A roof mounting

Abstract

The mounting includes a hanger bolt 10 that is received through an aperture 50 on a roof material 300. The bolt has a distal end 11 that is passed through the aperture and fixed to the roof structure

Description

Field of the Invention The present invention relates to a roof mounting, in particular a roof mounting with a seal to close an aperture made through a roof material. Background It is common for objects such as solar panels to be retrofitted to the roof of a building. To mount an object to a roof it is often necessary to remove part of the roof to enable installation which is timely. Some methods of installation require roof material to be cut to enable fitting of a roof hook and requires addition work to ensure the roof remains waterproof, such as to install flashing. Therefore this type of method is more timely, expensive and risks the waterproofing of the roof. In order for a mounting to be certified the load should not be transferred through the roof covering. When removing part of the roof or cutting part of the roof to fix a mounting it can make achieving certification more difficult. The present invention provides a means for quickly and easily retrofitting a roof mounting to any roof. Prior Art SolarFlash ™ https: / / www.qeniusroofsolutions.com / products / solarflash / discloses a waterproof solution to refitting roofing slates or tiles around a roof bracket. Solar Limpets https: / / www.soiariimpets.co.uk / disclose a roof hook for rooftiles. 16 04 24 Solar Slate Plate ™ https: / / www.solarslateplate.co.uk / discloses a roof mounting system. Summary of the Invention According to a first aspect of the present invention there is provided a roof mounting with a seal comprising: a roof hanger bolt that is received through an aperture in a roof material having a distal end that is passed through the aperture and fixed to a roof structure and a proximal end with a means for attachment to an object; a seal is arranged around an outer circumference of the roof hanger bolt and is arranged in use through the aperture; and a compression cap is mounted on the roof hanger bolt wherein the compression cap is shaped to cover and retain an upper end of the seal in use during deformation of the seal; and an adjustment means is provided for moving the compression cap along the proximal end of the roof hanger bolt to compress the seal so that seal is deformed to engage with the aperture and create a waterproof connection. In this way a roof hanger bolt with a seal can be fitted to a roof whilst easily retaining the waterproof properties of the roof after an aperture has been made to receive the roof hanger bolt. Advantageously the compression cap acts to guide and cover the seal to encourage rain run-off and enable an effective seal with the aperture to be created and to cover the seal so that degradation of the seal over time is minimised. The roof mounting and seal can be safely and efficiently used to install roof installations such as, but not limited to, photovoltaic cells on a commercial or residential roofs in a way that does not compromise the water resistance or longevity of the roof surface or substructure. 16 04 24 It is appreciated that the roof mounting and seal may also be used to mount various other roof installations such as weather monitoring equipment, antennas, satellite dishes, lightning conductors, personnel access, and fixing points, signage, or decorations. The roof hanger bolt has a distal attachment end for fixing to the roof structure and a proximal end that has a means for receiving an object such as a solar panel with a photo voltaic cell. In a preferred embodiment the roof hanger bolt has a threaded distal end for screwing into a wood support element of the roof structure such as a rafter. In this way the roof hanger bolt can be fixed to a roof structure through an aperture made through the roof covering, such as the tile. It is appreciated that in some other embodiments the distal end of the roof hanger bolt may by fixed in another way, for example the distal end of the roof hanger bolt may be driven into the roof structure, bolted, connected with a flange and other fittings, and / or may be fitted into a hole by a by a chemical fixing or adhesive and in such embodiments the distal end is not required to be threaded. In some embodiments the roof hanger bolt has a shoulder to prevent the distal end being inserted to the roof structure beyond a certain point. The shoulder may be a displaceable part that it fitted to the shaft of the roof hanger bolt, for example a part that is threaded onto to the shaft or may be an integrated part of the roof hanger bolt. In some embodiments the shaft of the roof hanger bolt may include a tapered collar that engages with and splays the seal away from the shaft to direct the seal towards the aperture and reduce or prevent direct pressure (perpendicular load) of the seal against the roof material, such as the tile. 16 04 24 Typically the tapered collar is a region that gradually increases the circumference of the shaft of the roof hanger bolt. The tapered collar may be integrated with the shaft of the roof hanger bolt or may be a displaceable part that is fitted to the roof hanger bolt, for example fitted and positioned along a screw thread. In some embodiments the shoulder may be combined with a tapered collar. A proximal end