Patent Publication Number: US-2018030716-A1

Title: Modular roof mounting system

Description:
BACKGROUND 
     Technical Field 
     The present invention relates to structures for mounting panels and creating enclosed spaces above roofs and, more particularly, to a modular system for mounting such panels on existing roofs without the need for significant retrofit or construction. 
     Description of the Related Art 
     As city population density increases and cities themselves expand to occupy additional land area, the impact of cities on the environment increases. In particular, the effect of city space on land albedo, green spaces, and heat entrapment can be significant. As a result, a sustainable architecture movement has arisen that seeks to minimize the negative environmental impact of buildings. 
     One prominent feature of sustainable architecture is to maximize the utility of otherwise unused roof spaces. Buildings are increasingly being designed or retrofitted to include, for example, green spaces or solar panels to minimize the environmental impact of the building and to obtain some ecological or energy production benefit from what would otherwise be a barren, flat area. In particular, flat roofed buildings in dense urban areas prove challenging and expensive due to their relative small footprint, the multiplicity of mechanical and building service obstructions, fire code limitations, and zoning restrictions. 
     However, introducing such features to existing buildings can be prohibitively expensive, as existing solutions often must be custom-built canopies and racking structures to fit the particular roof in question and require significant expertise in design and construction. This limits the proliferation of sustainable and renewable energy development. 
     SUMMARY 
     A structure includes a mounting system configured to mount the mounting structure to an existing architectural feature. One or more legs are each connected to the mounting system. One or more wishbone structures, each including three flat sections connected at fixed angles with respect to one another, have end sections that are parallel to one another. Each wishbone structure is connected to one of the one or more of legs. 
     A structure includes a mounting system configured to mount the structure to an existing architectural feature. A plurality of legs are each connected to the mounting system. A plurality of wishbone structures are connected to a central spine, with wishbone structure having three flat sections connected at fixed angles with respect to one another. The end sections of each wishbone structure are parallel to one another. Each wishbone structure is connected to one of the plurality of legs at a first end by an insert that slots into the leg and the wishbone structure and to the central spine at a second end by a splice connection that inserts into the wishbone structure. 
     A structure includes a mounting system that has a pair of mounting plates and one or more tension bars connecting the pair of mounting plates. The mounting system is configured to mount the structure to an existing architectural feature. A plurality of legs are each connected to the mounting system. A central spine includes a plurality of spine pieces connected to one another by splice connections. A plurality of wishbone structures are connected to the central spine. Each wishbone structure has three flat sections connected at fixed angles with respect to one another, with end sections of each wishbone structure being parallel to one another. Each wishbone structure is connected to one of the plurality of legs at a first end by an insert that slots into the leg and the wishbone structure and to the central spine at a second end by the splice connections, which insert into respective wishbone structures. 
     These and other features and advantages will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       The disclosure will provide details in the following description of preferred embodiments with reference to the following figures wherein: 
         FIG. 1  is a diagram of a mounting system in accordance with the present principles; 
         FIG. 2  is a diagram of a wishbone structure that forms a part of the mounting system in accordance with the present principles; 
         FIG. 3  is a diagram of a joint between two wishbone structures and a leg of the mounting system in accordance with the present principles; 
         FIG. 4  is a diagram of an internal joint between two wishbone structures and the central spine of the mounting system in accordance with the present principles; 
         FIG. 5  is a diagram of an end joint between two wishbone structures and the central spine of the mounting system in accordance with the present principles; and 
         FIG. 6  is a diagram of the base plates and tension rods of the mounting system in accordance with the present principles. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present principles provide a modularly expandable framework for construction on rooftops that fits onto existing roof structures and provides a strong, lightweight, easy-to-assemble mounting system that facilitates the installation of solar panels on existing rooftops with a minimum of effort. 
     The present embodiments provide, in particular, a “wishbone” upper framework using modular pieces angled to provide support for a significant amount of weight. In addition, the present embodiments employ a mounting system that does not involve making incisions in the roof membrane or the construction of a new structure. Instead, the present embodiments make use of existing roof parapets to support the weight of the framework and any panels mounted thereto. It should be recognized that, although the present embodiments are described in the specific context of roof-mounted environments, it should be understood that the present principles may be applied equally to other contexts. Furthermore, the structural shape of the wishbone framework is designed to withstand heavy wind and snow loads, making the structure durable and suitable for year-round outdoor use. 
     Referring now to  FIG. 1 , a perspective view of a mounting system  100  is shown. The mounting system includes a set of wishbone structures  102 . Each wishbone structure  102 , described in greater detail below, is attached to neighboring wishbone structures  102  and to a central spine  106  via splice connections  104 . The wishbone structures  102  are furthermore attached to upright supports  108  via inserts  105 . The central spine  106  is itself formed from a series of individual pieces  107 , joined together at their respective ends by the splice connections  104 . The top and bottom edges of the wishbone structures  102  are configured to establish a plane to which additional structures, such as solar panels or decorations, may be mounted. 
