Abstract:
Disclosed is a tile roof equipment-mounting device for mounting solar panels and other equipment to tile roofs. The tile roof mount includes a base, a vertical bracket, and a hook arm. The base includes a vertical channel with stepped grooves and a horizontal slot. The vertical bracket has complementary stepped grooves and a vertical slot that engage the vertical channel and horizontal slot of the vertical channel. This combination allows the tile roof mount so that the height is vertically discreetly adjustable and horizontally continuously adjustable.

Description:
BACKGROUND 
     The present disclosure relates to a device for mounting equipment, such as solar panels and other equipment, to tile roofs. 
     Mounting solar panels, such as solar photovoltaic (PV) panels or solar thermal panels, to tile roofs present its own particular set of challenges. Roof tile can be made of a variety of materials such as ceramic, slate, concrete, or clay. These materials can be brittle and therefore do not present a stable mounting surface for solar panels or other roof mounted equipment as it goes through the normal stress of wind and weather. In addition, roof tiles come in a variety of different shapes and styles, for example, flat roof tile, or curved barrel tile. This variation in shape and style also presents challenges for mounting equipment. 
     One solution has been to use a mounting device that includes a base portion in combination with a hook or bracket member. A portion of roof tile is removed to expose the roof sheeting. The base engages and secures the mounting device to the exposed roof directly. The hook or bracket member engages the equipment racking system to the mounting device. Flashing is generally placed on top of the base to prevent water infiltration. The removed tile portion is then re-secured over the base with the top tab of bracket member exposed above the tile to allow equipment or mounting hardware to be attached. 
     One of the challenges with this arrangement is the position of the base is often dictated by the rafters below the roof sheeting and therefore limits the position of roof equipment racking with respect to the roof tile peaks and valleys and the position of the mounting device. 
     SUMMARY 
     The present disclosure describes a device that helps to overcome the challenges of mounting solar panels and other equipment to tile roofs presented in the Background section of this disclosure. In one aspect, the present disclosure describes a mounting device for mounting equipment to a tile roof where the mounting device can be constrained to adjust in discreet steps in two directions and continuously in a third direction after the device is mounted to a tile roof. This allows, for example, an equipment-mounting portion of the mounting device, to be adjusted in three directions relative where the device is attached to the tile roof. This simplifies installation because it allows flexibility in the placement of the equipment racking system relative to mounting device. For example, the mounting device can still be placed so it engages the rafters, as described in the background, but the racking system position is not solely determined by the position of the mounting device as there is some degree of flexibility. The two discrete step adjustments can be along the direction of maximum stress as compared with the continuous step adjustment. This helps assure minimum slippage in the directions of most stress while allowing for a more flexible adjustment along the line of less stress. 
     In another aspect, the present disclosure describes a mounting device for mounting equipment to a tile roof that includes a base, a bracket, and an equipment mounting extension. The base includes an upward projected channel with stepped grooves on the inside of the channel and a complementary pair of longitudinal slots along the length of each side of the channel. The bracket includes a first bracket portion and second bracket portion projecting away from the vertex edge of the bracket. The first bracket portion includes complementary stepped grooves and a slot transverse to its width that engages the channel and longitudinal slot of the upward projected channel. The transverse slot is aligned with the complementary pair of longitudinal slots and joined by a fastener, such as a complementary nut and bolt. When the fastener is engaged but loose, the bracket can be adjusted continuously along the longitudinal slot and in discrete steps up and down the height of the upward projected channel. 
     The second bracket portion includes a U-channel projecting away from the end distal to the vertex edge, and parallel to the plane of the second portion top surface. The U-channel includes toothed inner surfaces with the teeth, or steps, running transverse to the length of the second bracket portion or parallel to the vertex edge defining the width of the second bracket portion. 
     In a further aspect, the toothed inner surfaces of the U-channel are configured to adjustably engage toothed outer surfaces of an equipment mounting extension. In this configuration the equipment-mounting portion acts as an adjustable extension of the second bracket portion. The equipment mounting extension includes an equipment-mounting portion. This can include a slot or an aperture for engaging equipment or can be in the form of an angle bracket, L-bracket, C-bracket, or hook shaped. 
     This Summary introduced a selection of concepts in simplified form relating to a novel device for mounting equipment to tile roofs. The novel device for mounting equipment to tile roofs is described in further detail in the Description. The Summary is not intended to identify essential features or limit the scope of the claimed subject matter. 
    
