METAL BUILDING ROOF MOUNT FOR SOLAR ARRAY
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.
This application is a continuation of U.S. application Ser. No. 16/331,124, filed Mar. 6, 2019, entitled METAL BUILDING ROOF MOUNT FOR SOLAR ARRAY, which is a continuation of International Application No. PCT/US2019/014628, filed Jan. 22, 2019, entitled METAL BUILDING ROOF MOUNT FOR SOLAR ARRAY, which in turn claims the benefit of U.S. Provisional Patent Application Ser. No. 62/619,273, filed on Jan. 19, 2018, all of which are incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION 1. Field of the InventionThe present invention relates generally to solar panels, solar heating, and other solar based systems for rooftop positioning on buildings. More particularly, it relates to a system for mounting solar panel arrays of photovoltaic or heating in solar heating arrays or the like on building rooftops which have a roof formed of engaged metal rooftop panels or homes having a wood roof or similar planar rooftop installations. The system provides cooperatively engageable metal roof panels for forming a rack system with a sealed roof of the building, which so engaged, concurrently provides a plurality of vertically projecting sections of adjacent panels. These projecting sections formed as part of each adjacent roof panel form above support members for supporting a solar panel for photovoltaic or water heating or another frame-engaged array, elevated above the formed roof and form a passage therebetween. An engageable astragal is positionable to secure the solar panels and seal the passage between projecting sections of adjacent roof panels.
2. Prior ArtIn recent years, it has become more popular in the United States and many foreign countries for building owners to install solar panels and solar heating and other solar-based devices on the rooftops of such building. Such installations of solar panel arrays generate electricity which can power the building itself or be communicated to the local grid. Many state and national governments offer tax incentives to building owners who make the financial commitment to install solar panels on such buildings.
Conventional metal roof systems, however, perform acceptable weatherproofing functions but such metal roof panels are currently configured for engagement to each other and underlaying support surfaces. However, they are not configured to incorporate solar panel attachment as part of the formed roof panels and roof structure.
Solar panel and solar heating attachment to roofs, via conventional racking, is not a designed or intended use of any other roofing system. While racked solar panel engagement to roofs is allowable, the piercing of the metal roof panels to mount the various components for holding solar panels in an array on the metal rooftop, is not desirable because the more screws and fasteners which pierce the seal of a roof panel, the more likely it is to leak over time. Further, solar system engagement mounting components and fasteners and the like are designed and sold separately from the roof panels, and the panels themselves have no structural accommodation to hold the solar panels or their mounting system.
As a consequence, solar racking systems continue to employ a conventional rail mounting system for the solar panel array, in both tilt leg and flush mount configurations. They do not, however, integrate the solar panels with the metal roof system itself and, thus, do not provide both roofing panels adapted for engagement to each other which also configure on the roof for a seamless engagement with the solar panel array.
Such a lack of integration between metal roofing panels and the solar array engaged with them has caused conventional solar panels to be mounted a distance above the underlying metal roof panels. Such causes problems such as an uplifting force from wind communicating between the solar panels and the metal roof panels which can cause significant damage. Further, conventional systems having a gap up to five inches or more between the solar panels, and roof panels allow birds and small animals to climb into the gap where they nest. This animal occupancy can wreak havoc with the mechanics of tilting solar panels along with leaves and debris which can enter the gap.
The forgoing examples of related art as to solar panel and solar heating systems and their engagement to metal rooftops, and limitations related therewith, are intended to be illustrative and not exclusive, and they do not imply any limitations on the invention described and claimed herein. Various limitations of the related art will become apparent to those skilled in the art upon a reading and understanding of the specification below and the accompanying drawings.
