles in adjacent courses in the down-roof direction, and then hooks around back over the tile under which the hook is anchored. An example of this is hook  10  shown at  FIG. 7 . Additional mounting hardware can then be attached to hook  10  via one or more holes or other features located at distal end  12 . A disadvantage of this solution is that because of relatively flat and narrow width W of hook  10 , it must be relatively thick T to provide the requisite strength. Therefore, the use of conventional tile hooks often requires cutting or breaking off a portion of the elevating stand of the tile over the hook under which the hook must pass. Although effective, this solution is messy, imprecise and potentially requires the use of additional power tools on the roof. Also, in order to provide sufficient strength over it&#39;s relatively narrow profile, it must be very thick, increasing the material and transportation costs associated with making and using traditional tile hooks. 
         [0006]    Accordingly, there is a need for a robust photovoltaic mounting system for tile roofs that improves upon existing tile hook-based solutions. 
       BRIEF SUMMARY OF THE INVENTION 
       [0007]    Some embodiments of the invention are related to a bracket for supporting photovoltaic modules on a tile roof. 
         [0008]    In some embodiments, the bracket can include a base portion adapted to sit on a flat roof surface below a tile; a pair of curved portions above the base portion can be supported by a pair of vertical portions; a riser portion can be connected to the pair of curved portion and rising in a direction perpendicular to a roof surface; and a flange can be connected to and be perpendicular to the riser portion and parallel to the base. 
         [0009]    In some embodiments, the base portion can have one or more apertures that allow one or more fasteners to pass through the base portion into a roof surface. 
         [0010]    In some embodiments, one of the curved portions can be substantially convex and the other can be substantially concave. 
         [0011]    In some embodiments, the pair of curved portions can be adapted to fit between two overlapping tiles in two successive tile courses. 
         [0012]    In some embodiments, the flange can float above at least a portion of a roof tile covering the base portion. 
         [0013]    In some embodiments, the flange can include one more mounting holes for mounting additional photovoltaic module mounting hardware. 
         [0014]    In some embodiments, the bracket can include a base portion; a plurality of vertical portions can extend vertically from the base portion; a plurality of shaped portions can extend horizontally from the plurality of vertical portions; a riser portion can extend vertically from the plurality of curved portions; and a mounting flange can extend in cantilever from riser portion. 
         [0015]    In some embodiments, the base portion can have one or more apertures that allow one or more fasteners to pass through the base portion into a roof surface. 
         [0016]    In some embodiments, the plurality of shaped portions can be convex and concave curved portions. 
         [0017]    In some embodiments, the plurality of shaped portions can be adapted to fit between curved sections of overlapping tiles. 
         [0018]    In some embodiments, the flange can include one more mounting holes for mounting additional photovoltaic module mounting hardware. 
         [0019]    In some embodiments, the mounting flange can extend horizontally towards the base portion. 
         [0020]    In some embodiments, the bracket can include a base portion for attaching to a structure; first and second angled portions can extend vertically from the base portion; a concave member can extend horizontally from the first angled portion; a convex member can extend horizontally from the second angled portion; a riser portion can bridge ends of the concave and convex members; and a mounting flange can extend horizontally from riser portion. 
         [0021]    In some embodiments, the base portion can have one or more apertures that allow one or more fasteners to pass through the base portion into a roof surface. 
         [0022]    In some embodiments, the convex member can be positioned higher above the base than the concave member. 
         [0023]    In some embodiments, the convex member can be configured to fit between overlapping convex sections of adjoining tiles. 
         [0024]    In some embodiments, the concave member is configured to fit between overlapping concave sections of the adjoining tiles. 
         [0025]    In some embodiments, the riser portion can be configured to extend towards the mounting flange at a joint between the adjoining tiles. 
         [0026]    In some embodiments, the mounting flange can extend horizontally from riser portion in a direction towards the base portion. 
         [0027]    In some embodiments, the convex and concave members can extend horizontally towards the riser portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0028]      FIG. 1  is a perspective view of a bracket for supporting photovoltaic modules installed on a tile roof, according to some embodiments of the invention. 
