SOLAR PANEL MOUNTING RACK SYSTEM

A solar panel mounting rack includes a plurality of riser components. Each riser component includes a body, a first support member extending from a first end of the body and a second support member extending from a second end of the body. A roof engaging member is fixedly coupled to the first support member of each of the riser components. Each roof engaging member defines an aperture therethrough for securing the riser components to a roof. A plurality of transverse rails is also provided. The second support members of each of the riser components are fixedly coupled to the transverse rails. The riser components are spaced apart relative to one another along a length of the transverse rails. The plurality of transverse rails is positioned substantially parallel with respect to one another and defines at least one gap therebetween for securing a solar panel to the riser components.

Skip to: Description  ·  Claims  · Patent History  ·  Patent History
Description
BACKGROUND

The present disclosure relates to a mounting rack. More particularly, the present disclosure relates to a mounting rack system for mounting solar panels on a roof.

TECHNICAL FIELD

Solar power has become increasingly popular in recent years as an alternative to finite energy sources such as oil and coal. In particular, commercial and residential property roof solar panel systems have become a viable, cost-effective option for business owners and homeowners. A typical roof solar panel system includes several solar modules, or panels that are mounted on the roof. Each solar panel includes a plurality of solar cells arranged in a grid-like configuration for converting sunlight into DC power. An inverter is coupled to the solar panels for converting the DC power into AC power for powering utilities within the building, e.g., lighting systems, appliances, motors, etc. Batteries are also included in a typical solar panel system so that the AC power generated during sunny daylight hours may be used during the night and/or on non-sunny days. Another major component of a typical solar panel system is a mounting bracket, or mounting system for mounting the solar panels to the roof.

Solar panels are typically about 2 inches thick, 5 feet long and 2½ feet wide (although some may be larger or smaller) and weigh up to about 30 lbs. each. Residential roof solar panel systems may include up to 12 (or more) solar panels. Further, specific roof features, e.g., angled roofs, skylights, chimneys, etc., trees or other obstructions that may shade portions of the roof, and the direction of best sunlight are all factors that must be taken into account when determining how and where to mount the solar panels on the roof.

As can be appreciated, a solar panel mounting system must have sufficient strength to secure each solar panel to the roof and to withstand severe weather, e.g., wind and snow, and must be versatile enough to permit mounting of the solar panels on various roof configurations, e.g., roofs of varying size, shape, slope, frame structure and/or shingling, while taking into account the direction of best sunlight as well as the positioning of trees or other obstructions.

SUMMARY

In accordance with one embodiment of the present disclosure, a solar panel mounting rack is provided. The solar panel mounting rack includes a plurality of riser components. Each riser component includes a body portion, a first support member extending from a first end of the body portion and a second support member extending from a second end of the body portion. A plurality of roof engaging members is also provided. Each roof engaging member is fixedly coupled to the first support member of one of the riser components. Each roof engaging member further defines an aperture therethrough for securing the riser components to a roof. A plurality of transverse rails is also provided. The second support members of each of the riser components are fixedly coupled to the transverse rails. The riser components are spaced-apart relative to one another along a length of the transverse rails. The plurality of transverse rails is positioned substantially parallel with respect to one another and define one or more gaps therebetween for securing a solar panel to the riser components.

In one embodiment, the plurality of riser components is equally spaced along the transverse rails. The roof engaging members may be sufficiently spaced with respect to one another such that each roof engaging member is engageable with a roof rafter.

In another embodiment, the first support members extend normally from the first ends of the body portions in a first direction and the second support members extend normally from the second ends of the body portions in a second, opposite direction.

In yet another embodiment, the roof engaging members are configured and dimensioned for positioning between overlapping, adjacent roof shingles such that the integrity of the roof shingles is not compromised during installation of the mounting rack.

In still another embodiment, one or more of the roof engaging members includes an adjustable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point. Alternatively, one or more of the riser components may include a bendable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

In another embodiment, two substantially parallel transverse rails interconnect the riser components along a length of the transverse rails.

Each riser component may be formed as a single, integrated piece. Further, the first support member of each riser component may be welded to one of the roof engaging members and/or the transverse rails may be welded to the second support members of each riser component.

In yet another embodiment, the transverse rails are configured and dimensioned to secure at least one solar panel longitudinally along a longitudinal side of the solar panel. Further, the transverse rails may define a substantially linear configuration.

In still another embodiment, when the roof engaging members are engaged to the roof and when the solar panel is engaged to the transverse rails, the solar panel is spaced-apart from the roof.

