Solar roof attachment for tile roof without removing tile

Abstract

A roof attachment assembly includes a base, a post mechanically fastened to the base, a bracket, mechanically fastened to the post, a sleeve configured to fit around the post, one or more fasteners, and a flexible flashing membrane configured to interact with the sleeve and the post such that the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal. A method for installing a roof attachment assembly on a tile roof with a roof structure and a plurality of tiles includes providing the roof attachment assembly, locating a desired mounting location, creating a hole in a tile, fitting the base and the post through the hole, fastening the base to a roof structure, installing the sleeve and the flexible flashing membrane such that a watertight seal is formed, and mechanically fastening the bracket to the post.

Description

SOLAR ROOF ATTACHMENT FOR TILE ROOF WITHOUT REMOVING TILECROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority to and the benefit of U.S. Provisional Application No. 63 / 529,956, filed July 31 , 2023, entitled “Solar Roof Attachment for Tile Roof Without Removing Tile,” the disclosure of which is hereby incorporated by reference in its entirety.BACKGROUNDField of the Disclosure

[0002] The present disclosure relates to a roof attachment assembly for fixing attachments such as attachment for solar panels and solar arrays, to a roof, specifically to a rafter, decking, or other roof structure, with improved sealing, and easier installation.DESCRIPTION OF THE RELATED ART

[0003] Any discussion of the prior art in the specification should in no way be considered as an admission that the prior art is widely known or forms part of common general knowledge in the field.

[0004] The installation of solar panel arrays on residential roofs can be arduous and time-consuming. Depending on the array design, the components required to install the array can make the installation process even more difficult. Many of the assembly components require special tools or are generally difficult to install because they are utilized after the solar panels modules are arranged or positioned on their support elements. This is particularly true when the elements must be installed on a standard shingle roof that links to a rail guide for supporting the solar panel array.

[0005] Roof mounting assemblies designed for tile roofs typically attach to the roof underlayment in the gap between the roof and the underside of the roof tiles. An installer will typically remove one or more roof tiles to mount the solar panel roof mounting assembly. After installing the roof mounting assembly, the installer will reinstall the roof tile. The installer will often notch part of the tile to allow a portion of the mounting assembly to extend above the tile surface. However, removal of the tile is time-consuming and may lead to leaks in the roofing or breakage of the tile surface.The roof attachment assembly and a method of installing a roof attachment assembly on a tile roof.

[0006] The present invention overcomes these limitations and offers a solution that provides a support mechanism for shingle roofs that is both easy to install and use, which allows a structure for attachment of solar panels and solar arrays to a roof to be easily and precisely adjusted vertically along the support mechanism.SUMMARY

[0007] Accordingly, aspects of the present disclosure are directed to non-limiting embodiments of a roof attachment assembly and a method of installing a roof attachment assembly on a tile roof.

[0008] According to non-limiting embodiments, provided is a roof attachment assembly, which may include a base, a post, which may be mechanically fastened to the base, a bracket, which may be mechanically fastened to the post, a sleeve, which may be configured to fit around the post, one or more fasteners, and a flexible flashing membrane configured to interact with the sleeve and the post.

[0009] According to some non-limiting embodiments, provided is a roof attachment assembly, which may include a base, and the base may have a first base surface and a second base surface, one or more mounting apertures, a raised portion extending form the second base surface, and a coupling aperture extending from the first base surface through the raised portion and having a counter bore. The roof attachment assembly may also include a post, and the post may have a first end having internal threading and a second end having internal threading. The roof attachment assembly may also include a first coupling fastener disposed through the coupling aperture of the base and threadably engaged with the internal threading of the first end of the post. The roof attachment assembly may also include a sleeve which may be made of polymeric material and may include a rim having a first rim surface and a second rim surface, and a frustoconical portion extending from the second rim surface. The sleeve may be configured to fit over the post. The roof attachment assembly may also include a flexible flashing membrane having an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim and the flexible flashing membrane and the sleeve may interact with the post and a roofing surface to form a watertight seal. The roofattachment assembly may also include a bracket and a second coupling fastener disposed through a bracket aperture and threadably engaged with the internal threading of the second end of the post. The roof attachment assembly may also include one or more fasteners disposed through one or more mounting apertures of the base and configured to fasten the base to a roof structure.

[0010] According to some non-limiting embodiments, provided is a method of installing a roof attachment assembly on a tile roof, which may include providing a tile roof comprising a roof structure and a plurality of tiles, and providing a roof attachment assembly. The roof attachment assembly may include a base, a post, which may be mechanically fastened to the base, a bracket, a sleeve, which may be configured to fit around the post, one or more fasteners, and a flexible flashing membrane adhered to the sleeve. The method of installing a roof attachment assembly on a tile roof may also include locating a desired mounting location, creating a hole in a tile of the tile roof at the desired mounting location, fitting the base and the post which may be mechanically fastened to the base through the hole in the tile, fastening the base to a roof structure with one or more fasteners, installing the sleeve and the flexible flashing membrane over the post, such that the flexible flashing membrane and the sleeve may interact with the post and the tile to form a watertight seal, and mechanically fastening the bracket to the post.

