METAL BUILDING ROOF MOUNT FOR SOLAR ARRAY

Abstract

A solar panel mounting system forming an opening for holding solar panels therein for easy installation and removal and replacement. The system includes a plurality of support members adapted for positioning on a support surface. A roof panel is positioned on a top surface of adjacent support members and compressibly held in place by an astragal which is fastened to the support member sandwiching the roof panel between the astragal and the support member. A solar panel opening is formed between projecting portions on opposing sides of the roof panel which extend at an angle substantially perpendicular to a top surface of the support member.

Claims

1. A system for securing a solar panel perimeter edge to an exterior side of an underlying structure, comprising: an astragal, comprising: a linear center portion; two generally parallel ribs projecting from an underside of the center portion at an angle substantially normal to the center portion, the ribs having a gap therebetween; and opposing ledges aligned with the linear center portion and projecting in opposite directions on opposing sides of the center portion; and a screw engaged through the center portion such that a shaft of the screw extends between the parallel ribs and into an element coupled to the underlying structure, thus holding the astragal to the underlying structure, whereby when the system is coupled to the underlying structure with one solar panel perimeter edge interposed between the underlying structure and one ledge such that the astragal is in operative compressive engagement with the solar panel perimeter edge resulting in force being imparted to a bottom side of the solar panel perimeter edge against the underlying structure, the solar panel perimeter edge is secured to the underlying structure.

2. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 1, wherein a length of the downward projection of the ribs and a width of the gap are such that when an exterior panel is installed on the underlying structure prior to securing the solar panel perimeter edge to the underlying structure, an edge of the exterior panel is received between the ribs when the astragal is in operative compressive engagement with the solar panel perimeter edge.

3. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 2, wherein the underlying structure is a roof structure and the exterior panel is a roof panel.

4. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 1, wherein an exterior panel is installed on the underlying structure, and wherein when the astragal is in operative compressive engagement with the solar panel perimeter edge, the exterior panel is sandwiched between the underlying structure and the bottom side of the solar panel perimeter edge.

5. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 1, further comprising an engageable cap which has side edges which are configured to engage the opposing ledges.

6. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 5, wherein each opposing ledge has a recess configured to receive a side edge of the engageable cap.

7. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 5, wherein the engageable cap is formed of a flexible material.

8. The system for securing adjacent solar panel perimeter edges to the exterior side of the underlying structure of claim 1, wherein each ledge has a lower edge including projecting contact points.

9. A system for securing solar panel perimeter edges to an exterior side of an underlying structure, comprising: an astragal, comprising: a linear center portion; two generally parallel ribs projecting from an underside of the center portion at an angle substantially normal to the center portion, the ribs having a gap therebetween; and opposing ledges aligned with the linear center portion and projecting in opposite directions on opposing sides of the center portion; and a screw engaged through the center portion such that a shaft of the screw extends between the parallel ribs and into an element coupled to the underlying structure, thus holding the astragal to the underlying structure, whereby when the system is coupled to the underlying structure with a perimeter edge of a first solar panel interposed between the underlying structure and one ledge and a perimeter edge of a second solar panel interposed between the underlying structure and the opposing ledge such that the astragal is in operative compressive engagement with each solar panel perimeter edge resulting in force being imparted to a bottom side of each solar panel perimeter edge against the underlying structure, each solar panel perimeter edge is secured to the underlying structure.

10. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 9, wherein a length of the downward projection of the ribs and a width of the gap are such that when an exterior panel is installed on the underlying structure prior to securing one solar panel perimeter edge to the underlying structure, an edge of the exterior panel is received between the ribs when the astragal is in operative compressive engagement with the secured solar panel perimeter edge.

11. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 10, wherein the underlying structure is a roof structure and the exterior panel is a roof panel.

12. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 9, wherein an exterior panel is installed on the underlying structure, and wherein when the astragal is in operative compressive engagement with one solar panel perimeter edge, the exterior panel is sandwiched between the underlying structure and the bottom side of the engaged solar panel perimeter edge.

13. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 9, further comprising an engageable cap which has side edges which are configured to engage the opposing ledges.

14. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 13, wherein each opposing ledge has a recess configured to receive a side edge of the engageable cap.

15. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 13, wherein the engageable cap is formed of a flexible material.