    
     
       DRAWINGS 
         FIG. 1  shows in partially explode perspective view, a solar panel system and tile roof structure with a device for mounting solar panels and other equipment to the tile roof. 
         FIG. 2  shows in detail perspective view, the device for mounting solar panels and other equipment to the tile roof of  FIG. 1 , with an upper tile removed to expose a mounting plate. 
         FIG. 3  shows, in exploded perspective view, the device of  FIG. 1 . 
         FIG. 4  shows a perspective view of the device of  FIG. 1   
         FIG. 5  shows a side view of the device of  FIG. 1   
         FIG. 6  shows a front view of the device of  FIG. 1 . 
         FIG. 7  shows a top view of the device of  FIG. 1   
         FIG. 8  shows a sectional view of the device of  FIG. 1  taken along section lines  8 - 8  of  FIG. 7 . 
         FIG. 9  shows in perspective view the device of  FIG. 1  with an alternatively equipment mounting portion. 
         FIG. 10  shows a side view of the device of  FIG. 9 . 
     
    
    
     DESCRIPTION 
     The following description is made with reference to figures, where like numerals refer to like elements throughout the several views,  FIG. 1  shows in partially explode perspective view, a solar panel system and tile roof structure  10  with a mounting device  15  for mounting one or more solar panels  11  and other equipment to the tile roof  13 . Solar panels  11  are secured to rails  17  by solar panel end-clamps  19  and solar panel mid-clamps  21 . The rails  17  are secured the mounting device  15 . The mounting device  15  is secured to the tile roof  13  under the roofing tiles  23 . 
     To aid in understanding the mounting device  15  in relation to the tile roof  13  and the rails  17 ,  FIG. 2  shows the mounting device  15  mounted on roof sheeting  25  with roofing tiles  23  removed to expose the mounting device  15  structure. The roof sheeting  25  is typically plywood or tarpaper underlayment over plywood, but can be any material suitable for covering a roof. The mounting device  15  includes a base  27 , an angled bracket  29 , and an equipment-mounting extension  31 . The base  27  is shown mounted to the roof sheeting  25  by wood securing fasteners  33 , such as a wood screw or lag bolt, through apertures  35  in the base  27 . The base  27  includes a base portion channel  37  projecting upward from the plane of the base  27 . One end of the angled bracket  29  is secured to the base portion channel  37 . The equipment-mounting extension  31  is secured to the other end of the angled bracket  29 . The equipment-mounting extension  31  also secures the rail  17  to the mounting device  15  and thereby the roof sheeting  25 . To install the mounting device  15 , a portion of the roofing tiles  23  are removed, exposing the roof sheeting  25 , so that the base  27  can be secured to the roof sheeting  25  directly. Depending on the style of tile roof  13 , a portion of the roofing tile  23  may be cut in order to create a space to place both the angled bracket  29  and the equipment-mounting extension  31 , as illustrated. 
       FIG. 3  shows, in exploded perspective view, the mounting device  15 . Illustrated are the base  27 , the angled bracket  29 , and the equipment-mounting extension  31 , the wood securing fasteners  33  and a gasket  39 . The gasket  39 , which is optional, mounts between the base  27  and the roof sheeting. The gasket  39  includes apertures  35  for passing through the body of the wood securing fasteners  33 . The apertures  35  are similar in size and location as the apertures  35  of the base  27 . 
     The base  27  is shown with the base portion channel  37  projecting upward from the mounting plane of the base  27 . While the base portion channel  37  is shown projecting perpendicularly upward, the base portion channel  37  can project upward at other angles, as required. The base portion channel  37  includes toothed inner surfaces  41 . The teeth or steps run longitudinally along the base portion channel  37  and are approximately parallel to the mounting plane of the base  27 . 
     The angled bracket  29  includes a first bracket portion  43  and a second bracket portion  45 . The first bracket portion  43  includes toothed outer surfaces  47 . The teeth, or steps, run along the width of the angled bracket  29  and parallel to the vertex edge of the angled bracket  29 . These toothed outer surfaces  47  of the first bracket portion  43  of the angled bracket  29  are configured to engage with the toothed inner surfaces  41  of the base portion channel  37 . The angled bracket  29  can be a right angle L-bracket. Alternatively, the angle between the first bracket portion  43  and the second bracket portion  45  can be, for example, between approximately 80-degrees and 100-degrees as required by the installation. 
     The base portion channel  37  includes a first and second opposing slots  49  approximately parallel to the bottom edge of and on opposing surfaces of the base portion channel  37 . The first bracket portion  43  of the angled bracket  29  includes a third slot  51 ; the third slot  51  being transverse to width or longitudinal along the length of the angled bracket  29 . The toothed outer surfaces  47  of the first bracket portion  43  engages toothed inner surfaces  41  of the base portion channel  37  so that the first and second opposing slots  49  and third slot  51  cross at approximately a right angle. The first and second opposing slots  49  and third slot  51  are secured with a machine-threaded fastener  53  and a nut  55  with complementary threading to the machine-threaded fastener  53 . The first and second opposing slots  49  and third slot  51  are positioned so that when the machine-threaded fastener  53  and nut  55  are secured but loose, the angled bracket  29  can be adjusted continuously laterally along the length of the base portion channel  37 , captive in the toothed inner surfaces  41  and can be adjusted in discrete steps along the height of the base portion channel  37 , each step defined by the toothed inner surfaces  41 . 
