Patent Publication Number: US-7905064-B1

Title: System for attaching an article to a roof and method of use

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a Continuation of and claims the filing benefit under 35 U.S.C. §120 of application Ser. No. 11/529,161, filed Sep. 28, 2006, now U.S. Pat. No. 7,762,027, which is hereby incorporated by reference. 
    
    
     TECHNICAL FIELD 
     The present invention pertains to attaching articles such as photovoltaic panels to the roof of a structure, and more particularly to a system which is installed on the roof to serve as an anchor for the articles. 
     BACKGROUND OF THE INVENTION 
     On occasion it is necessary to attach articles to the roof of a structure. Such articles can include photovoltaic panels (solar panels), communication antennae, air conditioning equipment, heating equipment, and the like. The attachment is usually implemented by installing anchor devices on the roof, so that the article may be connected to the anchor devices. The anchor devices must necessarily penetrate the roof covering (such as shingles) and attach to a roof structural member such as a rafter. To minimize the possibility of water leaks, it is desirable to both minimize the number of roof penetrations and to ensure that the penetrations are water tight. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention is directed to a system for attaching articles such as photovoltaic panels to a roof having shingles disposed on top of a structural member. The system provides a one piece foundation to which the article is attached, and includes a weatherproof flashing member which is rotatably connected to a upright mounting stanchion. A single lag bolt attaches the system to the structural member of the roof, thereby minimizing the possibility of leaks. Some features of the system are:
         The system attaches to an existing roof without the need to remove, replace, or reseal any of the existing roofing. This reduces the potential for waterproofing failure.   The fastening hardware that attaches the system to the roof is directly attached through the existing roofing or new roofing to the roofs rafter framing and is not concealed under any existing part of the roof, thereby allowing for the ease of a visual secure installation.   The stanchion rotates 360 degrees parallel to the plane of the roof, and thus ensures equal integrity of weatherproofing at any angle.   Because of it&#39;s one piece construction, the system saves time and labor costs.   The system obviates the need for a sealing agent such as silicone.   The system universally accepts any solar panel mounting hardware.   The system can be either retro-fit onto an existing roof or installed with a new roof.   The size and shape of the flashing of the system may be varied to, accommodate most types of roofs.   The height of the stanchion may be varied to change the mounting distance from the plane of the roof.       