[0011] Further embodiments are set forth in the following numbered clauses:

[0012] Clause 1 : A roof attachment assembly comprising: a base; a post, mechanically fastened to the base; a bracket, mechanically fastened to the post; a sleeve configured to fit around the post; one or more fasteners; and a flexible flashing membrane configured to interact with the sleeve and the post.

[0013] Clause 2: The roof attachment assembly of clause 1 , wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal.

[0014] Clause 3: The roof attachment assembly of clause 1 or 2, wherein the base comprises: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending from the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore.

[0015] Clause 4: The roof attachment assembly of any of clauses 1 -3, wherein the post comprises: a first end having internal threading; and a second end having internal threading.

[0016] Clause 5: The roof attachment assembly of any of clauses 1 -4, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post.

[0017] Clause 6: The roof attachment assembly of any of clauses 1 -5, wherein the flexible flashing membrane comprises: an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

[0018] Clause 7: The roof attachment assembly of any of clauses 1 -6, wherein the bracket is configured to support a solar panel above the roofing surface.

[0019] Clause 8: The roof attachment assembly of any of clauses 1 -7, wherein the bracket is a slide.

[0020] Clause 9: The roof attachment assembly of any of clauses 1 -8, wherein the slide comprises: a slide base having a first slide base surface and second slide base surface; two members extending from the second slide base surface; and a slide aperture.

[0021] Clause 10: The roof attachment assembly of any of clauses 1 -9, wherein the bracket is an L foot.

[0022] Clause 1 1 : The roof attachment assembly of any of clauses 1 -10, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

[0023] Clause 12: The roof attachment assembly of any of clauses 1 -1 1 , wherein the polymeric layer is a sheet of thermoplastic-polyofins (TPO).

[0024] Clause 13: The roof attachment assembly of any of clauses 1 -12, wherein the resin layer is sheet mastic.

[0025] Clause 14: A roof attachment assembly comprising: a base comprising: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending form the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore, a post comprising: a first end having internal threading; and a second end having internal threading; a first coupling fastener disposed through the coupling aperture ofthe base and threadably engaged with the internal threading of the first end of the post, a sleeve comprised of polymeric material comprising: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post, a flexible flashing membrane comprising an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim; wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal, a bracket; a second coupling fastener disposed through a bracket aperture and threadably engaged with the internal threading of the second end of the post, and one or more fasteners disposed through one or more mounting apertures of the base and configured to fasten the base to a roof structure.

[0026] Clause 15: The roof attachment assembly of clause 14, wherein the bracket is configured to support a solar panel above the roofing surface.

[0027] Clause 16: The roof attachment assembly of clause 14 or 15, wherein the bracket is a slide.

[0028] Clause 17: The roof attachment assembly of any of clauses 14-16, wherein the slide comprises: a slide base having a first slide base surface and second slide base surface; two members extending from the second slide base surface; and a slide aperture.

[0029] Clause 18: The roof attachment assembly of any of clauses 14-17, wherein the bracket is an L foot.

[0030] Clause 19: The roof attachment assembly of any of clauses 14-18, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

[0031] Clause 20: The roof attachment assembly of any of clauses 14-19, wherein the polymeric layer is a sheet of thermoplastic-polyofins (TPO).

[0032] Clause 21 : The roof attachment assembly of any of clauses 14-20, wherein the resin layer is sheet mastic.

[0033] Clause 22: A method of installing a roof attachment assembly on a tile roof comprised of a roof structure and a plurality of tiles, the method comprising: providing a roof attachment assembly, the roof attachment assembly comprising: a base; a post, mechanically fastened to the base; a bracket; a sleeve configured to fit around the post; one or more fasteners; and a flexible flashing membrane adhered to the sleeve,locating a desired mounting location, creating a hole in a tile of the tile roof at the desired mounting location, fitting the base and the post mechanically fastened to the base through the hole in the tile, fastening the base to a roof structure with one or more fasteners, installing the sleeve and the flexible flashing membrane over the post, such that the flexible flashing membrane and the sleeve interact with the post and the tile to form a watertight seal, and mechanically fastening the bracket to the post.

[0034] Clause 23: The method of installing a roof attachment assembly on a tile roof of clause 22, wherein the base comprises: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending form the second base surface; and a coupling aperture extending from the first base surface on the raised portion and having a counter bore.

[0035] Clause 24: The method of installing a roof attachment assembly on a tile roof of clause 22 or 23, wherein the post comprises: a first end having internal threading; and a second end having internal threading.

[0036] Clause 25: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-24, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post.

[0037] Clause 26: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-25, wherein the flexible flashing membrane comprises: an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

[0038] Clause 27: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-26, wherein the bracket is configured to support a solar panel above the roofing surface.

[0039] Clause 28: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-27, wherein the bracket is a slide.

[0040] Clause 29: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-28, wherein the slide comprises: a slide base having a first slide base surface and second slide base surface; two members extending from the second slide base surface; and a slide aperture.