In accordance with another embodiment of the present disclosure, a solar panel mounting system is provided. The solar panel mounting system includes first and second solar panel mounting racks according to any of the above embodiments. The first solar panel mounting rack secures the solar panel thereto toward a first longitudinal side of the solar panel and the second solar panel mounting rack secures the solar panel thereto toward a second, opposite longitudinal side of the solar panel.

In one embodiment, a length of the body portions of each of the first and second solar panel mounting racks may be substantially equal such that the solar panel is substantially parallel with respect to the roof when mounted thereon. Alternatively, the length of the body portions of the first solar panel mounting rack may be different from the length of the body portions of the second solar panel mounting rack such that the solar panel is angled with respect to the roof when mounted thereon.

In another embodiment, the roof engaging members of each of the first and second solar panel mounting racks are sufficiently spaced for engaging one (or more) roof rafters. More particularly, the roof engaging members may be sufficiently spaced such that each roof engaging member is engageable with a roof rafter. Further, the roof engaging members may be spaced to engage adjacent roof rafters.

In accordance with yet another embodiment of the present disclosure, a method of attaching a solar panel to a roof is provided. The method includes providing first and second solar panel mounting racks according to any of the above embodiments. The method also includes attaching each roof engaging member of the first solar panel mounting rack to the roof and attaching each roof engaging member of the second solar panel mounting rack to the roof such that the first and second solar panel mounting racks are spaced-apart from one another a distance not greater than a width of the solar panel. Next, the solar panel may be attached to the transverse rails of the first solar panel mounting rack toward a first longitudinal side of the solar panel and to the transverse rails of the second solar panel mounting rack toward a second longitudinal side of the solar panel.

In one embodiment, additional solar panels may be mounted to the solar panel mounting racks. The additional solar panels may be positioned end-to-end with respect to one another to extend longitudinally along the transverse rails of the first and second mounting racks.

A securing member(s), e.g., screws, bolts, nails or the like, may be disposed through the apertures defined within each of the roof engaging members for attaching the solar panel mounting racks to the roof and/or may be disposed through the at least one gap defined between the transverse rails for attaching the solar panel to the solar panel mounting racks at various positions along a length thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Various illustrative embodiments of the present disclosure are described herein with reference to the drawings, wherein:

FIG. 1 is a perspective view of one illustrative embodiment of the present disclosure, which shows a pair of solar panel mounting racks of a solar panel mounting system including a solar panel secured thereto;

FIG. 2 is an enlarged, perspective view of a portion of one of the solar panel mounting racks of the solar panel mounting system of FIG. 1;

FIG. 3 is a front, cross-sectional view of the solar panel mounting rack of FIG. 2;

FIG. 4 is a side view of the solar panel mounting rack of FIG. 2;

FIG. 5A is a top view of one illustrative embodiment of a roof mounting member of the solar panel mounting rack of FIG. 2;

FIG. 5B is a top view of another embodiment of a roof mounting member of the solar panel mounting rack of FIG. 2;

FIG. 6A is a top view of the solar panel mounting rack of FIG. 2 showing two transverse rails extending therealong;

FIG. 6B is a perspective view of another embodiment of the solar panel mounting rack of FIG. 2 having an adjustable roof mounting member;

FIG. 7 is a schematic illustration showing the installation of the solar panel mounting system of FIG. 1;

FIG. 8 is a front view of a building where the pair of solar panel mounting racks of FIG. 1 are securing a solar panel to a roof of the building;

FIG. 9A is a side, cross-sectional view of the pair of solar panel mounting racks FIG. 1 shown secured to a roof where the mounting racks are equal in height;

FIG. 9B is a side, cross-sectional view of the solar panel mounting racks of FIG. 1 shown secured to a roof where the mounting racks define different heights;

FIG. 10 is a perspective view of several solar panels secured to the solar panel mounting system of FIG. 1; and

FIG. 11 is a side view of the building including several solar panels secured to the roof thereof via the solar panel mounting system of FIG. 1.

 DETAILED DESCRIPTION

Illustrative embodiments of the present disclosure are described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements.

Turning now to FIG. 1, one illustrative embodiment of a solar panel mounting system is shown generally identified by reference numeral 10. Solar panel mounting system 10 includes two (or more) solar panel mounting racks 100, 200 configured to securely mount a solar panel 300 (or solar panels) to a roof, e.g., a roof 410 of a building 400 (see FIG. 8). Each mounting rack 100, 200 of solar panel mounting system 10 is independent of the other mounting racks 100, 200, such that mounting racks 100, 200 may be positioned closer together, or farther apart with respect to one another to accommodate solar panels of varying dimensions. Additionally, more than two mounting racks 100, 200 may be provided for securing solar panel(s) 300 to roof 410 (see FIG. 8) and/or each mounting rack 100, 200 may be configured to secure multiple solar panels 300 thereto.