     In accordance with a preferred embodiment, a system for attaching an article to a roof having shingles disposed on top of a structural member includes a sheet of flashing having an aperture. An upstanding sleeve is connected to the sheet of flashing, the sleeve completely surrounding the aperture. A stanchion is connected to the sheet of flashing, the stanchion having a hole which is shaped and dimensioned to receive the sleeve. A bolt attaches the system to the structural member of the roof. The bolt is received by the hole in the stanchion and the aperture in the sheet of flashing and threadably engages the structural member. 
     In accordance with another embodiment, the stanchion is rotatable with respect to the sheet of flashing. 
     In accordance with another embodiment, the stanchion is 360° rotatable about the sleeve. 
     In accordance with another embodiment, the sleeve is cylindrical. 
     In accordance with another embodiment, the sheet of flashing has a center, and the stanchion is offset from the center of the sheet of flashing. 
     In accordance with another embodiment, the sheet of flashing is slidable underneath the shingles of the roof without the need to remove the shingles. 
     In accordance with another embodiment, a plug seals the hole in the stanchion. 
     Other possible embodiments, in addition to the possible embodiments enumerated above, will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the method and system. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is fragmented top plan view of a roof having shingles to which the system is attached; 
         FIG. 2  is an enlarged fragmented cross sectional view along the line  2 - 2  of  FIG. 1 ; 
         FIG. 3  is an enlarged fragmented view of area  3  of  FIG. 2 ; 
         FIG. 4  is an enlarged exploded fragmented perspective view of the system; 
         FIG. 5  is an enlarged fragmented perspective view of the system; 
         FIG. 6  is a top plan view of a flashing member; 
         FIG. 7  is a side elevation view of the flashing member; 
         FIG. 8  is an enlarged fragmented view of area  8  of  FIG. 6 ; 
         FIG. 9  is a side elevation view of  FIG. 8 ; 
         FIG. 10  is a cross sectional view along the line  10 - 10  of  FIG. 8 ; 
         FIG. 11  is a bottom plan view of  FIG. 9 ; 
         FIG. 12  is an enlarged top plan view of a stanchion; 
         FIG. 13  is an enlarged side elevation view of the stanchion; 
         FIG. 14  is an enlarged bottom plan view of the stanchion; 
         FIG. 15  is an enlarged side elevation view of the stanchion; 
         FIG. 16  is a top plan view of the flashing member and the stanchion; 
         FIG. 17  is a side elevation view of the flashing member and the stanchion; 
         FIG. 18  is an enlarged cross sectional view along the line  18 - 18  of  FIG. 16 ; 
         FIG. 19  is an enlarged cross sectional view as in  FIG. 18  showing a flared sleeve; 
         FIG. 20  is an enlarged exploded fragmented perspective view of a second embodiment of the system; 
         FIG. 21  is an enlarged fragmented perspective view of the second embodiment; 
         FIG. 22  is a reduced top plan view of the system installed on a roof; and, 
         FIG. 23  is a top plan view of an alternate installation configuration. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring initially to  FIGS. 1-5 , a system  20  for attaching an article to a roof  500  having shingles  502  disposed on top of a structural member  504 , includes a flashing member  22  (also refer to  FIGS. 6-11 ) and a stanchion  24  (also refer to  FIGS. 12-15 ) connected to flashing member  22 . Flashing member  22  is slidably receivable by shingles  502  of roof  500 . As used herein, the term “slidably receivable by shingles” means that flashing member  22  may be slid up underneath one or more shingles as is depicted in  FIGS. 1 and 2 . In practice, a thin blade may be used to slightly loosen the shingles  502  prior to sliding flashing member  22  in place beneath shingles  502 .  FIG. 4  is an enlarged exploded fragmented perspective view of system  20 , and  FIG. 5  shows system  20  in its installed configuration. 
     System  20  also includes a bolt  26  for attaching system  20  to structural member  504  (such as a rafter) of roof  500 . In the shown embodiment, a covering  505  (such as of plywood) is installed between shingles  502  and structural member  504 . Bolt  26  is received by an aperture  28  in flashing member  22  (also refer to  FIGS. 6 ,  8  and  11 ) and a hole  30  in stanchion  22  (also refer to  FIGS. 12 and 14 ) and threadably engages structural member  504 . A pilot hole is drilled through shingles  502  and into structural member  504  to accept bolt  26 . A plug  32  made of rubber or the like is provided for sealing hole  30  to prevent water leaks. In the shown embodiment bolt  26  includes both a lag bolt portion  27  for engaging structural member  504  and a threaded post portion  29  for receiving hardware to attach the article to the roof (refer also to  FIG. 22 ). System  20  also includes a washer  34  which engages stanchion  22  and bolt  26 . 
       FIGS. 6-11  show flashing member  22 . Flashing member  22  includes a sheet of substantially planar flashing  36  having an aperture  28 . In the shown embodiment flashing  36  is an approximate 12 inch by 12 inch square. A coupler connects stanchion  24  to flashing  36 . In the shown embodiment the coupler is integral with (i.e. part of) flashing member  22 , and includes an upstanding sleeve  40  which surrounds aperture  28 . Upstanding sleeve  40  has a distal end  42 . Upstanding sleeve  40  comprises a tube which is oriented perpendicular to flashing  36 , and is welded, press fit, or otherwise fixedly and sealingly connected to flashing  36  of flashing member  22 . Also, it may be appreciated that the coupler could be integral with stanchion  24  instead of flashing  36 , or could be a separate unit. 
     Referring also to  FIGS. 18 and 19 , hole  30  in stanchion  24  is shaped and dimensioned to receive sleeve  40 . In one embodiment, when sleeve  40  is received by hole  30 , distal end  42  of sleeve  40  is flared to connect stanchion  24  and flashing  36  together (refer to  FIG. 19 ). In another possible embodiment, stanchion  24  is rotatably attachable to flashing member  22  but not fixedly connected as in  FIG. 18 . That is, hole  30  removably and rotatably receives sleeve  40 . 
       FIGS. 12-15  depict stanchion  24 . Stanchion  24  has a hole  30  for receiving sleeve  40  of flashing member  22  (refer to  FIGS. 6-11 ). Hole  30  has a flared portion  44  to accommodate flared distal end  42  of sleeve  40  (refer also to  FIGS. 18 and 19 ). It may be appreciated that the height of stanchion  24 , that is the distance it extends above the plane of the roof&#39;s shingles  502  (refer to  FIG. 2 ), may be varied to accommodate various article installation needs. 
       FIGS. 16 and 17  are top plan and side elevation views respectively of flashing member  22  and stanchion  24 . It is noted that stanchion  24  is 360° rotatable with respect to flashing member  22 . This rotation feature is useful in that it permits article-attaching hardware to be oriented in any desired direction (refer to  FIG. 22  and the associated discussion). 
       FIG. 18  is an enlarged cross sectional view along the line  18 - 18  of  FIG. 16  showing how hole  30  in stanchion  24  receives sleeve  40  of flashing member  22 . In this embodiment, stanchion  24  rotatably engages sleeve  40  of flashing member  22 , and stanchion  24  is rotatably but not fixedly connected to flashing member  22 . The coupler (sleeve  40 ) is integral with flashing member  22  and effects the rotation of stanchion  24  with respect to flashing member  22 . 
       FIG. 19  is an enlarged cross sectional view as in  FIG. 18 , however in this embodiment distal end  42  of sleeve  40  is flared so that stanchion  24  and flashing member  22  are fixedly connected together. 
     The position of stanchion  24  and flashing member  22  as shown in  FIGS. 18 and 19 , in combination with plug  32  (refer to  FIG. 3 ), effects a water tight seal of system  20 . 
       FIG. 20  is an enlarged exploded fragmented perspective view of a second embodiment of system  20 . This embodiment is similar to that of  FIG. 3 , however bolt  26  only includes lag bolt portion  27 . Connection for receiving hardware to attach the article to the roof is effected by two threaded holes  46 .  FIG. 21  is an enlarged fragmented perspective view of the second embodiment in its installed configuration. 
       FIG. 22  is a reduced top plan view of system  20  installed on a roof  500  having shingles  502 . In the shown installation, a plurality of systems  20  are connected as shown in  FIGS. 1 and 2  to roof structural members in spaced-apart relationship (also refer to  FIGS. 1 and 2 ). The structural members could be one or more rafters or a solid roof covering. Carrier rails  600  and  700  are then connected to adjacent systems  20 . An article such as a solar panel  800  is then connected to carrier rails  600 . It is noted that stanchion  24  can be rotated a full 360° parallel to the plane of the roof so that the carrier rails can be oriented in a desired direction. As shown, carrier rails  600  are perpendicular to carrier rails  700 . 
       FIG. 23  is a top plan view of an alternate installation configuration. In this embodiment, system  20  is not slipped between shingles  502  as in  FIGS. 1 and 2 . Rather, system  20  is simply connected to a flat roof and a sealant  900  (such as tar) is applied around system  20  to ensure a water tight seal. It is also noted that in this embodiment stanchion  24  is substantially centered on flashing  36 , as opposed to being offset toward an edge. 
     In terms of use, a method for attaching an article to a roof includes: 
     (a) providing a roof  500  having shingles  502  disposed on top of a structural member  504 ; 
     (b) providing an article  800 ; 
     (c) providing a system  20  for attaching article  800  to roof  500 , the system including;
         a flashing member  22 ;   a stanchion  24  connected to flashing member  22 ; and,   flashing member  22  slidably receivable by shingles  502  of roof  500 ;       