SUMMARY OF THE INVENTIONThe device herein disclosed and described provides a solution to the shortcomings in prior art with regard to engaging solar panels, solar heating components, and other solar arrays to the rooftops of buildings having metal roofs. While, for convenience, the language herein is directed primarily to photovoltaic solar panels, the mounting system herein is also configurable to hold solar heating panels, and other solar-energized components on a rooftop of a metal building. As such, when the term solar panel is employed herein, any boxed or paneled component which is rooftop-mounted on a metal building is to be considered included.
The integrated metal roof and solar mounting system herein, is configured to allow conventional solar photovoltaic arrays to be installed with a metal roofing system using the same construction means and methods that are conventionally already widely used in the roofing industry. Thus, no exceptional training or tools are required for the installation of the metal roof panels herein, to the underlying structure.
One core element to the system herein is the provision of metal roofing sections, which are adapted for attachment to the underlying support surface for the roof in a conventional screw type engagement. However, rather than conventional planar opposing side edges for each metal roof panel, the opposing side edges of the metal roof panels of the system herein include the addition of vertically projecting portions running along opposing side edges. Each such metal roof panel is a unitary planar structure which on opposing sides has a bend which forms projecting side portions. One side portion extends substantially normal to the planar portion in between. The opposing side portion is adapted to slidably engage with that of an adjacent metal roof panel to allow for adjustment. By planar is meant substantially flat, although, corrugations or channels are formed in a conventional fashion which run parallel to the opposing sides of the metal roof panel and, thus, substantially parallel to the projecting portions on both sides.
Also provided is an astragal which is employable to compress and secure a solar panel to the roof formed by the metal panels. This astragal additionally forms a seal over adjacent roof panels in another particularly preferred component of the device and method herein. The formation of the metal roof panels with opposing projecting and slidably engaged side edges, and the inclusion of the astragal herein which is configured to hold the solar panels and concurrently seal the two adjacent roof panels and their respective projecting edges, effectively merges two historically different scopes of work into one, and roofing and solar panels become a solar roof system.
The roofing system herein increases the performance of the solar collection of the array, and with the system herein, the solar materials provide additional insulation factors that improve the heat loss/gain profile of the roof. This is accomplished with the system herein by its configuration which traps a layer of air between the solar panels and metal roof panels which also provide shade to the roof surface formed of the engaged metal panels herein.
Still further the system herein provides channels and gaps which protect the electrical conductors of the solar panels in the formed array. Additionally, for aesthetic reasons the system herein allows for insulation blanks to be positioned where needed to improve the seamless aesthetic of the installation of the solar array of panels along valleys and gables. Still further, by combining the solar panels and roof and underlying structure into a single function, the value of the tax credit to the building owner can increase substantially.
With respect to the above description, before explaining at least one preferred embodiment of the herein disclosed metal roofing system with integrated solar panel engagement and the method therefor, it is to be understood that the disclosed system herein is not limited in its application to the details of construction and to the arrangement of the components in the following description or illustrated in the drawings. The invention herein described is capable of other embodiments and of being practiced and carried out in various ways which will be obvious to those skilled in the art. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other roof and solar panel structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.
The objects, features, and advantages of the present invention, as well as the advantages thereof over existing prior art, which will become apparent from the description to follow, are accomplished by the improvements described in this specification and hereinafter described in the following detailed description which fully discloses the invention, but should not be considered as placing limitations thereon.
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:
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 INVENTIONIn 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.
Now referring to drawings in
In
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 (
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.
As shown in
An astragal 24, shown in
Depicted in
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
Also shown in
While not shown in detail in
Shown in
Shown in
In
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
As can be seen in
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.
In the system 10 herein, in a first step, shown in
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.
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.
In
This is followed by the positioning of the rest of the roof panel portions 12A shown in
Thereafter as shown in
Whether the roof panels 12 are formed in a single unit with projecting portions 14 on both opposing sides as in
Finally,
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.
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.
Type: Application
Filed: Sep 13, 2021
Publication Date: Dec 30, 2021
Inventor: Aaron Eriksson (Nolensville, TN)
Application Number: 17/473,104