of the roof hanger bolt is adapted to connect to an object or to a bracket or hook for receiving an object. The roof hanger bolt is also adapted to receive an adjustment means for adjusting and locking in position the compression cap along the roof hanger bolt. Typically the adjustment means if provided at least at a proximal end of the roof hanger bolt to move the compression cap along the proximal end of the roof hanger bolt towards the seal. In some embodiments a second adjustment is provided at the distal end of the roof hanger bolt to permit adjustment either side of the seal. In a preferred embodiment a proximal end of the roof hanger bolt is threaded to receive a threaded adjustment means to provide a means for adjusting position of the compression cap along the proximal end. The roof hanger bolt is made from a strong and durable material such as metal or metal alloy. It is appreciated that a standard roof hanger bolt may be assembled with the other parts of the invention to provide the roof support and seal. In this way 16 04 24 different roof hanger bolts can be used depending upon the roof structure and the object(s) to be attached. The roof mounting has a seal to retain the waterproof properties of the roof. When assembled the seal is arranged on the shaft of the roof hanger bolt. In preferred embodiments the seal is a bespoke cylindrical seal made from a supple silicone polymer. In preferred embodiments the seal is provided in a shape and of dimensions that correspond to the aperture made through the roof so that the seal can effectively close the aperture and create a seal. Preferably the outer diameter of the seal is substantially equal to the inner diameter of the aperture in the roof, for example through a tile, so that the seal can pass through the aperture so that when the seal is compressed it engages with and fully closes the aperture. It is appreciated that the desired location for the seal on the shaft of the roof hanger bolt varies depending on the type of roof to which the roof mounting will be attached. This is because the aperture in the roof covering can be a different distance from the roof structure, such as a roof rafter depending upon type and construction. Since the seal must always be arranged through the aperture, the position of the seal on the shaft of the roof hanger bolt is ideally variable, or different roof mountings are provided for different roof types. For example, for tiles, such as roman tiles, that are typically spaced apart from the rafter, spacers, such as synthetic plastic cylindrical spacers can be inserted onto the shaft of the roof hanger bolt, below the seal to space the seal from the rafter and to align the seal with the aperture. This ensures that the seal is provided at an effective operational level that provides an optimum position for the seal to be positioned to interface correctly with the inner wall of the roof aperture and provide an adequate seal when compressed. 16 04 24 The length of the seal along the shaft of the roof hanger bolt may vary for different applications to achieve an effective seal. For example, when installing a roof mounting at overlapping tiles a longer seal is required compared to an installation through a single tile. Alternatively for situations where the tile is spaced apart from the rafter such that the seal needs to be positioned away from the roof structure in order to correspond with the aperture a stopper may be used to locate the seal. For example a stopper may be a nut that is run down the thread with a penny washer to provide a seating face for the seal in place of the plastic spacers. The seal is formed from a strong, durable, resiliently deformable material. In a preferred embodiment the seal is to cast it out of a curable liquid polymeric material such as a polyurethane, polyurea or silicone using a suitable prefabricated mould. In order for the seal to have the correct application characteristics it is important for the polymeric material to be flexible, soft, low modulus and resilient. Particularly effective materials include two component condensation cured low modulus silicone rubbers. In a preferred embodiment the seal is formed from a material with a Shore hardness value of between 10 and 20. The properties of the seal permit an effective seal that allows a small amount of movement when force is applied to the item attached to the roof hanger bolt, for example in windy conditions where the object may move. Advantageously the flexibility of the seal enables the movement without detriment to the roof (tile) whilst maintaining a watertight seal. In some embodiments the seal is has a taper on the proximal end, where it meets the compression cap. This taper interacts with a corresponding female 16 04 24 taper on the compression cap to compress the seal inwards, encouraging it to conform to and seal the shaft of the bolt that is threaded and passes through the seal, thus preventing water ingress through the thread of the bolt. In some embodiments the seal is provided with a rigid collet that acts as a corset to control where the seal can deform. For example the rigid collet may be provided around part of the circumference of the seal that is between the roof material and the roof structure (such as the rafter) to prevent lateral deformation so that deformation only occurs at the aperture and optionally at a distal end