     The legs  108  are supported at their bottom ends by base plates  110 . The base plates  110 , in turn, may be mounted to existing roof structures and will be described in greater detail below. Between the base plates  110  are one or more tension bars or cables  112 , configured to provide a constant force on the base plates  110 . In particular, without the tension bars  112 , the mounting system  100  would exert an outward lateral force on the existing roof structures. In such a scenario, even movement by a fraction of an inch could cause the existing roof structures to crack. The tension bars  112  prevent this outward force from reaching the roof structures, creating a closed loop in the mounting system  100 . In this manner, the mounting system  100  is stably attached to the roof, for example by mounting the base plates  110  to existing parapets, without destructive changes to the roof surface itself. Since the existing roof structures are not likely to be perfectly level to one another, the base plates  110  with the connected tension bars  112  act as a single structure to establish a completely level surface between the parapets. Additionally it should be noted that, although the tension bars  112  are described herein as being rigid bars connected by an adjustable splicing piece  114 , cables or wires may be used instead. 
     It should be understood that the mounting system  100  shown in  FIG. 1  is just one configuration that is possible according to the present embodiments. Applicants contemplate that smaller configurations are possible, for example by excluding the outermost pairs of wishbone structures  102 , and that larger configurations are also possible, for example by repeating wishbone structures  102  with additional legs  108  and additional base plates  110  or, alternatively, longer base plates  110 . 
     As such, there is significant flexibility in the dimensions of the mounting system  100 . Along a longitudinal dimension (defined as the dimension parallel to the central spine  106 ), the length can be increased by addition additional wishbone structures  102 , spine pieces  107 , and splice connections  104 . Along a perpendicular dimension (defined as the dimension perpendicular to the central spine  106  in the plane defined by the wishbone structures  102 ), the length can be increased by mounting the wishbone structures  102  to the splice connections  104  at different points and the splice connections  104  and/or wishbone structures  102  themselves can be increased in length. In an alternative embodiment, the size of the mounting system  100  can be increased with the addition of one or more additional central spines, with connections between the central spines for stability. 
     In one specific embodiment of the particular configuration shown in  FIG. 1 , it is contemplated that the mounting plates  110  may have a longitudinal length of about 12 feet, that the entire mounting structure  100  may have a longitudinal length of about 20 feet, and that the entire mounting structure  100  may have a perpendicular length of about 18 feet to about 25 feet, with an overall height of about 10 feet. One notable advantage provided by the present embodiments is that the pieces that make up the mounting structure  100  may be made small enough and light enough to be carried up the stairs of a typical townhouse. This makes the use of an expensive crane to transport the structure to a rooftop unnecessary. 
     Referring now to  FIG. 2 , additional detail on the wishbone structure  102  is shown. The wishbone structure  102  is formed from three planar segments, connected to one another at respective angles. It should be noted that, although the segments are described separately herein, they may be formed from one contiguous piece of material. A first wishbone segment  202  has a vertical width that is less than that of the other wishbone segments and is configured to connect to one of the legs  108  via an insert  105 . The first wishbone segment  202  is formed from two parallel plates  203  that define an interior space into which the insert  105  mounts. The first wishbone segment  202  furthermore has mounting holes  204  through which a bolt may be passed to attach the insert  105 . Positioning the inserts  105  inside the interior space increases structural strength at the joints while maintaining a thin profile for aesthetic purposes. 
     It should be understood that, while bolts are described herein as being used to connect the pieces of the mounting system  100  together, alternative means of connection may be used instead. Examples of such alternative means may include friction fittings and welding. 
     The first wishbone segment  202  connects to second wishbone segment  206  at a bend  205 . Each of the parallel plates  203  conform to the bend  205  to allow the insert  105  to continuously fill an initial portion of the second wishbone segment  206 . The second wishbone segment  206  has a vertical width that increases from the vertical width of the first wishbone  202  segment to the vertical width of the third wishbone segment  210 . This increase in vertical width may be continuous or graduated, may be linear or curvilinear, and may occur over the entire length of the second wishbone segment  206  or, as shown, over only an interior length of the second wishbone segment  206 . The second wishbone segment  206  also includes mounting holes  204  to provide a strengthened connection to the insert  105 . 