[0041] Clause 30: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-29, wherein the bracket is an L foot.

[0042] Clause 31 : The method of installing a roof attachment assembly on a tile roof of any of clauses 22-30, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

[0043] Clause 32: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-31 , wherein the polymeric layer is a sheet of thermoplastic- polyofins (TPO).

[0044] Clause 33: The method of installing a roof attachment assembly on a tile roof of any of clauses 22-32, wherein the resin layer is sheet mastic.

[0045] Clause 34: The method of installing a roof attachment assembly on a tile roof of claim 32, wherein installing the sleeve and the flexible flashing membrane over the post comprises removing the protective sheet covering an exposed portion of the resin layer.

[0046] Clause 34: A roof attachment assembly comprising: a post, the post comprising a first end having internal threading and a second end having internal threading; a bracket, mechanically fastened to the post; a sleeve configured to fit around the post; and a flexible flashing membrane configured to interact with the sleeve and the post.

[0047] Clause 35: The roof attachment assembly of clause 34, wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal.

[0048] Clause 36: The roof attachment assembly of clause 35, wherein the roof attachment assembly further comprises: a base mechanically fastened to the post, the base comprising: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending from the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore.

[0049] Clause 37: The roof attachment assembly of clause 35, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post.

[0050] Clause 38: The roof attachment assembly of clause 37, wherein the flexible flashing membrane comprises: an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

[0051] Clause 39: The roof attachment assembly of clause 35, wherein the bracket is configured to support a solar panel above the roofing surface.

[0052] Clause 40: The roof attachment assembly of clause 35, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

[0053] Clause 41 : A roof attachment assembly comprising: a base comprising: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending form the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore, a post comprising: a first end having internal threading; and a second end having internal threading; a first coupling fastener disposed through the coupling aperture of the base and threadably engaged with the internal threading of the first end of the post, a sleeve comprised of polymeric material comprising: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post, a flexible flashing membrane comprising an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim; wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal, a bracket; a second coupling fastener disposed through a bracket aperture and threadably engaged with the internal threading of the second end of the post, and one or more mounting fasteners disposed through one or more mounting apertures of the base and configured to fasten the base to a roof structure.

[0054] Clause 42: The roof attachment assembly of clause 41 , wherein the bracket is configured to support a solar panel above the roofing surface.

[0055] Clause 43: The roof attachment assembly of clause 41 , wherein the bracket is a slide, the slide comprising a slide base having a first slide base surface and second slide base surface; two members extending from the second slide base surface; and a slide aperture.

[0056] Clause 44: The roof attachment assembly of clause 41 , wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

[0057] Clause 45: A method of installing a roof attachment assembly on a tile roof comprised of a roof structure and a plurality of tiles, the method comprising: providinga roof attachment assembly, the roof attachment assembly comprising: a base; a post, mechanically fastened to the base; a bracket; a sleeve configured to fit around the post; one or more fasteners; and a flexible flashing membrane adhered to the sleeve, locating a desired mounting location, creating a hole in a tile of the tile roof at the desired mounting location, fitting the base and the post mechanically fastened to the base through the hole in the tile, fastening the base to a roof structure with one or more fasteners, installing the sleeve and the flexible flashing membrane over the post, such that the flexible flashing membrane and the sleeve interact with the post and the tile to form a watertight seal, and mechanically fastening the bracket to the post.

[0058] Clause 46: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the base comprises: a first base surface, a second base surface, and a third base surface; one or more mounting apertures; a raised portion extending from the second base surface towards the third base surface; and a coupling aperture extending from the first base surface to the third base surface on the raised portion and having a counter bore extending from the first base surface.

[0059] Clause 47: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the post comprises: a first end having internal threading; and a second end having internal threading.

[0060] Clause 48: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post and the first rim surface of the sleeve contacts forms the watertight seal.

[0061] Clause 49: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the flexible flashing membrane comprises: an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

[0062] Clause 50: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the bracket is configured to support a solar panel above the roofing surface.

[0063] Clause 51 : The method of installing a roof attachment assembly on a tile roof of clause 45, wherein the bracket is a slide.

[0064] Clause 52: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein installing the sleeve and the flexible flashing membrane over the post comprises removing the protective sheet covering an exposed portion of the resin layer.

[0065] Clause 53: The method of installing a roof attachment assembly on a tile roof of clause 45, wherein installing the sleeve and the flexible flashing membrane over the post comprises removing a first side of the protective sheet covering exposing a first portion of the resin layer and an second side of the protective sheet covering exposing a second portion of the resin layer.

[0066] Further details and advantages of the various examples described in detail herein will become clear upon reviewing the following detailed description of the various examples in conjunction with the accompanying drawing figures.BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Additional advantages and details are explained in greater detail below with reference to the exemplary embodiments that are illustrated in the accompanying schematic figures, in which:

[0068] FIG. 1 A is a front side profile view of a non-limiting embodiment of a roof attachment assembly according to the present disclosure.

