BALLASTED SOLAR HOT WATER RACKING SYSTEM FOR FLAT PLATE COLLECTORS

A solar ballasted racking system holds hot water flat plate solar collectors in place on flat roofs without penetrating the roof surface. The racking system also holds the collector in place, providing a stable, long-term placement on the roof while protecting the roof surface with foam pads placed under the ballast tray. The ballast tray is built in two sections—one to hold the solar collector in place and a second to act as a wind deflector that deflects the wind off the solar collector. Ballast blocks are added into the ballast tray to hold the collector in place. The racking system may enhance the life of the roof while protecting the roof surface and allowing for lower ballasted weights due to the wind deflector.

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Description
BACKGROUND OF THE INVENTION

The present invention relates to solar energy systems and, more particularly, to a ballasted solar hot water racking system that holds hot water flat plate solar collectors in place on flat roofs without penetrating the roof surface.

The present method of mounting flat plate hot water solar collectors is to use racking systems that attach directly to the roof or use a concrete curb system that sits on the roof and can potentially damage the roof surface. These conventional mounting systems are often time consuming to build and install, often resulting in leaks in the roof surface over time.

As can be seen, there is a need for an improved solar hot water racking system for flat plate collectors.

SUMMARY OF THE INVENTION

In one aspect of the present invention, a solar flat plate collector racking system comprises a main unit ballast tray adapted to rest on a roof surface; a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface; at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray; a wind deflector ballast tray attached to the main unit ballast tray; a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray; and a wind deflector attached to the wind deflector channel.

In another aspect of the present invention, a solar flat plate collector racking system comprises a main unit ballast tray adapted to rest on a roof surface; a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface; at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray; a wind deflector ballast tray attached to the main unit ballast tray; a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray; a wind deflector attached to the wind deflector channel; side support angle extending from the main unit ballast tray and attached to the wind deflector ballast tray; a support angle disposed at the connection between the ballast back tray and the main unit ballast tray; and mounting brackets disposed on an edge of the main unit ballast tray and the ballast back tray.

In a further aspect of the present invention, a method for support a solar collector comprises attaching the solar collector to a racking system, the racking system including a main unit ballast tray adapted to rest on a roof surface; a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface; at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray; a wind deflector ballast tray attached to the main unit ballast tray; a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray; and a wind deflector attached to the wind deflector channel; and weighting down the racking system with one or more ballast blocks disposed in at least one of the main unit ballast tray and the wind deflector ballast tray, wherein the racking system rests on a roof surface without penetrating the roof surface.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of solar flat plate collector racking system according to an exemplary embodiment of the present invention;

FIG. 2 is a top view of the solar flat plate collector racking system of FIG. 1;

FIG. 3 is a side view of the solar flat plate collector racking system of FIG. 1;

FIG. 4 is an end view of the solar flat plate collector racking system of FIG. 1; and

FIG. 5 is an exploded view of the solar flat plate collector racking system of FIG. 1.

 DETAILED DESCRIPTION OF THE INVENTION

The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a solar ballasted racking system that holds hot water flat plate solar collectors in place on flat roofs without penetrating the roof surface. The racking system also holds the collector in place, providing a stable, long-term placement on the roof while protecting the roof surface with foam pads placed under the ballast tray. The ballast tray is built in two sections—one to hold the solar collector in place and a second to act as a wind deflector that deflects the wind off the solar collector. Ballast blocks are added into the ballast tray to hold the collector in place. The racking system of the present invention may enhance the life of the roof while protecting the roof surface and allowing for lower ballasted weights due to the wind deflector.

Referring now to FIGS. 1 through 5, a racking system 10 may include a main unit ballast tray 26 adapted to rest on a flat roof (not shown). A foam pad (not shown) may be disposed under the ballast tray 26 to provide cushioning between the main unit ballast tray 26 and the roof.

A ballast back tray 24 may attach along one side of the main unit ballast tray 26 at generally a 90 degree angle thereto, such that the ballast back tray 24 extends away from the roof surface when the racking system 10 is installed on a flat roof. A support angle 34 may be disposed where the main unit ballast tray 26 attaches to the ballast back tray 24. In some embodiments, the edge along the ballast back tray 24 and/or the edge along the main unit ballast tray 26 may be bent at a 90 degree angle to help secure these two elements together. The ballast back tray 24 may be secured to the main unit ballast tray 26 by conventional fasteners. In some embodiments, the ballast back tray 24 may be welded to, or formed integrally with, with main unit ballast tray 26.

Support straps 14 may run diagonally between the ballast back tray 24 and the main unit ballast tray 26 to provide additional support. In some embodiments, two support straps 14 may be spaced apart in each racking unit 10.

Support angle 30 may span at least part of the length of the ballast back tray 24. The support angle 30 may run generally parallel to the main unit ballast tray 26. In some embodiments, two support angles 30 may be spaced apart, running along the length of the ballast back tray 24. The support angle 30 may provide structural support for the ballast back tray 24. There may be from zero to about four such support angles 30 disposed on the ballast back tray 24.

The main unit ballast tray 26 may have an edge (an edge opposite the edge to which the ballast back tray 24 is attached) bent upward (parallel to the ballast back tray 24) and then bent outward (parallel to the main unit ballast tray 26 surface, but away therefrom) to provide a mounting surface. One or more, typically two, mounting brackets 16 may be attached to this mounting surface. Other mechanisms may be used to disposed the mounting brackets 16 onto the edge of the main unit ballast tray 26. Additional mounting brackets 16 may be attached to an upper edge of the ballast back tray 24.

A solar collector 12 may mount onto the mounting brackets 16. The design of the mounting brackets 16 may vary depending on the design and manufacturer of the solar collector 12. The solar collector 12 may be disposed at various angles from about 20 to about 60 degrees, for example. This angle may be adjusted by adjusting the height of the ballast back tray 24.

Side support angle 32 may connect to and extend from each outer edge of the main unit ballast tray 26. The side support angle 32 may extend to and attach to a wind deflector ballast tray 28. A wind deflector channel 20 may extend from the wind deflector ballast tray 28 to the ballast block tray 24. In some embodiments, two wind deflector channels 20 may be disposed on each end of the racking system 10 to support a wind deflector 18 thereupon. The wind deflector 18 may be adapted to block wind from blowing directly against the solar collector 12. The wind deflector 18 may also reduce the amount of ballast weight, described below, needed to hold the racking system 10 in place on the roof. The wind deflector 18 may be mounted at various angles relative to the roof. This angle may vary from about 30 degrees to about 70 degrees, typically about 50 degrees. The angle may be controlled, independently of the angle of the solar collector 12, by adjusting the location along the side support angle 32 to which the main unit ballast tray 26 and the wind deflector ballast tray 28 are attached.

Ballast block 22 may be disposed on the main unit ballast tray 26 and the wind deflector ballast tray 28. The ballast block 22 may be, for example, concrete, iron, steel, or the like. Typically, the ballast block 22 may be concrete. The weight of the ballast block 22 may be suitable to retain the racking system 10 to the roof. The wind deflector 18 may permit the use of less ballast block weight as compared to conventional systems without a wind deflector.

The racking system 10 allows the solar contractor who is installing the flat plate solar collector to assemble the racking system 10 with simple tools, providing for ease of use. The ballast trays 26, 28 supports the solar panel 12 while using simple braces 14 which are attached to the bottom of the main unit ballast tray 26 and the ballast back tray 24. The mounting brackets 16 may be pre-drilled so that the contractor may simply line up the brackets 16 to the lips on the main unit ballast tray 26 and the ballast back tray 24 and attach mounting clips to the mounting brackets 16 to install the solar panel 12. The contractor may make the necessary plumbing connections and install the wind deflector 18 to the support channel 20 with, for example, sheet metal screws.

It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.

Claims

1. A solar flat plate collector racking system comprising:

a main unit ballast tray adapted to rest on a roof surface;
a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface;
at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray;
a wind deflector ballast tray attached to the main unit ballast tray;
a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray; and
a wind deflector attached to the wind deflector channel.

2. The solar flat plate collector racking system of claim 1, further comprising side support angle extending from the main unit ballast tray and attached to the wind deflector ballast tray.

3. The solar flat plate collector racking system of claim 1, further comprising one or more support angles disposed along a length of the ballast back tray.

4. The solar flat plate collector racking system of claim 1, further comprising a support angle disposed at the connection between the ballast back tray and the main unit ballast tray.

5. The solar flat plate collector of claim 1, further comprising mounting brackets disposed on an edge of the main unit ballast tray and the ballast back tray.

6. The solar flat plate collector of claim 1, further comprising one or more ballast blocks adapted to be disposed in at least one of the main unit ballast tray and the wind deflector ballast tray.

7. A solar flat plate collector racking system comprising:

a main unit ballast tray adapted to rest on a roof surface;
a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface;
at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray;
a wind deflector ballast tray attached to the main unit ballast tray;
a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray;
a wind deflector attached to the wind deflector channel;
side support angle extending from the main unit ballast tray and attached to the wind deflector ballast tray;
a support angle disposed at the connection between the ballast back tray and the main unit ballast tray; and
mounting brackets disposed on an edge of the main unit ballast tray and the ballast back tray.

8. The solar flat plate collector racking system of claim 7, further comprising one or more support angles disposed along a length of the ballast back tray.

9. A method for support a solar collector, the method comprising:

attaching the solar collector to a racking system, the racking system including: a main unit ballast tray adapted to rest on a roof surface; a ballast back tray attached to the main unit ballast tray and adapted to extend away from the roof surface; at least two support straps running diagonally between and attached to the main unit ballast tray and the ballast back tray; a wind deflector ballast tray attached to the main unit ballast tray; a wind deflector channel extending from the wind deflector ballast tray to the ballast back tray; and a wind deflector attached to the wind deflector channel; and
weighting down the racking system with one or more ballast blocks disposed in at least one of the main unit ballast tray and the wind deflector ballast tray,
wherein the racking system rests on a roof surface without penetrating the roof surface.

10. The method of claim 9, further comprising deflecting wind from the racking system and the solar collector.

Patent History
Publication number: 20130192587
Type: Application
Filed: Feb 1, 2012
Publication Date: Aug 1, 2013
Inventors: David B.P. Lewenz (St. Petersburg, FL), Michael Joseph Moulder (Wilmington, DE)
Application Number: 13/364,232
Classifications
Current U.S. Class: Solar Collector Supported On Existing Roof Structure (126/623); Solar Energy Device Making (29/890.033)
International Classification: E04D 13/18 (20060101); B21D 53/02 (20060101);