     (d) sliding flashing member  22  under at least one shingle  502 ; 
     (e) attaching system  20  to structural member  504 ; and, 
     (f) attaching article  800  to stanchion  24 . 
     The method further including: 
     in step (c), stanchion  24  being rotatable with respect to flashing member  22 ; and, 
     before step (e), rotating stanchion  24  to a desired orientation. 
     The method further including: 
     in step (c), flashing member  22  including flashing  36  having an aperture  28 ; 
     in step (c), stanchion  24  having a hole  30 ; 
     in step (c), providing a bolt  26  for attaching system  20  to structural member  504  of roof  500 , bolt  26  receivable by hole  30  in stanchion  24  and aperture  28  in flashing  36 ; and, 
     in step (e), using bolt  26  to threadably engage structural member  504  of roof  500 . 
     The method further including: 
     in step (c), providing a plug  32  for sealing hole  30  in stanchion  24 ; and, 
     during step (e), inserting plug  32  in hole  30 . 
     The method further including: 
     in step (e), attaching a plurality of systems  20  to roof  500  in spaced apart relationship. 
     The method further including: 
     in step (e), drilling a pilot hole through shingles  502  and into structural member  504 . 
     The possible embodiments of the system and method described herein are exemplary and numerous modifications, combinations, variations, and rearrangements can be readily envisioned to achieve an equivalent result, all of which are intended to be embraced within the scope of the appended claims. Further, nothing in the above-provided discussions of the system and method should be construed as limiting the invention to a particular embodiment or combination of embodiments. The scope of the invention is best defined by the appended claims.