of the seal. This also allows for a longer seal to be used in place of plastic spacers. A compression cap is mounted onto the shaft of the roof hanger bolt and moved along the shaft to engage with the seal. The compression cap is used to apply pressure to the seal, causing the seal to deform so that the diameter of the seal expands and forms a tight seal against the aperture through the roof. In a preferred embodiment the compression cap has a female taper on a face of the compression cap which interacts with the seal top, forcing it to seal against the shaft of the roof hanger bolt and thread (if present) of the hanger bolt as previously described. In a preferred embodiment the compression cap is formed from synthetic plastic and is shaped and dimensioned to engage with and to cover and enclose the seal. In this way the compression cap also acts as a protective cap to deflect rain and snow while preventing damaging UV radiation from reaching the seal. It is appreciated that the compression cap may be formed from any strong durable material, such as metal. Preferably the compression cap is substantially dome shaped or conical so as to pass over and cover an upper end of the seal. This shaping also encourages rain runoff. 16 04 24 Ideally an inner face of the compression cap is angled for receiving an upper end of the seal in order to securely receive the seal. In a preferred embodiment an inner face of the compression cap has a corresponding angle to an upper end of the seal so that the seal and inner face of the compression cap engage tightly against each other. The compression cap has an adjustment means for incrementally moving the compression cap along the proximal end of the roof hanger bolt to compress the seal. Typically the adjustment means may either be an integrated adjustment means or a separate adjustment means. An example of an integrated adjustment means is the compression cap having a threaded aperture that is received onto the threaded shaft of the roof hanger bolt so that the compression cap can be incrementally moved along the threaded part of the proximal end of the shaft of the roof hanger seal to abut and deform the seal. In another embodiment the adjustment means is a separate adjustment means such as a nut that is installed on top of the compression cap to locate the compression cap at the desired position by moving the nut along the shaft of the roof hanger bolt. At least part of the proximal end is threaded and the nut is received onto, and moveable along, the threaded part of the proximal end of the roof hanger bolt to abut the compression cap and deform the seal. In some embodiments a second locking nut may be provided to secure the first nut of the adjustment means. In some embodiments another alternative locking method may be achieved, such as a pinned connection, thread lock or selflocking nut or washer. The adjustment means fixes the position of the seal between the compression cap and either the rafter, stopper, or spacer so that lateral compression between the outer face of the seal and inner surface of the aperture is maintained without imposing any vertical pressure on the roof. 16 04 24 In some embodiments the adjustment means may permit adjustment either side of the roof material for example having an adjustment means either side of the roof material when fitted to apply a more equal compression force from both sides of the roof material. This may be achieved by a mechanical means, such as a spring loaded mechanism, or ratchet mechanism, or by having opposing threads on the roof hanger bolt either side of the roofing material so that a nut can be received and tightened from both sides. Tightening of the compression cap acts to compress the seal between the compression cap and either the rafter / nut or spacer, to create a watertight seal between the shaft and thread of the hanger bolt and the seal inside diameter of the aperture. In some embodiments a face of the compression cap that engages with the seal is shaped to selectively deform the seal in a particular way to form a more effective seal. For example the surface of the compression cap may have a tapered cuff that acts to splay a proximal end of the seal to create an improved seal. In a preferred installation, the roof hanger bolt is installed through an apertured that is drilled directly through the roof material (for example tile, fibreglass, slate) and any roof lining to reach the rafter below. The aperture which penetrates the roof is of a larger size than the outside diameter of the roof hanger bolt to enable the roof hanger bolt to be easily inserted through the hole and providing a gap in which the seal is positioned in line with the aperture, before the seal is deformed. In a preferred embodiment the aperture has a diameter of at least 15mm and preferably at least 20mm. The roof hanger bolt is inserted through the aperture and is screwed into the rafter below. 16 04 24 The seal is positioned to be located through the aperture in the roof material. This may be achieved by: 1) the length of the seal so that a lower end of the seal rests on the roof structure and an upper end of the seal extends from the aperture above the roof material. 2) the use of spacers to space apart the seal from the roof structure so that the seal is passing through the aperture with a lower end extending below the aperture and an upper end extending above the aperture. 