     It should be understood that the configuration of the insert  105  need not extend to the second wishbone segment  206  at all. In alternative configurations, the insert  105  may be limited to the first wishbone segment  202 , with the second wishbone segment  206  forming a solid piece where the parallel plates  203  meet it. Outside of the initial portion of the second wishbone segment  206 , where the insert  105  is mounted, it is contemplated that the second wishbone segment  206  is formed from a single piece of material or, alternatively, may be formed from multiple pieces that are welded together, with an optional channel  208  being formed in an underside thereof to provide space for the routing of wires, cables, lighting, aesthetic details, or other structures. The channel  208  may be present on both sides of the wishbone structure  102  or may be present only on a top edge or bottom edge. 
     The second wishbone segment  206  connects to the third wishbone segment  210  at a bend  209 . The third wishbone segment is formed from parallel plates  212 , which form an interior space that is filled by a splice connection  104 . The third wishbone segment  210  includes mounting slots  214 . According to one specific embodiment, the mounting slots  214  have a length in the horizontal direction that is greater than their length in the vertical direction, providing the ability to mount the splice connection  104  at various points along the length of the third wishbone segment  210 . 
     In one specific embodiment, it is contemplated that the wishbone structures  102  may be formed from aluminum, to benefit from that material&#39;s lightweight strength, resistance to corrosion, and aesthetic appearance, but it should be understood that any appropriately rigid material may be used instead. It is specifically contemplated that carbon fiber may be used as an alternative to aluminum, with wood and steel also being contemplated. In addition, it although it is specifically contemplated that the segments of the wishbone structures  102  may be flat, to make bending possible with minimal distortion, curved or tubular structures may be used instead. 
     In the specific example described above with respect to  FIG. 1 , exemplary dimensions of the wishbone structures  102  may have bends  205  and  209  that are about 30°, with the first bend  205  turning the second wishbone segment  206  out of parallel with the first wishbone segment  202  and with the second bend  209  turning the third wishbone segment  210  back into parallel with the first wishbone segment  202 . It should be understood that any appropriate angle may be used, but it is specifically contemplated that both the first and third wishbone segments  202  and  210  may be arranged in parallel to make it easier to modularly expand the mounting structure  100  with the addition of more wishbone structures  102 . As can be seen from the figure, the wishbone structure&#39;s vertical dimension changes across the segments, with one exemplary embodiment having a 6″ vertical dimension where the wishbone structure  102  meets the leg  108  and a 12″ vertical dimension where the wishbone structure  102  meets the central spine  106 . Referring now to  FIG. 3 , additional detail is provided on the joint between the wishbone structures  102  and a leg  108 . In particular, insert  105  is shown forming a joint between a first wishbone structure  302  and the leg  108 . However, as shown in  FIG. 1 , a second wishbone structure  304  is also attached. In one embodiment (not shown), the insert  105  may have a double-pronged configuration such that it can attach to both wishbone structures  102  simultaneously. However, in the embodiment shown, a second insert  306  is used in the second wishbone structure  304  to provide structural support to that wishbone structure for the purpose of attaching the second wishbone structure  304  to the first wishbone structure  302 . In this manner, a single bolt can pass through the holes  204  of the first and second wishbone structures  302  and  304  as well as insert  105  and insert  106  to securely connect all of the pieces together. 
     As noted above, the wishbone structures  102  may be formed from any appropriately rigid material. It is specifically contemplated that the inserts  105  and  306  may be formed from steel or some other strong material. It is also contemplated that inserts  105  and  306  have a bend in them to match the bend  205  of the wishbone structure  102  (e.g., about) 30°. 
     Referring now to  FIG. 4 , additional detail is shown on how the wishbone structures  102  connect to the central spine  106  at a first type of splice connection  104 . In particular,  FIG. 4  illustrates an internal splice connection  402 , having a main body  404  that connects to the third wishbone segment  210  of two respective wishbone structures  102  and further having connecting fins  406  that connect to the spine pieces  107  on either side of the internal splice connection  402 . The mounting slots  214  on the third wishbone segment  210  of the respective wishbone structures align with holes on the main body  404  of the internal splice connection  402 . Mounting holes  408  on the spine pieces  107  similarly align with holes on the connecting fins  406 . 
     Referring now to  FIG. 5 , additional detail is shown on how the wishbone structures  102  connect to the central spine  106  at a second type of splice connection  104 . In this case, a T-splice connection  502  has a main body  504  and a connecting fin  506 . The T-splice connection  502  is used for wishbone structures  102  at the outside of the mounting structure  100 . The central spine  106  ends at such connections, so only one connecting fin  506  is needed. The T-splice connection  502  connects to the spine piece  107  and to the third wishbone segment  210  of the wishbone structures  102  in the same manner as the internal splice connection  402  discussed above. 