Solar panel mounting racks 100, 200 may be formed from any suitable bendable stock material, for example, heavy-gauge wire stock material having sufficient strength to support a plurality of solar panels mounted thereon and to withstand severe weather, e.g., wind and ice. However, it is also envisioned that solar panel mounting racks 100, 200 have some degree of flexibility to prevent fracture and/or disengagement from the roof in severe conditions. Some flexibility may also permit solar panel mounting racks 100, 200 to be bent in order to accommodate solar panels 300 of varying sizes and/or such that solar panel mounting racks 100, 1200 may be positioned on roofs of varying configurations. Thus, solar panel mounting racks 100, 200 may be formed from any suitable material with sufficient strength and flexibility. Further, solar panel mounting racks 100, 200 may be made from a non-corrosive material or may be coated with a non-corrosive material to inhibit rusting and to help maintain the strength and flexibility of solar panel mounting racks 100, 200 over time. Additionally, due to the wire-frame configuration of solar panel mounting system 10, solar panel mounting system 10 may be relatively light-weight and easy to maneuver while still maintaining sufficient strength to fixedly-retain one or more solar panels thereon.

With reference now to FIGS. 1-4, each solar panel mounting rack 100, 200 includes a plurality of generally “S”-shaped risers 110, 210, respectively, configured such that solar panel(s) 300 are spaced-apart from roof 410 (FIG. 8) when secured thereto. Each riser 110 of solar panel mounting rack 100 includes a body portion 112 and first and second support members 114, 116, respectively, disposed at either end of body portion 112 and extending in opposite directions with respect to each other. More particularly, as best shown in FIG. 3, support members 114, 116 may extend normally, i.e., at an angle of about 90 degrees, from body portion 112 in opposite radial directions to define the generally “S”-shaped configuration of risers 110, although other configurations are contemplated. Solar panel mounting rack 200 (FIG. 1) is substantially similar to solar panel mounting rack 100 and also includes a plurality of “S”-shaped risers 210, each including a body portion 212 and first and second support members 214, 216, respectively, extending from opposite ends of body portion 212.

With continued reference to FIGS. 1-4, risers 110, 210 of mounting racks 100, 200, respectively, may be formed as a single, integrated piece (as shown) or, alternatively, first and second support members 114, 214, 116, 216 of first and second mounting racks 100, 200, respectively, may be fixedly engaged to respective body portions 112, 212 in any suitable fashion, e.g., adhesion, welding, mechanical fastening, etc.

Referring now to FIGS. 5A and 5B, the first support member 114 of each riser 110 of first mounting rack 100 is fixedly engaged, e.g., welded, to a roof engaging member 120 that is configured to secure the riser 110 to the roof, e.g., roof 410 of residential home 400 (see FIG. 8). Roof engaging members 120 are relatively thin, rectangular-shaped panels having a slot 122 (FIG. 5A) or an aperture(s) 122′ (FIG. 5B) defined therethrough at a first end 124 thereof. Roof engaging members 120 may be formed from any suitable material having suitable strength to retain mounting rack 100 (including solar panels 300 mounted thereto) thereon. Roof engaging members 120 fixedly-engage first support members 114 at a second end 126 thereof.

More specifically, the first support member 114 of each riser 110 of mounting rack 100 is generally centered on and aligned with a corresponding roof engaging member 120. First support members 114 may be coupled, e.g., welded, to a top surface 128a of roof engaging members 120. With the first support member 114 of each riser 110 of mounting rack 100 engaged to a top surface 128a of a roof engaging member 120, roof engaging members 120 each define a generally planar bottom surface 128b that permits roof engaging members 120 to mate flush with roof 410 (see FIG. 8) when secured thereto. Such a configuration facilitate a secure engagement between roof engaging members 120 and roof 410 (FIG. 8) and also helps prevent debris and other materials from lodging between roof engaging members 120 and roof 410 (FIG. 8), which may compromise the engagement between roof engaging members 120 and roof 410 (FIG. 8).

Risers 210 (FIG. 1) and roof engaging members 220 of second solar panel mounting rack 200 (FIG. 1) are similarly configured to risers 110 and roof engaging members of first solar panel mounting rack 100 and, thus, the description of such will not be repeated.