[0069] FIG. 1 B is a front side profile view of an implementation of a non-limiting embodiment of a roof attachment assembly according to the present disclosure.

[0070] FIG. 1 C is a side profile view of a non-limiting embodiment of a roof attachment assembly according to the present disclosure.

[0071] FIG. 2A is a front side profile view of a non-limiting embodiment of a roof attachment assembly according to the present disclosure.

[0072] FIG. 2B is a side profile view of a non-limiting embodiment of a roof attachment assembly according to the present disclosure.

[0073] FIG. 3A is a side profile view of a non-limiting embodiment of a base of a roof attachment assembly according to the present disclosure.

[0074] FIG. 3B is a plan view of a non-limiting embodiment of a base of a roof attachment assembly according to the present disclosure.

[0075] FIG. 3C is a plan view of another non-limiting embodiment of a base of a roof attachment assembly according to the present disclosure.

[0076] FIG. 4A is a side profile view of a non-limiting embodiment of a post of a roof attachment assembly according to the present disclosure.

[0077] FIG. 4B is a side profile view of a non-limiting embodiment of a post mechanically fastened to a base of a roof attachment assembly according to the present disclosure.

[0078] FIG. 5A is a side profile view of a non-limiting embodiment of a sleeve of a roof attachment assembly according to the present disclosure.

[0079] FIG. 5B is a plan view of a non-limiting embodiment of a sleeve of a roof attachment assembly according to the present disclosure.

[0080] FIG. 6A is a side profile view of a non-limiting embodiment of a flexible flashing membrane interacting with a sleeve of a roof attachment assembly according to the present disclosure.

[0081] FIG. 6B is a side profile view of a non-limiting embodiment of a flexible flashing membrane interacting with a sleeve of a roof attachment assembly according to the present disclosure.

[0082] FIG. 6C is a side profile view of a non-limiting embodiment of a flexible flashing membrane interacting a roof surface according to the present disclosure.

[0083] FIG. 6D is a side cut away profile view of a non-limiting embodiment of a flexible flashing membrane interacting with a sleeve of a roof attachment assembly according to the present disclosure.

[0084] FIG. 7A is a front profile view of a non-limiting embodiment of a bracket of a roof attachment assembly according to the present disclosure.

[0085] FIG. 7B is a plan view of a non-limiting embodiment of a bracket of a roof attachment assembly according to the present disclosure.

[0086] FIGS. 8A-8I are perspective views of an implementation of a non-limiting embodiment of a method of installing a roof attachment assembly on a tile roof according to the present disclosure.

[0087] Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrate exemplary embodiments of the disclosure, and such embodiment are not to be construed as limiting the scope of the disclosure in any manner.DETAILED DESCRIPTION

[0088] It is to be understood that the present disclosure may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply exemplary and non-limiting embodiments or aspects. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects disclosed herein are not to be considered as limiting.

[0089] For purposes of the description hereinafter, the terms “end,” “upper,” “lower,” “right,” “left,” “vertical,” “horizontal,” “top,” “bottom,” “lateral,” “longitudinal,” and derivatives thereof shall relate to embodiments or aspects as they are oriented in the drawing figures. However, it is to be understood that embodiments or aspects may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification, are simply non-limiting exemplary embodiments or aspects. Hence, specific dimensions and other physical characteristics related to the embodiments or aspects of the embodiments or aspects disclosed herein are not to be considered as limiting unless otherwise indicated.

[0090] No aspect, component, element, structure, act, step, function, instruction, and / or the like used herein should be construed as critical or essential unless explicitly described as such. Also, as used herein, the articles “a” and “an” are intended to include one or more items, and may be used interchangeably with “one or more” and “at least one.” As used in the specification and the claims, the singular form of “a,” “an,” and “the” include plural referents, such as unless the context clearly dictates otherwise. Additionally, as used herein, the terms “set” and “group” are intended to include one or more items (e.g., related items, unrelated items, a combination of related and unrelated items, etc.) and may be used interchangeably with “one or more” or “at least one.” Where only one item is intended, the term “one” or similar language is used. Also, as used herein, the terms “has,” “have,” “having,” or the like are intended to be open-ended terms. Further, the phrase “based on” is intended to mean “based at least partially on” unless explicitly stated otherwise.

[0091] Embodiments of the present disclosure are directed to a roof attachment assembly for fixing attachments such as attachment for solar panels and solar arrays,to a roof, specifically to a rafter, decking, or other roof structure, with improved sealing, and easier installation. According to non-limiting embodiments, a roof attachment assembly may include a base, a post, which may be mechanically fastened to the base, a bracket, which may be mechanically fastened to the post, a sleeve, which may be configured to fit around the post, one or more fasteners, and a flexible flashing membrane configured to interact with the sleeve and the post. In some non-limiting embodiments, the flexible flashing membrane and the sleeve may interact with the post and a roofing surface to form a watertight seal.

[0092] In some non-limiting embodiments, the base may include a first base surface and a second base surface, one or more mounting apertures, a raised portion extending from the second base surface, and a coupling aperture extending from the first base surface through the raised portion and having a counter bore. In some nonlimiting embodiments, the post may include a first end having internal threading, and a second end having internal threading. In some non-limiting embodiments, the sleeve may be made of polymeric material and may further include a rim having a first rim surface and a second rim surface, and a frustoconical portion extending from the second rim surface. In some non-limiting embodiments, the sleeve may be configured to fit over the post. In some non-limiting embodiments, the flexible flashing membrane may include an aperture which may be configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

[0093] In some non-limiting embodiments, the bracket may be configured to support a solar panel above the roofing surface. In some non-limiting embodiments, the bracket may be a slide. In some non-limiting embodiments, the slide may include a slide base having a first slide base surface and second slide base surface, two members extending from the second slide base surface, and a slide aperture. In some non-limiting embodiments, the bracket may be an L foot.

[0094] In some non-limiting embodiments, the flashing membrane comprises may include a polymeric layer, a resin layer, and a protective sheet covering an exposed portion of the resin layer. In some non-limiting embodiments, the polymeric layer may be a sheet of thermoplastic-polyofins (TPO). In some non-limiting embodiments, the resin layer may be sheet mastic.

[0095] In this way, embodiments of the present disclosure allow for fixing attachments, such as attachment for solar panels and solar arrays, to a roof,specifically to a rafter, decking, or other roof structure, with improved sealing, and easier installation.

[0096] Referring now to FIGS. 1 A-1 C, FIGS. 1 A is a front side profile view of a nonlimiting embodiment of roof attachment assembly 100 according to the present disclosure; FIG. 1 B is a front side profile view of an implementation of a non-limiting embodiment of roof attachment assembly 100 according to the present disclosure; and FIG. 1 C is a side profile view of a non-limiting embodiment of roof attachment assembly 100 according to the present disclosure. As shown in FIGS. 1 A-1 C, roof attachment assembly 100 may include base 102, post 104, bracket 106, sleeve 108, one or more fasteners 1 10, and flexible flashing membrane 1 12. As further shown in FIGS. 1 A-1 C, sleeve 108 may be configured to fit around post 104 and flexible flashing membrane 1 12 may be configured to interact with sleeve 108 and post 104. The interaction of flexible flashing membrane 1 12 with sleeve 108 and with post 104 can also be seen, for example, in FIGS. 2A and 2B. The interaction between flexible flashing membrane 1 12 and sleeve 108 is further shown, for example, in FIGS. 6A and 6B.

[0097] In some non-limiting embodiments, as shown in FIG. 1 B, flexible flashing membrane 112 and sleeve 108 may interact with post 104 and roofing surface A to form a watertight seal. In some non-limiting embodiments, bracket 106 may configured to support a solar panel above a roofing surface. For example, as shown in FIG. 1 B bracket 106 may configured to support a solar panel above roofing surface A. In some non-limiting embodiments, roofing surface A may be a one or more tiles. In other non-limiting embodiments, a roofing surface may be one or more asphalt shingles, an asphalt or other roofing membrane, slate roofing, metal roofing, or another roofing surface. In some non-limiting embodiments, as shown in FIGS. 1 A-1 C, bracket 106 may be a slide (e.g., bracket 106 may be slide 706 as shown in FIGS. 7A-7B).

[0098] As further shown in FIG. 1 B, one or more fasteners 1 10 may be disposed through one or more mounting apertures of base 102 (e.g., one or more mounting apertures 318 of base 102 as shown in FIG. 3B) and one or more fasteners 100 may be configured to fasten base 102 to roof structure B. In some non-limiting embodiments, roof structure B may be decking, one or more rafters, or another roof structure or roof substructure.

[0099] Referring now to FIGS. 2A-2B, FIGS. 2A-2B are a front side view and a side profile view of a non-limiting embodiment of roof attachment assembly 200 accordingto the present disclosure. In some non-limiting embodiments, roof attachment assembly 200 may be the same or similar to roof attachment assembly 100. As shown in FIGS. 2A-2B, roof attachment assembly 200 may include bracket 106. In some non-limiting embodiments, as shown in FIGS. 2A-2B, bracket 106 may be L foot 206. In some non-limiting embodiments, bracket 106 may be mechanically fastened to post 104 and post 104 may be mechanically fastened to base 102. As shown in FIG. 2B, first coupling fastener 232 may be disposed through a coupling aperture 322 of base 102 (e.g. coupling aperture 322 as shown in FIG. 3B), and first coupling fastener 232 may threadably engage with internal threading of a first end of post 104 (e.g. internal threading 430 of first end 426 of post 104 as shown in FIG. 4A). As shown in FIG. 2B, second coupling fastener 233 may be disposed through a bracket aperture of bracket 106 (e.g., slide aperture 760 as shown in FIGS. 7A-7B), and second coupling fastener 233 may threadably engage with internal threading of a second end of post 104 (e.g. internal threading 430 of second end 428 of post 104 as shown in FIG. 4A).

