Replacement tile mount for mounting solar panels on tile roofs

Patent metadata

Field	Value
Publication number	US-10601360-B2
Application number	US-201715699637-A
Country	US
Kind code	B2
Filing date	Sep 8, 2017
Priority date	Sep 8, 2017
Publication date	Mar 24, 2020
Grant date	Mar 24, 2020

Abstract

A one-piece, monolithic tile support mount attaches to a roof and provides rigid structural support for a lateral attachment bar or L-foot that is used to hold a height-adjustable mounting mechanism or mounting rail, which is used to attach solar photovoltaic panels to the roof of a roof covered with roofing tiles. A custom-designed, sheet-metal or polymer, aperture-less replacement tile is mounted between the lateral attachment bar or the L-foot and the tile support mount. Also provided is a compact, magnetic positioning tool that provides proper alignment of a drill bit when drilling or punching holes through the replacement tile.

First claim

What is claimed is:

1. A tile mount, including a monolithic “L”-shaped structure, comprising:
a horizontal base defining a pair of vertically-oriented through-holes; and
a monolithic riser defining a vertically-oriented mounting hole in the monolithic riser, the monolithic riser including:
a closed top platform;
at least one magnet disposed in the closed top platform,
wherein the at least one magnet holds a magnetic position tool in proper alignment when placed in close proximity to the closed top platform.

2. The tile mount of claim 1 , wherein the monolithic riser further includes a substantially hollow structure comprising a substantially hollow internal volume, an open floor, and the closed top platform.

3. The tile mount of claim 1 , further comprising a raised concentric circular ring surrounding the vertically-oriented mounting hole.

4. The tile mount of claim 3 , wherein the raised concentric circular ring is a first raised concentric circular ring, and
wherein the tile mount further comprises a second raised concentric circular ring surrounding the first raised concentric circular ring, with an annular groove disposed in-between the first and second raised concentric circular rings.

5. The tile mount of claim 1 , wherein the at least one magnet includes a pair of spaced-apart magnets disposed in the closed top platform of the monolithic riser.

6. The tile mount of claim 1 , wherein the at least one magnet includes a rectangular bar magnet disposed in the closed top platform of the monolithic riser.

7. The tile mount of claim 1 , wherein the vertically-oriented mounting hole has a smooth interior surface.

8. The tile mount of claim 1 , wherein the vertically-oriented mounting hole has a threaded interior surface.

9. The tile mount of claim 1 , wherein an upper surface profile of the tile mount is shaped correspondingly with a lower surface profile of tile mount such that multiple tile mounts are flushly stackable on top of one another to minimize a volume of space used for shipment and storage of the multiple tile mounts.

10. The tile mount of claim 1 , wherein the monolithic “L”-shaped structure is made of cast or molded or 3-D printed aluminum or aluminum alloy or plastic.

11. The tile mount of claim 1 , further comprising a locating pin disposed in the closed top platform.

12. The tile mount of claim 1 , wherein the vertically-oriented mounting hole is a first vertically-oriented mounting hole, and
wherein the tile mount further comprises a second vertically-oriented mounting hole defined in the monolithic riser.

13. The tile mount of claim 12 , wherein an interior surface of the first vertically-oriented mounting hole is threaded and an interior surface of the second vertically-oriented mounting hole is smooth.

14. A tile mount, for mounting solar panels to a roof, comprising:
a monolithic “L”-shaped structure including:
a horizontal base defining a pair of vertically-oriented through-holes, and
a monolithic riser having defined therein a pair of vertically-oriented mounting-holes, and the monolithic riser further having a substantially hollow structure defined by:
a hollow internal volume,
an open floor,
a closed top platform;

four cutout windows in the monolithic riser,
four vertically-extending legs supporting the closed top platform of the monolithic riser;
a first raised concentric circular ring surrounding each of the pair of vertically-oriented mounting holes;
a second raised concentric circular ring surrounding the first raised concentric circular ring with an annular groove disposed in-between the first raised concentric circular ring and the second raised concentric circular ring; and
a pair of spaced-apart magnets disposed in a pair of holes located in the closed top platform of the monolithic riser.

15. A replacement tile sub-assembly, for mounting solar panels to a roof, comprising:
a tile mount structure for holding a lateral attachment bar, including a monolithic “L”-shaped structure having a horizontal base defining a pair of vertically-oriented through-holes;
a monolithic riser defining a vertically-oriented mounting hole in a top platform of the monolithic riser, the monolithic riser including:
four vertical legs supporting the top platform, each vertical leg of the four vertical legs being tapered from the top platform to the horizontal base;

a flashing disposed in-between the tile mount structure and a roof;
a pair of lag screws for attaching the tile mount structure to the roof;
a pair of rubber or EDPM soft washers disposed in-between respective heads of the pair of lag screws and the horizontal base of the tile mount structure;
a replacement tile disposed on top of the tile mount structure; and
a lateral attachment bar positioned above the replacement tile and mounted to the tile mount structure with at least one self-tapping screw or machine bolt.

16. The replacement tile sub-assembly of claim 15 , wherein the replacement tile comprises a top section comprising an over-molded polymeric membrane.

17. A replacement tile sub-assembly, for mounting solar panels to a roof, comprising:
a tile mount structure for holding a lateral attachment bar, including a one-piece, monolithic “L”-shaped structure having a horizontal base defining a pair of vertically-oriented through-holes;
an integral, monolithic riser defining a vertically-oriented mounting hole in a top platform of the riser, the monolithic riser including:
four vertical legs supporting the top platform, each vertical leg of the four vertical legs being tapered from the closed top platform to the horizontal base;

a flashing disposed in-between the tile mount structure and a roof;
a pair of lag screws for attaching the tile mount structure to the roof;
a pair of rubber or EDPM soft washers disposed in-between a head of the lag screws and the horizontal base of the tile mount structure;
a replacement tile disposed on top of the tile mount structure; and
an L-foot, mounted to the tile mount structure with at least one self-tapping screw or machine bolt.

18. The replacement tile sub-assembly of claim 17 , wherein the replacement tile comprises a top section comprising an over-molded polymeric membrane.

Assignees

• Unirac Inc

Inventors

• Mayfield Jason
• Schuit Nathan
• Harris Stacy

Classifications

• F24S2025/6006

  by using threaded elements, e.g. stud bolts · CPC title

• H02S20/23 Primary

  specially adapted for roof structures · CPC title

• F24S25/61

  for fixing to the ground or to building structures · CPC title

• F24S25/636

  clamping by screw-threaded elements · CPC title

• F24S25/10

  extending in directions away from a supporting surface · CPC title