With reference now to FIG. 6A, in conjunction with FIG. 4, a plurality, e.g., two (2), of spaced-apart transverse rails 130, 140 interconnect risers 110 to form mounting rack 100. Transverse rails 130, 140, as shown, may be parallel with respect to one another, as best shown in FIG. 6A, and may be spaced-apart a sufficient distance to permit insertion of a shank 510 (FIG. 7) of a securing member 500 (FIG. 7), e.g., the shank of a screw or bolt, therebetween, but in close-enough proximity to prevent washer 530 (FIG. 7) and securing member 500 (FIG. 7) from passing between transverse rails 130, 140. Second support members 116 of risers 110 are engaged, e.g., welded, to a bottom side 132, 142 of each of transverse rails 130, 140, respectively, and may be positioned substantially perpendicular with respect to transverse rails 130, 140. With second support members 116 of risers 110 engaged to bottom side 132, 142 of respective transverse rails 130, 140, transverse rails 130, 140 define a generally planar top side 134, 144, permitting solar panels 300 (FIG. 1) to mate flush with transverse rails 130, 140 when secured thereto, thereby facilitating a secure engagement therebetween. Further, risers 110 may be equally-spaced longitudinally along transverse rails 130, 140, as best shown in FIG. 1, although other configurations are contemplated. For example, greater (or fewer) risers 110 may be provided, i.e., risers 110 may be spaced closer-together or farther apart, depending on the required support strength of mounting rack 100, which may ultimately depend on the number, weight and dimensions of solar panels 300 to be mounted thereon. The risers 110, 210 may also be spaced according to the configuration of roof 410 (FIG. 8), e.g., such that each roof engaging member 120, 220 may be secured to a rafter 420 of roof 410 (see FIG. 7). Further, the risers 110, 210 and, thus, the roof engaging members 120, 220 may be spaced such that adjacent roof engaging members 120, 220 may be secured to adjacent rafters 420 (FIG. 7).

Referring momentarily back to FIG. 1, transverse rails 230, 240 of mounting rack 200 are similar to transverse rails 130, 140 of mounting rack 100. More specifically, transverse rails 230, 240 may be spaced-apart and substantially parallel with respect to one another to accommodate securing members 500 therebetween, and to accommodate washers 530 therearound, and may be fixedly-engaged to risers 210 on a bottom side thereof. As with mounting rack 100, risers 210 of mounting rack 200 may be equally spaced along a length of transverse rails 230, 240, or may be positioned along transverse rails 230, 240 in any other suitable configuration.

With reference now to FIG. 6B, another embodiment of a roof engaging member, roof engaging member 120″ is shown. Roof engaging member 120″, like roof engaging member 120 (FIG. 6) defines a relatively thin, elongated panel including first and second ends 124″ and 126″, respectively. First support member 114 of riser 110 is fixedly engaged to roof engaging member 120″ at second end 126″ thereof. A pair of longitudinal slots 122″ is defined through first end 124″ of roof engaging member 120″. Slots 122″ may be substantially parallel with respect to one another and, additionally, with respect to first support member 114.

With continued reference to FIG. 6B, roof engaging member 120″ includes a second panel 150 moveably engaged thereto such that roof engaging member 120″ defines an adjustable length. More particularly, second panel 150 includes an aperture 152 defined at a first end 154 thereof for securing second panel 150 to roof 410 (FIG. 8). Second end 156 of second panel 150 is overlapped by first end 124″ of roof engaging member 120″. A set screw 128″ is disposed through each of slots 122″ of roof engaging member 120″ and is engaged within a threaded aperture (not explicitly shown) of second panel 150. As can be appreciated, when set screws 128″ are tightened, the relative positioning of second panel 150 with respect to roof engaging member 120″ is fixed. However, when set screws 128″ are loosened, second panel 150 may be translated with respect to roof engaging member 120″, e.g., to a move-overlapping position or a less-overlapping position. Accordingly, second panel 150 may be translated with respect to roof engaging member 120″ from first ends 122a″ of slots 122″ to second ends 122b″ of slots 122″ (and visa versa) to decrease (or increase) the overall length of roof engaging member 120″. In other words, translating second panel 150 with respect to roof engaging member 120″ changes the distance between the solar panel 300 (FIG. 1) and the roof attachment point (slot 152). It is also contemplated that slots 122″ including graduations, or other indexing features (not shown) for providing incremental adjustment of roof engaging member 120″.

The adjustable configuration of roof engaging member 120″ allows mounting racks 100, 200 to be positioned between the shingles of a roof, e.g., shingles 440 (FIG. 7) of roof 410 (FIG. 7), regardless of the size and/or configuration of the shingles or the roof. Thus, the mounting racks 100, 200 may be adapted for use with a variety of roofs having different configurations, providing a secure engagement to the roof 410 (FIG. 7) and inhibiting compromise of the roof shingles 440 (FIG. 7) for each of the roof configurations.

Referring now to FIGS. 7 and 8, the installation of solar panel mounting racks 100, 200 and the securing of solar panel(s) 300 thereto will now be described. In the following description, by way of example, two solar panel mounting racks 100, 200 are positioned on opposite longitudinal sides 310, 320, respectively, of solar panel 300 for securing solar panel 300 to roof 410. However, as mentioned above, the number and positioning of solar panel mounting racks 100, 200 may vary depending on the size and dimensions of the solar panels 300. Additionally, as will be described in greater detail below, solar panel mounting racks 100, 200 may be configured, e.g., may have sufficient length, for securing multiple solar panels 300 thereto, as shown in FIGS. 10 and 11.

Initially, the positioning of first solar panel mounting rack 100 is determined. More specifically, first solar panel mounting rack 100 may be positioned on roof 410, away from obstructions that may shade a portion of the solar panels 300 when mounted thereto. It is also contemplated that the first solar panel mounting rack 100 be positioned to align roof engaging members 120 with one or more roof rafters 420 of building structure 410, such that first solar panel mounting rack 100 may be secured thereto and to help ensure a secure engagement. When the positioning has been determined, exposed portion 444 of a roof shingle 400, e.g., roof shingle 440a, as shown in FIG. 7, is bent, or curved upward such that roof engaging member 120 may be slid between adjacent shingles 440a, 440b. Roof engaging member 120 is slid underneath exposed portion 444 of roof shingle 440a and is slid on top of covered portion 442 of adjacent shingle 440b such that slot 122 defined at first end 124 of roof engaging member 120 is disposed between the adjacent shingles 440a, 440b, e.g., underneath the first shingle 440a and above the second shingle 440b, between the nails 446 that secure adjacent shingles 440a, 440b to the roof 410.

When properly positioned, a securing member 500, e.g., a screw, bolt, nail, etc., is inserted through the slot 122 (or aperture 122′) defined within roof engaging member 120 and is fixedly-engaged, e.g., anchored, within roof 410 to secure roof engaging member 120 to roof 410. In embodiments where roof engaging member 120 is positioned adjacent a roof rafter 420, securing member 500 is advanced into roof rafter 420 for securing roof engaging member 120 to roof 410. As can be appreciated, due to the positioning of roof engaging member 120, securing member 500 is advanced directly through roof 410, and not through any of shingles 440. Thus, the integrity of shingles 440 is maintained. Similarly, each of the other roof engaging members 120 disposed on first support members 114 of risers 110 of mounting rack 100 are fixedly-secured to roof 410 in a similar fashion, e.g., between adjacent shingles 440, such that first solar panel mounting rack 100 is fixedly-secured to roof 410 along a substantially length thereof without interfering with the shingling 440. It is envisioned that washers, braces, plates, or other additional securing components (not explicitly shown) may be used to facilitate securing of roof engaging members 120 to roof 410. Alternatively, roof engaging members 120 may be secured to roof 410 via any other suitable mechanism.

Next, second solar panel mounting rack 200 is positioned on roof 410, similarly as discussed above with regard to solar panel mounting rack 100, spaced-apart from first solar panel mounting rack 100 an appropriate distance for engaging first and second longitudinal sides 310, 320, respectively, of solar panel 300 to first and second solar panel mounting racks 100, 200, respectively. It is envisioned that second solar panel mounting rack 200 be substantially parallel to first solar panel mounting rack 100. As discussed above with respect to the embodiment of FIG. 6B, roof engaging member 120″ (and/or roof engaging member 220) may be adjusted for positioning adjacent a roof rafter 420, while still accommodating solar panel 300 such that each of roof engaging members 120″, 220 may be secured to a roof rafter 420, helping to ensure a secure engagement therebetween.

With second solar panel mounting rack 200 properly positioned, each roof engaging member 220 of second solar panel mounting rack 200 may be inserted between adjacent shingles 440 and secured to roof 410 similarly as mentioned above regarding first solar panel mounting rack 100 to fixedly-secure second solar panel mounting rack 100 to roof 410 and roof rafters 420.

With continued reference to FIGS. 7 and 8, once first and second solar panel mounting racks 100, 200, respectively, have been securely-engaged to roof 410 as described above, solar panel 300 may be mounted to solar panel mounting racks 100, 200. To mount solar panel 300 to each of solar panel mounting racks 100, 200, solar panel 300 is longitudinally aligned atop transverse rails pairs 130, 140 and 230, 240 of first and second solar panel mounting racks 100, 200, respectively. Next, a securing member 500, e.g., a screw or bolt, is inserted through washer 530 and from the bottom side 132, 142 of transverse rails 130, 140 up between the spaced-apart transverse rails 130, 140. Securing member 500 may then be fixedly-secured to solar panel 300 on first longitudinal side 310 thereof, e.g., screw 500 may be threadingly-engaged within a threaded aperture defined within a bottom surface 330 of solar panel 300 toward first longitudinal side 310 thereof, such that screw 500 and washer 530 secure solar panel 300 to transverse rails 130, 140. Similarly, another securing member 500 and washer 530 may be used to secure solar panel 300 to transverse rails 230, 240. Additional washers, braces, plates, or other additional securing components (not explicitly shown) may also be used to facilitate securing of solar panel 300 to transverse rail pairs 130, 140 and 230, 240. When engaged, securing members 500 and washers 530 secure solar panel 300 to transverse rails 130, 140 and 230, 240 of mounting racks 100, 200, respectively, on each longitudinal side 310, 320 of solar panel 300. In other words, the engagement of solar panel 300 and securing member 500 on bottom side 132, 142 of transverse rails 130, 140, respectively, and the positioning of washer 530 disposed between head 520 and transverse rails 130, 140 on a top side 134, 144 of transverse rails 130, 140, respectively, fixedly-secures solar panel 300 to the first and second solar panel mounting racks 100 and 200, respectively.

Solar panel 300 may be secured to first and second pairs of transverse rails 130, 140 and 230, 240, respectively, of first and second solar panel mounting racks 100, 200, respectively, as described above, at multiple positions (using a plurality of securing members 500) along the length of transverse rail pairs 130, 140, and 230, 240. The number and/or positioning of securing members 500 for securing solar panel 300 to solar panel mounting racks 100, 200 may be determined by the number of pre-defined apertures within solar panel 300 (which is determined by the manufacturer of the solar panel). As can be appreciated, the ability to position securing members 500 substantially along the entire length of transverse rail pairs 130, 140 and 230, 240 allows solar panel mounting system 10 to be adapted for use with solar panels having varying configurations, e.g., solar panels having varying number, size, shape and positioning of the securing components (e.g., threaded apertures) therealong.

With reference now to FIGS. 8 and 9A-9B, solar panel 300 is shown fixedly-secured to roof 410 of building 400, although solar panel mounting system 10 may be configured for mounting on a roof of any building structure. As best shown in FIG. 8, risers 110, 210 displace, or space-apart solar panel 300 from roof 410. As can be appreciated, this spaced-apart configuration permits rainwater and other debris to pass under solar panel 300, reducing any interference with the operation of solar panel 300 that may result from debris or other unwanted materials blocking the top, functional surface 340 of solar panel 300. Further, since the installation of solar panel mounting racks 100, 200 does not interfere or damage the shingles 440 of roof 410, the integrity of the roof is maintained.

As shown in FIG. 9A, the height of risers 110, 210 of first and second solar panel mounting racks 100, 200, respectively, are substantially equal such that solar panel 300 is substantially parallel with respect to roof 410 when mounted thereon. Such a configuration may be advantageous where a solar panel mounting racks 100, 200 are engaged to a shingled, angled roof, e.g., the roof of FIG. 8, having an adequate slope for receiving a relatively large amount of direct sunlight throughout the day.

However, where the roof is too flat (or too steep), positioning solar panel 300 substantially parallel with respect to the roof may limit the time, area and/or intensity of direct sunlight exposure to top surface 340 of solar panel 300. Accordingly, as shown in FIG. 9B, which depicts a roof 410′, riser 112 of first solar panel mounting rack 100 may define a first height “h” and riser 212′ of second solar panel mounting rack 200 may define a second, different height “H” such that solar panel 300 is disposed at an angle with respect to roof 410′. As can be appreciated, the solar panel mounting racks 100, 200 may define a range of heights such that solar panel 300 may be positioned on roofs of varying slope without reducing the time, area and/or intensity of direct sunlight exposure to top surface 340 of solar panel 300. Further, the uncoupled, or independent mounting racks 100, 200 permit interchanging of racks of carious heights and configurations, further addition to the versatility and adaptability of solar panel mounting system 10.

Referring now to FIGS. 10 and 11, solar panel mounting system 10 is shown including two pairs of solar panel mounting racks 100, 200 and 100′, 200′, each fixedly-securing multiple solar panels 300 thereto in an end-to-end configuration. As mentioned above, solar panel mounting racks 100, 200, 100′, 200′ may be configured to define lengths sufficient to secure multiple solar panels 300 thereto, or, alternatively, each pair of solar panel mounting racks 100, 200 and 100′, 200′ may be configured for securing a single solar panel 300 (on opposite longitudinal sides thereof) to roof 410.