[0100] Referring now to FIGS. 3A-3C, FIGS. 3A-3C are a side profile view and a plan view of a non-limiting embodiment of base 102 of roof attachment assembly 100 according to the present disclosure. As shown in FIGS. 3A-3C, base 102 may include first base surface 314, a second base surface 316, and a third base surface 317. As shown in FIG. 3B, base 102 may include mounting aperture 318 and mounting apertures may be sized and configured to accept fasteners (e.g., one or more fasteners 1 10 as shown in FIGS. 1 A-2A) for fastening base 102 to a roof structure. As further shown in FIGS 3A-3C, base 102 may include raised portion 320 extending from second base surface 316 to the third base surface 317, and coupling aperture 322 extending from first base surface 314 through the raised portion 320 to the third base surface 317. As shown in FIG. 3A, coupling aperture 322 may further include counter bore 324. The counter bore 324 and the coupling aperture may be any shape or size to fit the post 104 being a similar shape and size. The counter bore 324 may extend from the first base surface 314 toward, near, to, or past the second base surface 316. The counter bore 324 may be sized to coordinate with the head of the coupling fastener 232 so as to restrain the coupling fastener 232 from rotating. The counter bore 324 may also be shaped to coordinate with the head of the coupling fastener 232 so as to restrain the coupling fastener 232 from rotating. This may advantageously help with installation of a non-limiting embodiment. Further, the shape of the counter bore 324 and the coupling fastener 232 may be shaped so the post 104 sits againstthe third base surface 317 of the raised portion 320 or second base surface 316 of the base 102. Referring now to FIG. 4A, FIG. 4A is side profile view of a non-limiting embodiment of post 104 of roof attachment assembly 100 according to the present disclosure. As shown in FIG. 4A, post 104 may include first end 426 and first end 426 may have internal threading 430. The post 104 may be any shape or size. As further shown in FIG. 4A, post 104 may include second end 428 and second end 428 may include internal threading 430.

[0101] Referring now to FIG. 4B, FIG. 4B is a side profile view of a non-limiting embodiment of post 104 mechanically fastened to base 102 of roof attachment assembly 100 according to the present disclosure. As shown in FIG. 4B, second coupling fastener 232 may be disposed through a coupling aperture of base 102 (e.g. coupling aperture 322 as shown in FIG. 3B), and first coupling fastener 232 may threadably engage with internal threading 430 of first end 426 of post 104 as shown in FIG. 4A.

[0102] Referring now to FIGS. 5A-5B, FIGS. 5A-5B are a side profile view and a plan view of a non-limiting embodiment of sleeve 108 of roof attachment assembly 100 according to the present disclosure. As shown in FIGS. 5A-5B, sleeve 108 may include rim 536 and rim 536 may include first rim surface 538 and second rim surface 540. As shown in FIGS. 5A-5B, sleeve 108 may include frustoconical portion 542 extending from second rim surface 540. In some non-limiting embodiments, sleeve 108 may be comprised of polymeric material. In some non-limiting embodiments, sleeve 108 may be configured to fit over post 104 (e.g., as shown in FIGS. 1 A-2B).

[0103] Referring now to FIGS. 6A-6C, FIGS. 6A-6C are a side profile view and a plan view of a non-limiting embodiment of flexible flashing membrane 1 12 interacting with sleeve 108 of roof attachment assembly 100 according to the present disclosure. As shown in FIGS. 6A-6C, flexible flashing membrane 1 12 may include aperture 644 and aperture 644 may be configured to fit over a post (e.g., post 104 as shown in FIGS. 1A-2B) and sleeve 108 such that flexible flashing membrane 112 engages second rim surface 540 of rim 536 of sleeve 108 and flexible flashing membrane 1 12 extends beyond rim 536. As further shown in FIGS. 6A-6C, flexible flashing membrane 1 12 may include polymeric layer 646, resin layer 648, and protective sheet 650 covering an exposed portion of resin layer 648. In some non-limiting embodiments, in an implementation of roof attachment assembly 100 and flexible flashing membrane 112, such as when installing sleeve 108 and flexible flashingmembrane 1 12 over a post (e.g., post 104 as shown in FIGS. 1 A-2B), protective sheet 650 covering an exposed portion of resin layer 648 may be removed. In such an implementation, exposed resin layer 648 may be adhered to a roofing surface (e.g., roofing surface A as shown in FIG. 1 B), such that flexible flashing membrane 112 and the sleeve 108 may interact with the post and a roofing surface to form a watertight seal. As further shown in 6A-6C, the polymeric layer 646, when applied to the protective sheet 650 may cover the rim 536 such that the polymeric layer 646 slopes downward radially outward to contact they rim 536 and protective sheet 650. In some non-limiting embodiments, polymeric layer 646 may be a sheet of thermoplastic- polyofins (TPO). In some non-limiting embodiments, resin layer 648 may be sheet mastic.