           [0029]      FIGS. 2-4  are perspective views of a bracket for supporting photovoltaic modules on a tile roof, according to some embodiments of the invention. 
           [0030]      FIG. 5  is another perspective view of the bracket of  FIG. 1 . 
           [0031]      FIG. 6  is a perspective view of brackets supporting photovoltaic modules on a tile roof, according to some embodiments of the invention. 
           [0032]      FIG. 7  is a perspective view of a prior art tile hook. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    The following description is intended to convey a thorough understanding of the embodiments described by providing a number of specific embodiments and details involving PV mounting hardware for sloped tile roofs. It should be appreciated, however, that the present invention is not limited to these specific embodiments and details, which are exemplary only. It is further understood that one possessing ordinary skill in the art, in light of known systems and methods, would appreciate the use of the invention for its intended purposes and benefits in any number of alternative embodiments, depending upon specific design and other needs. 
         [0034]      FIG. 1  illustrates exemplary hook and flashing bracket  100  for photovoltaic module installation on tile roofs according to various embodiments of the invention. Bracket  100  can be a rigid assembly formed from steel, aluminum, or other rigid, corrosion resistant material. In some embodiments, bracket  100  may be press formed from a sheet of material, such as steel or aluminum, and coated or painted with a corrosion resistant material. In other embodiments, bracket  100  may be forged, stamped, cast, molded, assembled, or otherwise formed from a metal, plastic polymer, or fiber/particle reinforced resin. However, the specific manufacturing technique for bracket  100  is not critical to the various inventive embodiments. By creating a hook and flashing that not only prevents water from reaching the roof surface  200 , but also that provides structural support by spanning substantially the entire width of a tile, bracket  100  can be thinner than a conventional tile hook, eliminating the need to remove material or cut tiles for installation. 
         [0035]    As shown at  FIGS. 1 and 5 , bracket  100  fits into a course of tiles in a curved tile roof under one of the tiles located above the location of roof rafter  201  (e.g., 2×4, 2×6, 2×8, 2×10 studs supporting the roof surface). In some embodiments, this may require completely removing or simply sliding the tile directly above bracket  100  in the up-roof direction to reveal roof surface  200  so that bracket  100  can be attached to roof surface  200 , as discussed in greater detail below. If the tile is simply slid upward under the next up-roof tile, that tile is then returned down-roof until it hits bracket  100 , with bracket  100  passing between that tile and the next down-roof tile upon which that tile rests. The tile should return to the same position with respect to the other surrounding tiles in that row. In various embodiments, roof surface  200  can be formed from plywood, composite wood, or other suitable material. In some embodiments, roof surface  200  may also include an outer layer of tarpaper or other vapor barrier (not shown). 
         [0036]      FIGS. 2, 3, and 4  provide isolated views at different angles of bracket  100  according to some embodiments of the invention. Bracket  100  depicted in these figures includes base portion  101  for mounting on a bare roof surface, either directly on wood roof surface  200  or over a layer of tarpaper or other vapor barrier. In some embodiments, base portion  101  will contain apertures  102  running from left to right that enable a number of lag screws or other fasteners to pass through base portion  101  at a various locations ideally penetrating at least one roof rafter  201 . 
         [0037]    Moving upwards and away from base portion  101 , bracket  101  includes portions  103 A and  103 B that rise up from base portion  101  to stepped curved portions  104 A,  104 B. Portions  103 A and  103 B may begin extension towards stepped curved portions  104 A,  104 B from base portion  101  at different lateral distances in a staggered formation so that they can rise at the same angle with respect to base portion  110  because portion  103 B must go higher than  103 A since  104 B goes over the convex (e.g., upper) section of the down-roof tile while  104 A goes over the concave (e.g., lower) portion of the down-roof tile. As best illustrated at  FIG. 2 , portions  103 A and  103 B can extend at angles with respect to base portion  101 , for example ranging from 20-80 degrees. In some embodiments, portions  103 A and  103 B can extend vertically at perpendicular angles with respect to base portion  101 . 