3) the use a stopper to space the seal apart from the roof material so that the seal is passing through the aperture with a lower end extending below the aperture and an upper end extending above the aperture. These options enable the seal to be correctly located to accommodate different roof types, or when space between the roof structure and the roof material varies, such as for undulate tiles or uneven construction such is in historic buildings. Once the seal is correctly located the compression cap is moved along the shaft of the roof hanger bolt to abut and deform the seal until the seal has deformed to close the aperture and create a water tight seal. The proximal end of the roof hanger bolt protrudes out though the centre of the aperture so that the proximal end can be connected to an object such as a roof hook for receiving a solar panel. Typically the proximal end of the roof hanger bolt extends at least 100mm above the roof surface. Advantageously the roof mounting can be assembled as a single piece with all required parts arranged on the shaft of the roof hanger bolt to avoid the requirement for any assembly of parts whilst on the roof, saving time on the roof and reducing the risk of dropped objects. The whole assembly of the roof 16 04 24 mounting is fitted through the aperture and the compression cap is tightened to achieve the seal. The present invention has a number of advantages of existing systems. The roof mounting can be used with any roof covering and there is no requirement for any part of the roof to be removed, only for an aperture to be drilled through the roof. In this way the roof mounting can be easily used on roofs with any rafter spacing and up to all edges for a roof, for example up to ridge tiles. As the seal closes the aperture there is no requirement for sealant or flashing to finish any part of the roof. Once installed the roof mounting is discrete, as only a proximal end of the roof hanger bolt and the compression cap are visible. The installation is simple and does not require specialist skills or equipment therefore making it suitable for any user. The roof mounting is lightweight and small, making it easy for installation allowing multiple roof mountings to be carried and minimal risk of damage if a roof mounting is dropped. The roof mounting is low cost and simple to assemble and store making it cost effective and easy for parts to be stored and transferred in bulk. Advantageously as the roof mounting only has one seal there is lower risk of failure, since only one component can fail and lead to a leak. Preferred embodiments of the invention will now be described, by way of example and with reference to the Figures in which: Brief Description of Figures 16 04 24 Figure 1A shows a first embodiment of the roof mounting in which the seal is not deformed; Figure 1B shows a second embodiment of the roof mounting in which the seal is deformed; Figure 2A shows a second embodiment of the roof mounting with a spacer in which the seal is not deformed; Figure 2B shows a second embodiment of the roof mounting with a spacer in which the seal is deformed; Figure 3A shows a third embodiment of a roof mounting with a seal and a rigid collet in which the seal is not deformed; Figure 3B shows a third embodiment of a roof mounting with a seal and a rigid collet in which the seal is deformed; Figure 4A shows a fourth embodiment of the roof mounting including a spacer and a second shoulder seal in which the seal is not deformed; Figure 4B shows a fourth embodiment of the roof mounting including a spacer and a second shoulder seal in which the seal is deformed; Figure 5A shows a fifth embodiment of a roof mounting in which the compression cap has a tapered cuff and, the shaft of the roof hanger bolt has a spacer and a taper collar, in which the seal is not deformed; and Figure 5B shows a fifth embodiment of a roof mounting in which the compression cap has a tapered cuff and the, the shaft of the roof hanger bolt has a spacer and a taper collar, in which the seal is deformed. Detailed Description of Figures 16 04 24 Figures 1 to 5 show various embodiments of a roof mounting 101, 102, 103, 104, 105. All embodiments have the same roof hanger bolt 10 and adjustment means 40 for adjusting the compression cap 30. The roof hanger bolt 10 has an elongate shaft with a distal attachment end 11 for fixing to the roof structure 300 and a proximal end 12 that has a means for receiving an object (not shown) such as a solar panel with a photo voltaic cell. In the pictured embodiments the roof hanger bolt 10 has a distal end 11 for fixing into a support element such as a rafter 300. In this way the roof hanger bolt can be fixed to a roof structure 300 through an aperture 50 made through the roof material 200, such as a tile. In a preferred embodiment, at least the distal end of the roof hanger bolt 10 is threaded so that it can be screwed into a support element. The roof hanger bolt 10 is received through an aperture 50 in the roof material 200 and screwed into the roof structure 300. The roof hanger bolt 10 has a tubular seal 20 arranged below a compression cap 30. In all embodiments the seal 20 is formed from a resiliently deformable material. In the pictured embodiments should in Figures 1 to 4 an upper end 21 of the seal is angled to correspond to the inner surface of the compression cap 30. This shaping helps to retain the seal 20 under the compression cap 30 and ensure that deformation is achieved around the aperture 50. The adjustment means is a nut 40 arranged above the compression cap 30. Part of the shaft of the roof hanger bolt 10 is threaded to receive the nut 40 so that the nut can be moved incrementally long the shaft to adjust and fix the position of the compression cap 30. The compression cap 30 is domed shaped to enclose the upper end of the seal 20. 