     Referring now to  FIG. 6 , additional detail is shown on how the legs  108  connect to the mounting plates  110 . In particular, the legs  108  attach to upright structural mounting tabs  602  and are connected by means of bolts through holes  612 . The upright structural mounting tabs  602  fit into an interior space of the legs  108  and may be formed as a single unit with the mounting plates  110  or may, alternatively, be separate pieces that are themselves attached to the mounting plates  110 . The legs  108  angle outward in the longitudinal dimension to minimize the footprint of the mounting plates  110 . The legs  108  furthermore angle inward in the perpendicular dimension to avoid conflicts that may be present on the existing structures, such as vent pipes or chimneys. 
     The mounting plates  110  themselves include a horizontal portion  604  and a vertical portion  606  that meet at an angle. It is specifically contemplated that the horizontal portion  604  and the vertical portion  606  meet at a right angle, but it should be understood that other angles are also possible. It should be understood that, although the upright structural mounting tabs  602  are shown as being connected to the horizontal portion  604 , they may alternatively be connected to the vertical portion  606 . The use of continuous mounting plates  110  along each side of the mounting structure  100  simplifies levelling and installation, as only one piece is needed per side (as opposed to using a separate mounting plate for each leg  108 ). In an alternative embodiment, however, each leg  108  may have a separate mounting plate  110 , for example to accommodate a scenario where a chimney on a parapet would prevent the installation of a single, continuous mounting plate. 
     A series of attachment holes  608  are spaced along the vertical portion  606 . The attachment holes  608  provide points for bolts to pass through the mounting plates  110  to attach the mounting plates  110  to a fixed structure such as, e.g., the parapets of a building&#39;s roof. A hole may be drilled into the parapet at the point of each roof attachment hole  608  to accommodate the bolt. When mounted on a fixed structure, the horizontal portion  604  rests on a top surface of the structure and the vertical portion  606  presses against a sidewall of the structure. In an alternative embodiment, the attachment holes  608  may be formed on the horizontal portion  604  such that a bolt may be put down into the fixed structure vertically. In an alternative embodiment, the mounting plates may have only horizontal portion  604  or only a vertical portion  606 . 
     Expansive tension bars  112  are attached to the mounting plates  110  at attachment points  610  and maintain a hard connection between opposing mounting plates  110  to simplify the leveling process. It is specifically contemplated that the attachment points  610  may be formed as a single piece with the mounting plates  110 , but it should be understood that other configurations are possible, where the attachment points  610  are separate structures that are attached to the mounting plates  110  in turn. The expansive tension bars  112  may be any variety of tension bar that is configured to prevent an outward force on the mounting plates  110 . 
     The mounting system  100  provides a modular, expandable framework not only for the mounting of solar panels and other structures/architectural elements (e.g., functional shading by fabric or purely aesthetic elements) on top, but also for creating a usable space underneath. In particular, the shape created by the base plates  110  and attached legs  108  is fixed, making it possible to build and install modular attachments to the mounting system  100  such as, e.g., furniture, lighting, planters, and adornments. It is also contemplated that a deck may be installed to create flooring in the mounting system  100 . Such a deck may span the entire width of the roof, with the addition of structural elements spanning from one mounting plate  110  to another. Such structural elements may include wood or metallic joists or trusses. The mounting plates  110  may include holes to facilitate mounting such structures, or may alternatively include pre-welded brackets or threaded rods. The deck may be formed from individual planks or, alternatively, may form a grid with modular pieces that provide openings for the modular installation of different flooring materials. In one example, a region of the deck may be used by a container for grass or a water feature. 
     Reference in the specification to “one embodiment” or “an embodiment” of the present principles, as well as other variations thereof, means that a particular feature, structure, characteristic, and so forth described in connection with the embodiment is included in at least one embodiment of the present principles. Thus, the appearances of the phrase “in one embodiment” or “in an embodiment”, as well any other variations, appearing in various places throughout the specification are not necessarily all referring to the same embodiment. 
     It is to be appreciated that the use of any of the following “/”, “and/or”, and “at least one of”, for example, in the cases of “A/B”, “A and/or B” and “at least one of A and B”, is intended to encompass the selection of the first listed option (A) only, or the selection of the second listed option (B) only, or the selection of both options (A and B). As a further example, in the cases of “A, B, and/or C” and “at least one of A, B, and C”, such phrasing is intended to encompass the selection of the first listed option (A) only, or the selection of the second listed option (B) only, or the selection of the third listed option (C) only, or the selection of the first and the second listed options (A and B) only, or the selection of the first and third listed options (A and C) only, or the selection of the second and third listed options (B and C) only, or the selection of all three options (A and B and C). This may be extended, as readily apparent by one of ordinary skill in this and related arts, for as many items listed. 
     Having described preferred embodiments of file transfer using an in-browser staging database (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments disclosed which are within the scope of the invention as outlined by the appended claims. Having thus described aspects of the invention, with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims.