"J" Bolt Roof Hardware Mounting System

Abstract

A “J” Bolt Roof Hardware Mounting stanchion for elevating and supporting objects such as wind turbines and solar panels upon a roof where high load and wind sheer are present. This invention presents a new method of capturing the roof rafter with a bolt shaped in the form of a “J” rather than running the risk of damaging a rafter with a lag bolt. A hole is drilled along side of the roof rafter and the “J” bolt is slipped through the hole and hooked around the bottom of the rafter. The Roof Plate is slid down the shaft of the “J” bolt to the roof deck and then the nut on the shaft of the “J” bolt is tightened to secure the “J” bolt and base plate in place. The stanchions and vibration dampener are installed and the system is ready for use.

Description

FIELD OF THE INVENTION[0001]The present invention relates to a roof hardware mounting system and, more particularly, to a system that captures the existing roof structure increasing its load capabilities without degrading the structures integrity.BACKGROUND OF THE INVENTION[0002]The present invention relates to the alternative renewable energy industry and specifically to the method of mounting and securing renewable generation, both wind and solar to the roof tops of residential homes, small businesses and agricultural structures. The mounting equipment provides a method for securing the installation directly to the underside of the roofing rafters comprising the structural integrity of the roof system. The method of attachment will provide for the necessary structural strength to support the applied loads resulting from the attachment of a wind turbine and / or series of solar panels.[0003]Roof tops are a common, out of the way location to place mechanical systems, air conditioners,...

AI Technical Summary

Benefits of technology

[0025]It would be advantageous to provide a mounting system that does not degrade the structural integrity of the rafter system. With the “J” bolt mounting system no holes are drilled in the rafter system leaving them completely intact.

[0026]It would also be advantageous to provide a mounting system that could comply with all building codes and be earthquake

Problems solved by technology

Unlike other roof mounted appliances wind turbines and to a lesser degree, solar panels, pose a problem with the sheer and compression loads that must be supported by the roof structure.

Most, use some sort of bolt on standoff approach, some are very invasive and use a pole mounted through the attic space.

1. Fast Jack attachment system from Professional Solar Products Inc. provides a quick and strong installation solution. The patented design (U.S. Pat. No. 6,360,491) places the bolt directly under the stanchion post where it provides the most support. This feature allows standard roof flashing to lay flat on the roof deck. The removable post allows flashing to be slipped over the base without damaging surrounding composition shingles. The Fast Jack is an engineered and flash-able roof stanchion designed for optimum strength while using a single lag bolt.

2. Unirac Solarmount PV Module Mounting System works very similar to the Fast Jack System. Whereas the Fast Jack systems uses a single lag bolt the Unirac system uses two or more lag bolts.

3. Quick Mount PV is an all-in-one waterproof flashing and mount designed to anchor photovoltaic tracking systems and small wind turbines to a new or existing roof. The flashing includes an attached standoff block and stainless steel hardware to attach the system to the roof. No roof cutting is required and again similar to the Fast Jack system is attached with a single lag bolt.

4. Sun Earth, another recommends the use of 1″ pipe nipples and floor flanges as the roof mounting system. The bottom flange can be directly lag bolted into the rafter and the upper flange serves the same purpose as the mounting foot to anchor photovoltaic racking systems and small wind turbines to a new or existing roof. This system is anchored to the roof system with two or more lag bolts.

5. Windterra uses a “U” shaped channel attached to the roof rafters with lag bolts. The channel spans over several rafters giving it a larger area of distribution of forces.

6. Southwest Windpower uses a pole that you mount through the roof and bolt directly to the roof structure in the attic space. There system uses a special mounting puck that acts as vibration dampers. However, the system does nothing to stop or prevent noise.

The severity of the angle and the trajectory of the fastener's penetration into the rafter could cause the rafter to split; there by reducing the structural integrity of the rafter itself and mounting system.

This leaves the installation subject to premature failure under loaded conditions.

The Merrin design, as well as all similar prior art, have a common design limitation.

Also, because of the floor flange design, it would not permit industry standard flashing to install flat on the roof; primarily due to the base flashing circumference interfering with the height of the floor flange.

A mounting system based upon the Merrin patent, while appropriate for roof mounting of heavy objects such as air conditioners, is not practical for use with solar panels or satellite dishes and definitely not with the load and force that are acting on wind turbines.

Further, Merrin views rafter attachment as a limitation and therefore teaches away from using rafters for structural support.

Therefore, Merrin teaches attachment to the roof decking which generally consists of only plywood or composite sheeting; either of which do not provide the strength of a bolt mounted to a rafter in an uplift condition.

There is nothing on the current market that completely addresses the needs of the wind turbine industry.

However, none of the current systems will handle the long term stress and loading requirements of wind turbine sheer loads.

Lag bolts in wood will never handle the 10,000 Lb's of force from wind shear loading during extreme weather or hurricane conditions.

Furthermore, none of the systems that are currently on the market have any vibration and harmonic dampening.

None of the systems have been tested for earthquakes or high Wind sheer loads.

None of the systems have been submitted to the Department of Energy or the American Wind Energy Association for approval in the new small wind category.

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