         [0038]    In some embodiments, curved portion  104 A is concave and curved portion  104 B is convex so that they fit between the lower and upper portions of first and second curved tiles, such as tiles  202  shown in  FIGS. 1 and 2 . To that end, in some embodiments, the height of portion  103 A is less than the height of portion  103 B to account for the relative heights of the lower and upper portions of a curved tile with respect to the roof surface  200 . This is particularly visible in  FIG. 4 , which shows a front view of bracket  100 . 
         [0039]      FIG. 4  also illustrates the downward and upward curves dimensioned to match the curves of the upper and lower tiles caused by concave curved portion  104 A and convex curved portions  104 B. Opening  108  formed in bracket  100  allows the structure to fit around the mid-point of a tile where the tile changes from concave to convex, i.e., at point  202 A in  FIG. 5 . Because of the vertical transition shown in this figure, this portion is typically thicker than the remainder of a tile. 
         [0040]    In the embodiment shown, concave curved portion  104 A is located to the left of convex curved portions  104 B, as depicted in the view of  FIG. 3 . Thus, concave curved portion  104 A and convex curved portions  104 B can fit under a single tile. However, in some embodiments, concave curved portion  104 A can be located to the right of convex curved portions  104 B, and thus fit under tiles patterned in the opposite direction of tiles  202  or fit between laterally adjacent tiles  202 . In addition, in some embodiments, concave curved portion  104 A can be arranged to be higher than convex curved portions  104 B, instead of lower as illustrated, again to be compatible with different tiles and/or arrangement of tiles. Other shapes of concave curved portion  104 A and convex curved portions  104 B are possible to match any type of common undulating tile pattern, such as wave tiles, S-tiles, etc. 
         [0041]    Continuing from curved portions  104 A and  104 B, away from base  101 , bracket  100  again rises vertically around opening  108  via vertical portions  105 A,  105 B. As shown in  FIG. 4 , in various embodiments, vertical portion  105 A is larger than portion  105 B so that the two portions terminate at a common height into support flange  106 . Vertical portions  105 A,  105 B can bridge to one another before meeting support flange  106 . In various embodiments, support flange  106  floats above tiles  202  in a plane that is generally parallel with both base  101  and the roof surface  200  (i.e., a the same angle as the roof), and therefore perpendicular to vertical portions  105 A and  105 B. It should be appreciated that flange  106  may included on or more strengthening ribs or other structure under flange  106  or spanning between the underside of flange  106  and vertical portions  105 A,  105 B to provide greater rigidity. 
         [0042]    Flange  106  may include one or more holes, such as holes  107  through which a mounting foot, bar or other photovoltaic module support hardware may be attached. In the example of  FIG. 3 , three holes are shown, however, it should be appreciated that in other embodiments more or fewer holes may be used. In various embodiments additional mounting hardware is mounted to flange  106  by passing a bolt through the flat surface of flange  106  through one of the holes  107  and attaching a nut to the bolt at the bottom side of flange  106 . Alternatively, a bolt may be passed from below up through the bottom of the flange  106  via one of the holes  107  and capped with a nut after passing through a mounting foot or other vertical module support. 
         [0043]    To install bracket  100  onto a preassembled tile roof, an installer is required to first remove a tile  202  of the roof for access to roof surface  200  for each system  100  to be installed. Typically, tiles  202  are not bonded to the roof, and therefore can be slid upwards or even completely removed without much difficultly, although care should be taken to avoid damaging tiles  202 . In cases of bonded or cemented tiles, some demolition may be required to remove tiles  202 . Of course such steps are not required when installing bracket  100  during assembly of a new roof. 
         [0044]    Once access to roof surface  200  is made clear, the installer can determine a proper location to permanently attach bracket  100  to roof surface  200 . Ideally, at least a portion of base portion  101  lays over roof rafter  201 , or other secure roof portions. Interior portions of vertical portions  105 A and  105 B should be aligned to be parallel with, and slightly down-roof of, an exposed edge of a row of adjacent tiles so that vertical portions  105 A,  105 B provide clearance for removed tiles to be placed back into location. Whichever tile bracket  100  overlaps with, can also be used as a guide for proper placement. When placed in a tile opening and partially over the down-roof tile on the roof, the curvature of bracket  100  will orient bracket  100  at the optimal location. 
         [0045]    After proper placement is determined, the installer can permanently attach bracket  100  to roof surface  200  by use of one or more fasteners, such as lag bolts, through apertures  102 . Ideally one or more of the fasteners is attached to roof rafter  201 , or some other secure roof portion. By having an entire row of apertures  102  the changes of one or more being over a roof rafter are greatly increased. Water proofing of any holes made into roof surface  200  should also be considered, such as, for example, by applying sealant to the holes prior to driving a screw, lag bolt or other fastener, as well sealing any errant holes that missed the roof rafter. After bracket  100  has been attached to roof surface  200 , tiles  202  that have been displaced are placed back into location. Tile  202  should be arranged to overlap concave curved portion  104 A and convex curved portions  104 B, as depicted at  FIGS. 1 and 5 . 
         [0046]    Vertical displacement of tiles  202  should be inspected at this point. If the overlapping tile is displaced upward such that a gap is present between tiles, caused by bracket  100  lifting the overlapping tile, then tiles should be removed for modification of the installation. For the example, with bracket  100  still attached to roof surface  200 , the installer can impart a downward force onto flange  106  to downwardly bend bracket  100  where portions  103 A,  103 B meet base portion  101 , and thus reduce any lifting effect bracket  100  imparts to an overlapping tile. In contrast, if bracket  100  is found to adversely compress the underlapping tile, the installer can impart an upward force onto flange  106  to upwardly bend bracket  100  where portions  103 A,  103 B meet base portion  101 , and thus reduce any compression bracket  100  imparts to an underlapping tile. 
         [0047]    After bracket  100  has been properly installed, along with additional similar brackets as necessary, the installer can attach one or more PV module coupling devices to flange  106 . A mounting foot, bar, or other PV module support hardware can be attached through holes  107 . In various embodiments, this is accomplished by passing a bolt through the flat surface of flange  106  through one of the holes  107  and attaching a nut to the bolt at the bottom side of flange  106 . Alternatively, a bolt may be passed from below up through the bottom of the flange  106  via one of the holes  107  and capped with a nut after passing through a mounting foot or other vertical module support. 
         [0048]      FIG. 6  shows a perspective view of bracket  100  in use, according to some embodiments. Here, brackets  100  have been installed between sets of overlapping tiles, and PV module coupling devices  220  have been secured to brackets  100 . PV module coupling device  220  is a “rock-it” style connector manufactured by SolarCity Corp., which is arranged to connect to respective frames of two adjacent PV modules. Such a coupling device is described and illustrated, for example, in commonly assigned U.S. patent application Ser. No. 14/615,320, Publication No. 2015/0155823-A1, the disclosure of which is herein incorporated by reference in its entirety. However, bracket  100  is not limited to use of such a coupling device. A multitude of different styles of coupling devices are compatible with bracket  100 . For example, a wrap-around clamping style coupling device may be used with various embodiments of the invention. 
         [0049]    The embodiments of the present inventions are not to be limited in scope by the specific embodiments described herein. For example, although many of the embodiments disclosed herein have been described with reference to sloped tile roofs, the principles herein may be equally applicable to other types of roofs. Indeed, various modifications of the embodiments of the present inventions, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings and claims. Thus, such modifications are intended to fall within the scope of this invention. Further, although some of the embodiments of the present invention have been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the embodiments of the present inventions can be beneficially implemented in any number of environments for any number of purposes. Accordingly, this disclosure should be construed in view of the full breath and spirit of the embodiments of the present inventions as disclosed herein and claimed below.