16. The system for securing solar panel perimeter edges to the exterior side of the underlying structure of claim 9, wherein each ledge has a lower edge including projecting contact points.

Description

BRIEF DESCRIPTION OF DRAWING FIGURES

[0018] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate some, but not the only or exclusive, examples of embodiments and/or features of the invention. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than limiting. In the drawings:

[0019] FIG. 1 shows a sectional view of the system herein showing the metal roof panels formed with side edges which project substantially normal to the metal panel therebetween, and showing the astragal and engageable cap which hold the solar panels and form a seal between adjacent metal roof panels.

[0020] FIG. 1A is a sectional view of another mode of the system herein similar to that of FIG. 1, except that it employs a single support member which is positioned underneath the roofing panels rather than on top as in FIG. 1.

[0021] FIG. 1B shows the astragal engaged to an underlying support member and holding adjacent panels in a compressed sandwiched engagement, without a solar panel engaged which can be added at a subsequent time by loosening the screw and inserting solar panels under the opposing edges of the astragal.

[0022] FIG. 2 shows a side view of the astragal herein employed as in FIG. 1.

[0023] FIG. 3 shows the metal roofing panel herein provided having projecting portions formed along opposing side edges of the metal panel.

[0024] FIG. 4 shows the system herein in a perspective end view showing a cap engaged along the astragal which holds the solar panels atop the underlying support members and showing the very small gap between the back of the solar panel and planar portions of the roof.

[0025] FIG. 5 shows an end view of an end cap engageable with the astragal as in FIG. 4.

[0026] FIG. 6 depicts a conventional solar panel installation wherein the metal roof panels are not integral to the installation and instead the solar panels are supported on a frame supported by posts with a large gap between the frame and roof surface.

[0027] FIGS. 7-11 show components of the system herein being installed onto an existing roof of a metal or wood roof of a building to form a rack system adapted for the easy and secure positioning of solar panels thereon.

[0028] Other aspects of the present invention will be more readily understood when considered in conjunction with the accompanying drawings, and the following detailed description, neither of which should be considered limiting.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0029] In this description, the directional prepositions of up, upwardly, down, downwardly, front, back, top, upper, bottom, lower, left, right and other such terms refer to the nose engagement device as it is oriented and appears in the drawings and are used for convenience only; they are not intended to be limiting or to imply that the device has to be used or positioned in any particular orientation.

[0030] Now referring to drawings in FIGS. 1-11, wherein similar components are identified with like numerals, FIG. 1 shows a depiction of a sectional view of the engaged components of the device 10 herein, enabling the method herein of FIGS. 7-11 where a rack system is formed for positioning of solar panels thereon above a metal or wood or other roof structure.

[0031] In FIG. 1 is shown the novel metal roof panels 12 each of which is formed with side edges having formed projecting portions 14. In some cases there may be only one projecting portion 14 along one edge of a roof portion of the roof panel 12, such as shown in FIG. 9 in the enlarged sections. In this mode, a first roof portion 12A engages a second roof portion 12B along a folded edge 15 located on the opposite side of each from the projecting portion 14 thereof. Thus, the roof panel 12 is formed by the first roof portion 12A engaged to the second roof portion 12B along the folded edge 15 of each to form the full roof panel 12.

[0032] In some installations the roof panels will be formed in a unitary structure with projecting portions 14 running along both side edges. In other roof panels 12 where more adjustment for positioning is desired, the folded edges 15 on the opposite sides of roof portions 12A and 12B from the projecting portion 14, allow for a sliding engagement to adjacent roof portions to form the roof panels 12 and to adjust the roof panels 12 slightly side to side during installation. This allows for a slight adjustment of the size of the formed openings 41 for the solar panels 22 between the projecting portions 14 on opposite sides of the formed roof panel 12. This sliding engagement of folded edges 15 of two roof portions 12A and 12B (FIG. 9) also forms a secondary supporting member 17 (FIGS. 9-11) for holding center portions of the solar panels 22 elevated which is particularly preferred.

[0033] The projecting portions 14, along one side edge of the roof panels 12, are formed by a bend in the metal material along the side edge. Each projecting portion 14 extends from the side edge on which it is positioned, at an angle substantially normal to the planar mid-section 16 of the metal roof panels 12. By substantially normal is meant plus or minus 10 degrees from perpendicular.

[0034] As shown in FIG. 1, each roof panel 12, whether formed of two engaged roof portions or a roof panel 12 in one section, sits atop an underlying support structure 20 shown in dotted line. Screws 26 engaged to the underlying support structure impart force against the support members 18 to hold them and to hold the metal roof panels 12 sandwiched under them, in position. Such underlying support structures for example include a metal roof of an existing building or a wood or shingled roof. Also shown are the support members 18, which abut and overlay the projecting portions 14 of the adjacent roof panels 12, which are positioned thereon and can support the solar panel 22, thereon. The support members 18 may be formed in two sections as in FIG. 1, or in a single section shown in FIG. 1A or 1B which is preferred, since it positions a seal formed by the bent portions of the roof panel 12 over the top of the support member 18 leading to the projecting portion 14. This positions the roof panel 12 in the mode of FIGS. 1A and 1B, above any communication of the screw 26 through the underlying roof structure.

[0035] An astragal 24, shown in FIG. 1, is placed in operative compressive engagement with adjacent solar panels 22 which is particularly preferred in all modes of the system 10 herein. A screw 26 is engaged through a central portion 29 thereof during installation, to hold the astragal 24 to the underlying support surface 20. This screw 26 can be adjusted to impart a measured compression to the astragal 24, which in turn will contact and engage the edges of the solar panels 22 or frames surrounding them in a compressive sealed contact therewith. This compressive engagement will also impart force to the bottom side of the solar panel 22 against the support members 18 and will compressively engage projecting contact points 28 (FIG. 2) on opposing sides of the astragal 24 against the perimeter edge of the solar panel 22 to compressibly engage it and hold it in place.

[0036] Depicted in FIG. 1, also, are parallel ribs 30 having a gap 32 therebetween. This gap 32 is aligned with an opening 34 positioned between the two projecting portions 14 which are on one respective side of each of the two roof panels 12. With the screw 26 operatively engaged with the underlying surface 20, and the astragal 24 compressibly engaged against the adjacent solar panels 22, the gap 32 and opening 34 between projecting portions 14, align to provide the path for the screw 26 to be engaged with the underlying support surface 20.

[0037] Additionally, the two ribs 30 are formed of a length projecting from the center portion 29, to extend past the distal ends 15 of the projecting portions 14 when the screw 26 is tightened to compress the astragal 24 against the solar panels as in FIGS. 1 and 1A. This forms a moisture seal to prevent fluid which might get past the compressive engagement and seal of the astragal 24 against the adjacent solar panels 22 and prevent such from getting into the opening 34 between adjacent roof panels 12.

[0038] Also shown in FIGS. 1, 1A, and 1B, is an engageable cap 36 which has side edges 38 which are configured to engage into recesses 40 in the opposing sides of the astragal 24. The cap 36 is formed of a flexible or elastic material which allows the side edges 38 to temporarily when the cap 36 is pushed against the surfaces of the astragal 24 above the recesses 40 and deflect and then compress into the recesses 40. Once the edges 38 engage into the recesses 40 they form a water tight seal over the top and sides of the astragal 24.

[0039] While not shown in detail in FIG. 1, the interior cavities 19 of the support members 18 or more preferable, the area within the opening 34 between the projecting portions 14, both define passages which may be employed for positioning of wiring for both the solar panels 22 and any controllers or the like. The opening 34 works especially well since prior to positioning of the astragal 24 thereover, the wires are easily tucked into the opening 34 and then covered with the astragal 24.

[0040] Shown in FIG. 1B, is a unique functional aspect of the system 10 herein, where the solar panels 22 have not yet been installed or have been removed. This is particularly preferred because there are instances where solar panel installation is delayed, or where they must be removed and replaced. Using the system 10 herein, the support members 18 can be installed onto the underlying support structure, and the roof panels 12 can be operatively positioned with the projecting portions 14 extending thereabove. The astragal 24 can then be engaged to form a seal with the ribs 30 contacting the support member 18 by tightening the screw 26. Once the solar panels become available, or are repaired and ready for replacement, the screw 26 may be loosened temporarily, and the solar panels 22 can be installed as in FIG. 1A. The utility provided by the system 10 as shown in FIG. 1A is particularly important because there are times when solar panels are damaged and must be removed and replaced, or when the panels arrive too late for a winter installation. The ability to form the mounting system 10 herein which forms the racks for easy installation, and or removal and reinstallation of subsequently installed solar panels 22 gives the contractor an advantage.

[0041] Shown in FIG. 2 is an end view of the typical astragal 24 herein employed as in FIG. 1. The projecting contact points 28 can be seen on the lower edges of opposing projecting ledges 42 projecting in opposite directions on opposing sides of the body forming the astragal 24. These points 28 have been found to better engage with the surface of the solar panels 22 and form a secure contact and seal therewith. Also shown are the ribs 30 projecting from the center portion 29 a distance for surrounding the opening 34 between the two projecting portions 14. Also depicted are the two recesses 40 formed into the edges of the ledges 42 which engage to the side edges 38 formed on the flexible cap 36.

[0042] In FIG. 3 is shown one side edge of the metal roofing panel 12 per the device 10 and method herein. As depicted, the projecting portions 14 can extend from one or both side edges of the roof panel 12. As noted, the projecting portions 14 run substantially normal to the planar mid section 16 of the panel 12. As also noted, in a particularly preferred mode of the system 10 which uses two roof portions 12A and 12B (FIG. 9) engaged at folded edges 15 which forms the secondary support members 17, the opposite side edges of the formed roof panels 12 from the projecting portion 14 of each, can be configured with the folded edge 15 as in FIGS. 9 and 11. When engaged over each other, the folded edges 15 form the secondary support member 17 shown in FIGS. 9-11.

[0043] Where both side edges of the roof panels 12 have the projecting portion 14 and the roof panel is formed in a single sheet, support members 18 may be positioned on the underlying structure instead of forming the secondary support members 17. However, by forming the roof panels 12 in a first and second portion 12A and 12B as noted herein, each having folded edges 15 such that they will engaged and form the secondary support members 17, additional support is provided to the solar panels 22. This additional support is provided without the need or expense for extra support members 18 such as shown in FIGS. 9-11. Optionally the folded edges 15 can be formed to slide slightly upon each other, to allow for a side to side adjustment of the first and second portions 12A and 12B of roof panel 12, (FIG. 9) to provide additional function in that the size of the openings 41 (FIG. 10) can be adjusted if needed.

[0044] FIG. 4 depicts the device herein in a perspective end view of the device 10 in an assembled mode, showing the cap 36 engaged along the astragal 24. The astragal 24 is engaged by the screw 26 to the underlying support structure 20 and compressibly engages the ledges 42 against the solar panel 22 edge. An end cap 46 is shown engaged to the upper side edge of the astragal 24 using projecting prongs 48 (FIG. 5). An end cap 50 is also shown covering the open ends of the support members 18 and the gap 32 and covers the opening 34 shown in FIG. 1.

[0045] As can be seen in FIG. 1 and FIG. 4, using the system herein, a very small gap 27 is formed between the rear surface 23 of the solar panel 22 and the upper surface of the roof panel 12. Such is preferably between ½ to ¾ of an inch and can be smaller if the peak of the formed ridges 44 are less than inch above the surface of the mid section 16 of the roof panel 12. Such prevents lift from wind and the intrusion of animals and birds underneath the solar panels 22 and a secondary cover not shown can be provided to cover this gap 27. The gap 27 provides a passage for venting heat from the solar panels 22.

[0046] The end cap 46 can be formed to fit inside the cap 36 on top of the solar modules. This requires that the astragal 24 to shortened sightly shorter than the solar modules to provide space for the end cap 46. The end cap 46 in all modes is preferably formed of a compliant material (for example rubber or foam) and it could also serve as an expansion joint between sections of the astragal 24 to prevent thermal expansion stresses while concurrently eliminating any gaps.

[0047] FIG. 5 shows an end view of the end cap 46 engageable with the top portion of the astragal 24 as in FIG. 4. The prongs 48 are configured to removably engage in recesses 40 formed in the astragal 24 as can be seen in FIG. 1.

[0048] FIG. 6 is for reference and depicts a typical prior art view of the mounting of conventional solar panel systems on rooftops, which those skilled in the art will be familiar with. As can be seen, the roof panels conventionally are separate from and form no part of the engagement system, which is mounted on purlins and rafters elevated above the roof. In conventional systems, many more holes are drilled through the support structure such as a roof and they are not covered by any sealing system such as herein.

[0049] FIGS. 7-11 show components of the system 10 herein being installed onto an existing roof of a metal or wood roof of a building to form a rack system adapted for the easy and secure positioning of solar panels thereon. As shown in FIGS. 7-11 the roof panels 12 can be formed of a first section 12A and second section 12B, which engage at respective folded edges 15 opposite respective projecting portions 14 thereon.

[0050] In the system 10 herein, in a first step, shown in FIG. 7, support members 18 are positioned on the support structure 20 such as an underlying roof surface of a building. Where the roof panels 12 have projecting portions 14 on both opposing side edges, extra support members 18 may be installed to provide center support to overlying solar panels 22 if needed.

[0051] Where the roof panels 12 are formed in sections 12A and 12B, with a first side edge having the projecting portion 14 and the opposing second side edge having a folded edge 15 configured to engage over and with a similar folding edge 15 of an adjacent roof panel 12, the engagement forms the secondary support member 17. This secondary support member provides support to the solar panels 22 and maintains the gap 32 between them and the underlying support structure 20.

[0052] This mode of the system 10 herein is preferable since it allows for smaller sections 12A and 12B to form the roof panels 12 which are easier to handle in wind and weather. It is additionally preferred since it forms an overlapping seal of the folded edges 15 as well as a strong secondary support member 17 to help support the solar panels 22 better.

[0053] In FIG. 8 is shown the positioning of portions of the roof panels 12 to be formed in the manner shown in FIG. 9, upon the support members 18 shown installed in FIG. 7. Each roof panel portion 12B has a first side edge with the projecting portion 14 and an opposing second side edge with a folded edge 15 such as shown in FIGS. 9 and 11 where the folded edges 15 overlap.

[0054] This is followed by the positioning of the rest of the roof panel portions 12A shown in FIG. 9, wherein each of the support members 18 have a pair of parallel projecting portions 14 of adjacent roof panels 12 thereabove, and each of the folded edges 15 on the second side edges of the roof panels 12 are overlapped to form the secondary support members 17.

[0055] Thereafter as shown in FIG. 10, the solar panels 22 are placed within openings 41 formed between the support members 18 which have the two projecting portions 14 of roof panels 12 extending thereabove. Central areas of the openings 41 have the formed secondary support members 17 therein to support the underside of the solar panels 22. The width of the formed openings 41 between the projecting portions 14 on opposing sides of each formed roof panel 12 is adapted for positioning the solar panels 22 therein.

[0056] Whether the roof panels 12 are formed in a single unit with projecting portions 14 on both opposing sides as in FIG. 1, or as two roof panel portions having engaged folded edges 15 as in FIGS. 7-11, the width of the openings 41 is configured to position sides of the solar panels 22 over the support members 18 and adjacent the projecting portions 14 so they are engaged by the contact points 28 of the ledges 42 extending from the center portion 29 of the astragal 24 when the screw 26 is tightened.

[0057] Finally, FIG. 11 shows the system 10 herein, formed from the roof panels 12 of FIGS. 7-10 where second sides of the roof panels 12 overlap and form the secondary support members 17. However, if roof panels 12 having projecting portions 14 formed on both opposing side edges are employed, the assembly of the system 10 shown in FIG. 11 is substantially the same but for the positioning of additional support members 18 where the secondary support members 17 are formed by roof panels 12 with the folded edges 15 on second sides.

[0058] While all of the fundamental characteristics and features of the combined metal roof panel and solar panel mounting components of the device herein enabling the method herein have been shown and described herein, with reference to particular embodiments thereof, a latitude of modification, various changes and substitutions are intended in the foregoing disclosure and it will be apparent that in some instances, some features of the invention may be employed without a corresponding use of other features without departing from the scope of the invention as set forth. It should also be understood that various substitutions, modifications, and variations may be made by those skilled in the art without departing from the spirit or scope of the invention. Consequently, all such modifications and variations and substitutions are included within the scope of the invention as defined by the following claims.