     The second bracket portion  45  includes a slotted or hollowed end portion forming a U-channel portion  57 . The U-channel portion  57  includes toothed inner surfaces. The equipment-mounting extension  31  includes a first portion  59  with toothed outer surfaces  61  that are configured to engage the toothed inner surfaces of the U-channel portion  57 . The teeth, or steps, run transverse to the length of the first portion  59 . The U-channel portion  57  includes an aperture  35  sized to pass through a machine-threaded fastener  62  and engage a fourth slot  63  in the equipment-mounting extension  31 . The machine-threaded fastener  62  is secured to a threaded portion  65  in the bottom of the U-channel portion  57 . The machine-threaded fastener is shown as a countersunk screw with a hex-head but is not limited as such. For example, the machine-threaded fastener  62  can be a non-countersunk bolt. The machine-threaded fastener  62  can alternatively be a slot-head, Philips, or torx-head screw, for example. 
     The equipment-mounting extension  31  includes a second portion  67  or in the form of an equipment mounting portion. The second portion  67  and the first portion  59  together form an angled bracket. The second portion  67  includes slot  69 , or alternatively an aperture, for securing the mounting device. Referring back to  FIG. 2 , the equipment-mounting extension  31  is secured to the rail  17  by a machine-threaded fastener  53  and a nut  55  through the slot  69 . 
       FIG. 4  shows the mounting device  15  in assembled perspective view.  FIG. 5  shows the mounting device  15  in side view.  FIG. 6  shows the mounting device  15  showing the base portion channel  37  in relation to the base  27  as well as the first and second opposing slots  49  in relation to the base portion channel  37  in front view.  FIG. 7  shows a top view of the mounting device  15  showing the base  27  and the base portion channel  37 , in relation to the angled bracket  29  and equipment-mounting extension  31 .  FIG. 8  shows a sectional view of the mounting device  15  taken along section lines  8 - 8  of  FIG. 7 . Referring to  FIG. 7 , the base portion channel  37  is shown offset in relation to the centerline of the base  27 . This is done in order to provide a larger fastening surface in order to offset the forces or rotational torque applied to the equipment-mounting extension  31  applied by the solar panels, rails, and other roof mounted equipment. The position of the base portion channel  37  can be adjusted or centered, as desired, in order to accommodate different designs of the equipment-mounting extension  31 . 
       FIGS. 4-5 , and  8  show the angled bracket  29  secured to the base  27  with the first bracket portion  43  of the angled bracket  29  engaged with the base portion channel  37  and is secured by the machine-threaded fastener  53  and the nut  55 . The wood securing fasteners  33  are shown with their threaded portions passing through the planar portion of the base  27  and with their heads seated against the planar portion of the base  27 . 
     In  FIG. 5 , the base portion channel  37  is shown with toothed inner surfaces  41 , in side view, engaging the toothed outer surfaces  47  of the first bracket portion  43 . In  FIG. 4 , the first and second opposing slots  49  are shown allowing the angled bracket  29  to slide laterally along the toothed inner surfaces  41 . 
     Referring again to  FIGS. 4-5  and  8 , the second bracket portion  45  of the angled bracket  29 , is shown with the U-channel portion  57  with toothed channels transverse to the length of the second bracket portion  45 . The U-channel portion  57  is shown engaged with the toothed outer surfaces  61  of equipment-mounting extension  31  and secured with the machine-threaded fastener  53  into the threaded portion  65  of the bottom of the U-channel portion  57 . 
       FIG. 9  shows in perspective view the mounting device  15  with an alternatively equipment mounting portion folded over the first portion  59  of the equipment mounting extension  31 .  FIG. 10  shows a side view of the mounting device  15  of  FIG. 9 . In  FIGS. 9 and 10 , the equipment-mounting extension  31  includes an equipment-mounting end portion  71  the projects upward and then inward creating an inverted L-shape or hook shape with respect to the first portion  59  of the equipment-mounting extension  31 . In  FIG. 9 , the equipment-mounting end portion  71  includes a slot  69  or alternatively, a circular aperture, for mounting equipment. In  FIGS. 9 and 10 , the equipment-mounting extension  31 , angled bracket  29  and base  27  are shown in approximately the same relationship as described for  FIGS. 1-8 . 
     A device for mounting equipment, such as solar panels, to tile roof structures has been described. It is not the intent of this disclosure to limit the claimed invention to the examples, variations, and exemplary embodiments described in the specification. Those skilled in the art will recognize that variations will occur when embodying the claimed invention in specific implementations and environments. For example, it is possible to implement certain features described in separate embodiments in combination within a single embodiment. Similarly, it is possible to implement certain features described in single embodiments either separately or in combination in multiple embodiments. It is the intent of the inventor that these variations fall within the scope of the claimed invention. While the examples, exemplary embodiments, and variations are helpful to those skilled in the art in understanding the claimed invention, it should be understood that, the scope of the claimed invention is defined solely by the following claims and their equivalents.