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

1. A solar panel mounting rack, comprising:

a plurality of riser components, each riser component including a body portion, a first support member extending from a first end of the body portion and a second support member extending from a second end of the body portion;
a plurality of roof engaging members, each roof engaging member fixedly coupled to the first support member of one of the riser components, each roof engaging member defining an aperture therethrough for securing the riser components to a roof; and
a plurality of transverse rails, the second support members of each of the riser components fixedly coupled to the transverse rails, the riser components spaced apart relative to one another along a length of the transverse rails, the plurality of transverse rails positioned substantially parallel with respect to one another and defining at least one gap therebetween for securing a solar panel to the riser components.

2. The solar panel mounting rack according to claim 1, wherein the plurality of riser components are equally spaced along the transverse rails.

3. The solar panel mounting rack according to claim 1, wherein the first support members extend normally from the first ends of the body portions in a first direction and wherein the second support members extend normally from the second ends of the body portions in a second, opposite direction.

4. The solar panel mounting rack according to claim 1, wherein the roof engaging members are configured and dimensioned for positioning between overlapping roof shingles such that the integrity of the roof shingles is not compromised.

5. The solar panel mounting rack according to claim 1, wherein the roof engaging members are spaced relative to one another a pre-determined distance such that each of the roof engaging members is engageable with a roof rafter.

6. The solar panel mounting rack according to claim 1, wherein at least one of the roof engaging members includes an adjustable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

7. The solar panel mounting rack according to claim 1, wherein at least one of the riser components includes a bendable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

8. The solar panel mounting rack according to claim 1, wherein two substantially parallel transverse rails interconnect the riser components along a length of the transverse rails.

9. The solar panel mounting rack according to claim 1, wherein each riser component is formed as a single, integrated piece.

10. The solar panel mounting rack according to claim 1, wherein the first support member of each riser component is welded to one of the roof engaging members.

11. The solar panel mounting rack according to claim 1, wherein the transverse rails are welded to the second support members of each riser component.

12. The solar panel mounting rack according to claim 1, wherein the transverse rails are configured and dimensioned to secure at least one solar panel longitudinally along a longitudinal side of the solar panel.

13. The solar panel mounting rack according to claim 1, wherein, when the roof engaging members are engaged to the roof and when the solar panel is engaged to the transverse rails, the solar panel is spaced-apart from the roof.

14. The solar panel mounting rack according to claim 1, wherein the transverse rails define a substantially linear configuration.

15. A solar panel mounting system, comprising:

first and second solar panel mounting racks, each solar panel mounting rack including: a plurality of riser components, each riser component including a body portion, a first support member extending from a first end of the body portion and a second support member extending from a second end of the body portion; a plurality of roof engaging members, each roof engaging member fixedly coupled to the first support member of one of the riser components, each roof engaging member defining an aperture therethrough for securing the riser components to a roof; and a plurality of transverse rails, the second support members of each of the riser components fixedly coupled to the transverse rails, the riser components spaced apart relative to one another along a length of the transverse rails, the plurality of transverse rails positioned substantially parallel with respect to one another and defining at least one gap therebetween for securing a solar panel to the riser components; and
wherein, the first solar panel mounting rack is configured to secure the solar panel thereto toward a first longitudinal side of the solar panel and wherein the second solar panel mounting rack is configured to secure the solar panel thereto toward a second, opposite longitudinal side of the solar panel.

16. The solar panel mounting system according to claim 15, wherein a length of the body portions of each of the first and second solar panel mounting racks is substantially equal such that the solar panel is substantially parallel with respect to the roof when mounted thereon.

17. The solar panel mounting system according to claim 15, wherein a length of the body portions of the first solar panel mounting rack is different from a length of the body portions of the second solar panel mounting rack such that the solar panel is angled with respect to the roof when mounted thereon.

18. The solar panel mounting system according to claim 15, wherein the roof engaging members are configured and dimensioned for positioning between overlapping roof shingles such that the integrity of the roof shingles is not compromised.

19. The solar panel mounting system according to claim 15, wherein at least one of the roof engaging members includes an adjustable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

20. The solar panel mounting system according to claim 15, wherein at least one of the riser components includes a bendable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

21. The solar panel mounting system according to claim 15, wherein the roof engaging members of each of the first and second solar panel mounting racks are sufficiently spaced relative to one another for engaging at least one roof rafter.

22. The solar panel mounting system according to claim 15, wherein the roof engaging members of each of the first and second solar panel mounting racks are sufficiently spaced relative to one another such that each of the roof engaging members is engageable a roof rafter.