[0104] Referring now to FIGS. 7A-7B, FIGS. 7A-7B are a front profile view and a plan view of a non-limiting embodiment of bracket 106 of roof attachment assembly 100 according to the present disclosure. As shown in FIGS. 7A-7B, bracket 106 may be slide 706. As shown in FIGS. 7A-7B, slide 706 may include slide base 752 and slide base 752 may include first slide base surface 754 and second slide base surface 756. Slide 706 may also include two members 758 extending from second slide base surface 756. Slide 706 may further include slide aperture 760. In some non-limiting embodiments, slide aperture 760 may receive a coupling fastener (e.g., second coupling fastener 233 shown in FIG. 2B) disposed through slide aperture 760, and the coupling fastener may threadably engage with internal threading of a second end of a post (e.g. internal threading 430 of second end 428 of post 104 as shown in FIG. 4A) to mechanically fasten slide 706 to the post.

[0105] Referring now to FIGS. 8A-8I, FIGS. 8A-8I are perspective views of an implementation of a non-limiting embodiment of a method of installing a roof attachment assembly on a tile roof according to the present disclosure. As shown in FIGS. 8A-8I, in a method of installing a roof attachment assembly (e.g., roof attachment assembly 100) on a tile roof C , tile roof C may include a roof structure (e.g., roof structure B as shown in FIG. 1 B), and a plurality of tiles, such as tile T, or other tiles.

[0106] In some non-limiting embodiments, a method of installing a roof attachment assembly on a tile roof may include providing a roof attachment assembly, such as roof attachment assembly 100 or 200 of the present disclosure, or another roof attachment assembly. In some non-limiting embodiments, the roof attachmentassembly may include base 102, post 104 mechanically fastened to base 102, bracket 106, sleeve 108 configured to fit around post 104, one or more fasteners, and flexible flashing membrane 1 12 adhered to sleeve 108.

[0107] As shown in FIG. 8A, the method may include locating a desired mounting location, and creating hole H in tile T at the desired mounting location. As shown in FIGS. 8B-8C, the method may include fitting base 102 and post 104 mechanically fastened to base 102 through hole H in tile T. In some non-limiting embodiments, the method may include fastening base 102 to a roof structure (e.g., roof structure B as shown in FIG. 1 B) with one or more fasteners (e.g., fasteners 1 10 as shown in FIG. 1 B). The post 104 may be fixed directly to the roof structure (e.g., roof structure B as shown in FIG. 1 B) with one or more fasteners. The coupling of base 102 and post 104 may preferably occur prior to insertion through hole H on site, or in a factory setting prior to delivery to installer on the site. However, it is also considered that base 102 may be inserted through hole H, separately from post 104, then base 102 may fastened to a roof structure, and then post 104 may be coupled to base 102. In a nonlimiting embodiment, the post 104 may be coupled to the roof structure B with at least one fastener, the at least one fastener being a hanger bolt or the like, having a first end with threads that threadedly engage the internal threading 430 of the first end 426 and a second end with threads that fasten to or engage the roof structure B.

[0108] As shown in FIGS. 8D-8G, the method may include installing sleeve 108 and flexible flashing membrane 1 12 over post 104 such that flexible flashing membrane 1 12 and sleeve 108 interact with post 104 and tile T to form a watertight seal. In some non-limiting embodiments, the method, when installing sleeve 108 and flexible flashing membrane 112 over post 104, may include removing or partially removing protective sheet 650 covering an otherwise exposed portion of a resin layer of flexible flashing membrane 1 12 (e.g., resin layer 648 as shown in FIGS. 6A-6B) thereby exposing at least a portion of adhesive resin layer 648. The protective sheet 650 may be sectioned into two or more sections such that one or more sections may be removed individually or together. This advantageously allows for the resin layer of the flexible flashing membrane 1 12 to be exposed gradually for an ease in installation. Flexible flashing 1 12 may then be adhered to the tile surface by pressing an exposed central portion of resin layer 648 to the surface of tile T. As protective sheet 650 is further removed from flexible flashing membrane 1 12, resin layer 648 may be progressively pressed against the surface of tile T until the entire exposed area ofresin layer 648 is fully adhered to the surface of tile T. In some non-limiting embodiments, an exposed portion of resin layer 648 may be adhered to a tile T or another roofing surface, such that flexible flashing membrane 1 12 and the sleeve 108 may interact with post 104 and tile T or the other roofing surface to form a watertight seal.