16 04 24 Figures 1Aand 1B show a first embodiment of the roof mounting 101. In Figure 1A the seal 20 is not deformed and in Figure 1B the seal has been compressed by the compression cap 30 and is deformed. When the seal 20 is deformed by pressure applied by the compression cap 30, the diameter of the seal 20 at the aperture 50 increases which closes the aperture 50 that passes through the roof material 200. In Figure 1A the seal 20 is also in contact with the roof structure, and therefore there is also a contact seal between a lower end of the seal 20 and the roof structure 300. Figures 2A and 2B show a second embodiment 102 of the roof mounting in which the roof hanger bolt 10 includes a shoulder 13 which prevents the distal end 11 being driven / inserted into the roof structure 300 beyond a certain point that is set by the shoulder 13. The shoulder 13 may be a displaceable part that it fitted to the shaft of the roof hanger bolt 10, for example a part that is threaded onto to the shaft or may be an integrated part of the roof hanger bolt 10. The circumference of the shoulder 13 is also intended to close the hole 55 in the roof structure 300. In this way when a membrane is present along an outer surface of the roof structure this is compressed and thereby sealed against the roof structure 300 and closing the hole 55. In some embodiments an underside of the shoulder 13 may include a sealing layer (not shown), or a sealant or adhesive may be used to create a seal. In Figures 2A and 2B the roof mounting 102 includes a spacer 60 to space apart the seal 20 from the roof structure 300. In this way the seal 20 is positioned at the aperture 50 and does not need to extend the full length between the roof structure 300 and roof material 200. The spacer 60 is a rigid disc received on the shaft of the roof hanger bolt 10. An upper face of the spacer 60 provides a base upon which a lower end of the seal 20 is received. It is appreciated that 16 04 24 spacers 60 of different shapes and sizes may be provided and / or that two or more spacers 60 may be used (stacked one atop another) to create the desired separation. In Figure 2B the seal 20 is deformed either side of the aperture 50 to close the aperture 50 and create a seal making the roof material 200 watertight. Figures 3A and 3B show a third embodiment of a roof mounting with a seal 20 and a rigid collet 70 encircling part of the seal 20. The rigid collet 70 prevents deformation of the seal that is encircled by the collet 70. In this way the seal 20 is only able to bulge under compression either side of the collet 70. In Figure 3B the seal is deformed at the aperture 50 and at the hole 55 in the roof structure 300 provided two seal zones. The rigid collet 70 is formed from a strong durable material. For example, the rigid collet 70 may be a synthetic plastic tube that is place over the seal 20. Figures 4A and 4B show a fourth embodiment of the roof mounting 104 including a spacer 60 and a second embodiment of a shoulder 13. The shoulder 13 acts to provide a second seal. The shoulder 13 is a cylinder with upper and lower flanges 13A, 13B to assist with creating a seal. The shoulder 13 is fixed to the shaft of the roof hanger bolt 10 and acts to prevent the distal end 11 of the roof hanger bolt 10 from entering the roof structure 300 beyond the position of the shoulder 13. The lower flange 13B assists with creating a seal with the hole 55 and the upper flange 13A provides a stable surface to receive the spacer 60. The shoulder seal 13 is made from a strong material such as metal or metal alloy. The sealing material may be a standard nitrile O-ring or ring seal made from the same material as the main seal. 16 04 24 The shoulder 13 shown in Figures 4A and 4B is an alternative option to the shoulder 13 shown in Figures 2A and 2B, performing the same function of creating a seal between the roof mounting 104 and the roof structure 300. In Figure 4B shows a fourth embodiment of the roof mounting 104 in which the seal 20 is deformed. The seal 20 is bulged (extending laterally) above and below the roof material 200 create a complete seal. Figures 5A and 5B show a fifth embodiment of a roof mounting 105 in which the compression cap 30 has a tapered cuff 31 and, the shaft of the roof hanger bolt 10 has a spacer 50 and a tapered shoulder 13. The tapered cuff 31 and tapered shoulder 13 both act to displace the seal 20 so that upper and lower ends of the seal are splayed to ensure a tight seal against the walls of the aperture 50. Both the tapered cuff 31 and tapered shoulder 13 taper towards the seal 20. In this way, as the seal 20 is compressed by the compression cap 30, the upper and lower ends of the seal 20 are forced over, and splayed out by, the tapered cuff 31 and tapered shoulder 13 as shown in Figure 5B. The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention as defined by the claims.