23. The solar panel mounting system according to claim 22, wherein the roof engaging members are spaced such that adjacent roof engaging members are engageable with adjacent roof rafters.

24. The solar panel mounting system according to claim 15, wherein the plurality of riser components of each of the first and second solar panel mounting racks are equally spaced along the transverse rails.

25. The solar panel mounting system according to claim 15, wherein the first support members extend normally from the first ends of the body portions in a first direction and wherein the second support members extend normally from the second ends of the body portions in a second, opposite direction.

26. The solar panel mounting system according to claim 15, wherein two substantially parallel transverse rails interconnect the riser components along a length of the transverse rails.

27. The solar panel mounting system according to claim 15, wherein each riser component is formed as a single, integrated piece.

28. The solar panel mounting system according to claim 15, wherein the first support member of each riser component is welded to one of the roof engaging members.

29. The solar panel mounting system according to claim 15, wherein the transverse rails are welded to the second support members of each riser component.

30. The solar panel mounting system according to claim 15, wherein the transverse rails are configured and dimensioned to secure at least one solar panel longitudinally along a longitudinal side of the solar panel.

31. The solar panel mounting system according to claim 15, wherein, when the roof engaging members are engaged to the roof and when the solar panel is engaged to the transverse rails, the solar panel is spaced-apart from the roof.

32. The solar panel mounting system according to claim 15, wherein the transverse rails define a substantially linear configuration.

33. A method of attaching a solar panel to a roof, the method comprising the steps of:

providing first and second solar panel mounting racks, each solar panel mounting rack including: a plurality of riser components; a plurality of roof engaging members, each roof engaging member fixedly coupled to one of the riser components, each roof engaging members defining an aperture therethrough for securing the riser components to a roof; and a plurality of transverse rails, each riser component fixedly coupled to the transverse rails, the riser components spaced apart relative to one another along a length of the transverse rails, the plurality of transverse rails defining at least one gap therebetween for securing a solar panel to the riser components;
attaching each roof engaging member of the first solar panel mounting rack to the roof;
attaching each roof engaging member of the second solar panel mounting rack to the roof such that the first and second solar panel mounting racks are spaced-apart from one another a distance not greater than a width of the solar panel;
attaching the solar panel to the transverse rails of the first solar panel mounting rack toward a first longitudinal side of the solar panel; and
attaching the solar panel to the transverse rails of the second solar panel mounting rack toward a second longitudinal side of the solar panel.

34. The method according to claim 33, further comprising the step of attaching additional solar panels to the solar panel mounting racks such that the solar panels are positioned end-to-end with respect to one another and extend longitudinally along the transverse rails of the first and second mounting racks.

35. The method according to claim 33, wherein a securing member is disposed through the aperture defined within each of the roof engaging members for attaching the solar panel mounting racks to the roof.

36. The method according to claim 33, wherein securing members are disposed through the at least one gap defined between the transverse rails at a plurality of positions along the transverse rails for attaching the solar panel to the solar panel mounting racks.

37. The method according to claim 33, wherein, when the roof engaging members are engaged to the roof and when the solar panel is engaged to the transverse rails, the solar panel is spaced-apart from the roof.

38. The method according to claim 33, wherein a height of each of the first and second solar panel mounting racks is substantially equal such that the solar panel is substantially parallel with respect to the roof when mounted thereon.

39. The method according to claim 33, wherein a height of the first solar panel mounting rack is different from a height of the second solar panel mounting rack such that the solar panel is angled with respect to the roof when mounted thereon.

40. The method according to claim 33, wherein the roof engaging members of the first and second solar panel mounting racks are attached to the roof between overlapping roof shingles such that the integrity of the roof shingles is not compromised.

41. The method according to claim 33, wherein at least one of the roof engaging members of at least one of the first and second solar panel mounting racks includes an adjustable portion for adjusting the longitudinal distance between a roof engagement point and a solar panel engagement point.

42. The method according to claim 41, further comprising the step of adjusting the adjustable portions of the roof engaging members such that the first and second solar panel mounting racks are attached to the roof between overlapping roof shingles

Patent History
Publication number: 20110314751
Type: Application
Filed: Jun 29, 2010
Publication Date: Dec 29, 2011
Inventor: Roger Jette (West Islip, NY)
Application Number: 12/826,003
Classifications
Current U.S. Class: With A Sunlight Activated Device (e.g., Passive Solar Or Photoelectric) (52/173.3); Roof (248/237); Anchor, Bond, Etc. (52/745.21)
International Classification: E04D 13/18 (20060101); E04B 7/18 (20060101);