[0109] As shown in FIGS. 8H-8I, the method may include mechanically fastening bracket 106 to post 104. In some non-limiting embodiments, bracket 106 may be configured to support a solar attachment, a solar panel, a solar array, or any portion or combination thereof above the roofing surface, such as above tile roof C and above tile T, or another roofing surface.DESCRIPTION OF REFERENCE SIGNS

[0110] 100 roof attachment assembly

[0111] 102 base

[0112] 104 post

[0113] 106 bracket

[0114] 108 sleeve

[0115] 1 10 one or more fasteners

[0116] 1 12 flexible flashing membrane

[0117] 200 roof attachment assembly

[0118] 206 L foot

[0119] 232 first coupling fastener

[0120] 233 second coupling fastener

[0121] 314 first base surface

[0122] 316 second base surface

[0123] 318 one or more mounting apertures

[0124] 320 raised portion

[0125] 322 coupling aperture

[0126] 324 counter bore

[0127] 426 first end

[0128] 428 second end

[0129] 430 internal threading

[0130] 434 polymeric seal

[0131] 536 rim

[0132] 538: first rim surface

[0133] 540: second rim surface

[0134] 542: frustoconical portion

[0135] 644: aperture

[0136] 646: polymeric layer

[0137] 648: resin layer

[0138] 650: protective sheet

[0139] 706: slide

[0140] 752: slide base

[0141] 754: first slide base surface

[0142] 756: second slide base surface

[0143] 758: two members

[0144] 760: slide aperture

[0145] A: roofing surface

[0146] B: roof structure

[0147] C: tile roof

[0148] T: tile

[0149] H: hole

Claims

WHAT IS CLAIMED IS:1 . A roof attachment assembly comprising: a post, the post comprising a first end having internal threading and a second end having internal threading; a bracket, mechanically fastened to the post; a sleeve configured to fit around the post; and a flexible flashing membrane configured to interact with the sleeve and the post.

2. The roof attachment assembly of claim 1 , wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal.

3. The roof attachment assembly of claim 2, wherein the roof attachment assembly further comprises: a base mechanically fastened to the post, the base comprising: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending from the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore.

4. The roof attachment assembly of claim 2, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post.

5. The roof attachment assembly of claim 5, wherein the flexible flashing membrane comprises:an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

6. The roof attachment assembly of claim 2, wherein the bracket is configured to support a solar panel above the roofing surface.

7. The roof attachment assembly of claim 2, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

8. A roof attachment assembly comprising: a base comprising: a first base surface and a second base surface; one or more mounting apertures; a raised portion extending form the second base surface; and a coupling aperture extending from the first base surface through the raised portion and having a counter bore, a post comprising: a first end having internal threading; and a second end having internal threading; a first coupling fastener disposed through the coupling aperture of the base and threadably engaged with the internal threading of the first end of the post, a sleeve comprised of polymeric material comprising: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post, a flexible flashing membrane comprising an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim;wherein the flexible flashing membrane and the sleeve interact with the post and a roofing surface to form a watertight seal, a bracket; a second coupling fastener disposed through a bracket aperture and threadably engaged with the internal threading of the second end of the post, and one or more mounting fasteners disposed through one or more mounting apertures of the base and configured to fasten the base to a roof structure.

9. The roof attachment assembly of claim 8, wherein the bracket is configured to support a solar panel above the roofing surface.

10. The roof attachment assembly of claim 8, wherein the bracket is a slide, the slide comprising a slide base having a first slide base surface and second slide base surface; two members extending from the second slide base surface; and a slide aperture.1 1 . The roof attachment assembly of claim 8, wherein the flashing membrane comprises: a polymeric layer; a resin layer; a protective sheet covering an exposed portion of the resin layer.

12. A method of installing a roof attachment assembly on a tile roof comprised of a roof structure and a plurality of tiles, the method comprising: providing a roof attachment assembly, the roof attachment assembly comprising: a base; a post, mechanically fastened to the base; a bracket; a sleeve configured to fit around the post; one or more fasteners; anda flexible flashing membrane adhered to the sleeve, locating a desired mounting location, creating a hole in a tile of the tile roof at the desired mounting location, fitting the base and the post mechanically fastened to the base through the hole in the tile, fastening the base to a roof structure with one or more fasteners, installing the sleeve and the flexible flashing membrane over the post, such that the flexible flashing membrane and the sleeve interact with the post and the tile to form a watertight seal, and mechanically fastening the bracket to the post.

13. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the base comprises: a first base surface, a second base surface, and a third base surface; one or more mounting apertures; a raised portion extending from the second base surface towards the third base surface; and a coupling aperture extending from the first base surface to the third base surface on the raised portion and having a counter bore extending from the first base surface.

14. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the post comprises: a first end having internal threading; and a second end having internal threading.

15. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the sleeve is comprised of polymeric material and further comprises: a rim having a first rim surface and a second rim surface; and a frustoconical portion extending from the second rim surface; wherein the sleeve is configured to fit over the post and the first rim surface of the sleeve contacts the roofing surface.

16. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the flexible flashing membrane comprises: an aperture configured to fit over the post and the sleeve such that the flexible flashing membrane engages the second rim surface and extends beyond the rim.

17. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the bracket is configured to support a solar panel above the roofing surface.

18. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein the bracket is a slide.

19. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein installing the sleeve and the flexible flashing membrane over the post comprises removing the protective sheet covering an exposed portion of the resin layer.

20. The method of installing a roof attachment assembly on a tile roof of claim 12, wherein installing the sleeve and the flexible flashing membrane over the post comprises removing a first side of the protective sheet covering exposing a first portion of the resin layer and an second side of the protective sheet covering exposing a second portion of the resin layer.

Images