Claims

16 04 241. A roof mounting with a seal comprising: a roof hanger bolt that is received through an aperture in a roof material having a distal end that is passed through the aperture and fixed to a roof structure and a proximal end with a means for attachment to an object; a seal is arranged around an outer circumference of the roof hanger bolt and is arranged in use through the aperture; and a compression cap is mounted on the roof hanger bolt wherein the compression cap is shaped to cover and retain an upper end of the seal in use during deformation of the seal; and an adjustment means is provided for moving the compression cap along the proximal end of the roof hanger bolt to compress the seal so that seal is deformed to engage with the aperture and create a waterproof connection.

2. A roof mounting with a seal according to claim 1 wherein at least part of the proximal end of the roof hanger bolt is threaded and the adjustment means is a nut received onto, and moveable along, the threaded part of the proximal end of the roof hanger bolt to abut the compression cap and deform the seal.

3. A roof mounting with a seal according to claim 1 wherein at least part of the proximal end of the roof hanger bolt is threaded and the adjustment means is a corresponding thread on a channel through the compression cap so that the compression cap is incrementally moveable along the threaded part of the proximal end of the roof hanger bolt to abut and deform the seal.

4. A roof mounting with a seal according to any preceding wherein the adjustment means include a first adjustment means fitted at a proximal end of the roof hanger bolt and a second adjustment means fitted at a distal end of the roof hanger bolt to permit adjustment either side of roof material.16 04 245. A roof mounting with a seal according to any preceding claim wherein the compression cap is substantially dome shaped.

6. A roof mounting with a seal according to any preceding claim wherein the compression cap is substantially conical.

7. A roof mounting with a seal according to any preceding claim wherein an inner face of the compression cap is angled for receiving an upper end of the seal with a corresponding angle.

8. A roof mounting with a seal according to any preceding claim wherein the seal has at least one rigid collet surrounding part of an outer surface of the seal to prevent lateral deformation.

9. A roof mounting with a seal according to any preceding claim including at least one shoulder arranged on the roof hanger bolt for limiting passage of the roof hanger bolt through the roof structure.

10. A roof mounting with a seal according to any preceding claim including a tapered collar provided on the roof hanger bolt arranged to splay a distal end of the seal to create an improved seal.

11. A roof mounting with a seal according to claim 9 and claim 10 wherein the shoulder is combined with the tapered collar.

12. A roof mounting with a seal according to any preceding claim wherein the compression cap has a tapered cuff that engages with and splays the seal to create an improved seal.

13. A roof mounting with a seal according to any preceding claim wherein the seal is formed from a resiliently deformable material.

14. A roof mounting with a seal according to claim 13 wherein the seal is formed from a resiliently deformable material with a Shore hardness in a range of 10 to 20.

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