SOLAR PANEL ROOF MOUNTING BRACKET AND RELATED METHODS

Abstract

A system for mounting at least one solar panel on a roof may include a plurality of panel mounting brackets each including a base to be positioned on the roof having a first opening(s) therein, and a vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends. The distal end may define a fastener channel having a fastener slot opening vertically aligned with the first opening(s) in the base. The central portion may include a cross member(s) defining a second opening(s) therein vertically aligned with the fastener slot opening and the first opening(s) in the base. The system may further include a bracket fastener(s) to be inserted through the fastener slot opening, the second opening(s), and the first opening(s) of a respective panel mounting bracket and coupled to the roof.

Description

TECHNICAL FIELD

The present disclosure generally relates to mounting fixtures, and, more particularly, to mounting fixtures or brackets for panel installations, such as for solar panels, for example, to standing seam metal rooftops.

BACKGROUND

Solar panels, such as photovoltaic (PV) and solar water heating panels, are frequently used to take advantage of electrical power generation and heating properties of sunlight. To provide space savings and potentially enhanced efficiency, solar panels are in many cases installed on rooftops of buildings (e.g., office buildings, houses, etc.). However, because of winds and storms, the mounting fixtures used for installing solar panels on buildings need to be sufficiently strong and durable to reduce the chances of damage or injury from a panel coming loose during a storm, etc.

Various mounting fixtures have been developed for solar panel installation. For example, U.S. Pat. No. 7,963,074 discloses a device for fixing a photovoltaic module on a sloping roof having a roof structure and a roof covering with individual roof covering elements. The device includes a roof-side connecting piece disposable beneath the roof covering and a module-side connecting piece disposable on an edge of the photovoltaic module. A flexible retaining element interconnects the roof-side connecting piece and the module-side connecting piece. The flexible retaining element is loadable by pulling and adapted to be guided through the roof covering without altering a position or shape of the individual roof covering elements.

Despite the existence of such mounting fixtures, further enhancements may be desirable in some applications.

SUMMARY

A system for mounting at least one solar panel on a roof may include a plurality of panel mounting brackets each including a base to be positioned on the roof having at least one first opening therein, and a vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends. The distal end may define a fastener channel having a fastener slot opening vertically aligned with the at least one first opening in the base. The central portion may include at least one cross member defining at least one second opening therein vertically aligned with the fastener slot opening and the at least one first opening in the base. The system may further include at least one bracket fastener to be inserted through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupled to the roof. Furthermore, a plurality of clamps and corresponding clamp fasteners may be configured to couple the at least one solar panel with the fastener channel of a respective panel mounting bracket so that each clamp fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel.

The at least one first opening may comprise a plurality of spaced-apart first openings, the at least one second opening may comprise a plurality of second spaced-apart openings, and the at least one bracket fastener may comprise a plurality of bracket fasteners for each panel mounting bracket. Furthermore, the at least one cross member may comprise a plurality of cross members vertically spaced apart from one another.

The at least one first opening may comprise a central opening in the base, and the base may further define a plurality of peripheral openings laterally spaced apart from the central opening. The base may have a non-linear cross section, such as a an arcuate cross section, for example. The base may have a bottom surface to be positioned on the roof, and each bracket may further include a pad coupled to the bottom surface.

A related panel mounting bracket, such as the one described briefly above, is also provided. A related method is for mounting at least one solar panel on a roof, which may include arranging a plurality of panel mounting brackets, such as the ones described briefly above, on the roof. The method may also include inserting at least one bracket fastener through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupling the bracket fastener to the roof, and coupling a plurality of clamps and corresponding clamp fasteners to the at least one solar panel so that each fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an end view of a panel mounting bracket in according with an exemplary embodiment of the invention including a set screw locking mechanism.

FIG. 2 is an end view of a panel mounting bracket in according with an alternative embodiment of the invention including a cam bolt locking mechanism.

FIG. 3 is an end view of a panel mounting bracket in according with another alternative embodiment of the invention including a toothed locking cam mechanism.

FIGS. 4-6 are end views illustrating the installation of the brackets of FIGS. 1-3, respectively, on a metal standing seam rooftop.

FIG. 7 is a side view of a solar panel installation with an end-clamp using one the bracket of FIG. 1.

FIG. 8 is a side view of a panel installed with a mid-clamp using the bracket of FIG. 1.

FIG. 9 is a top view illustrating solar panel installation panel using the bracket of FIG. 1.

FIGS. 10-12 are bottom, side, and top views, respectively, of the mounting bracket of FIG. 2.

FIGS. 13-15 are end, bottom, and cutaway end views, respectively, of the mounting bracket of FIG. 3.

FIGS. 16-17 are side and top views, respectively, of another exemplary embodiment of a panel mounting bracket.

FIGS. 18-20 are top, side, and perspective views, respectively, of another exemplary embodiment of a panel mounting bracket which includes holes for providing rafter connections.

FIGS. 21 and 22 are side views of further exemplary bracket embodiments including various based profiles.

DETAILED DESCRIPTION

The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in different embodiments.

Referring initially to FIGS. 1-3, mounting brackets 30, 30′, and 30″ (which are individually also referred to as a “foot” herein) for installing panels or modules, such as solar modules, is first described. By way of background, solar modules or panels are typically mounted to standing seam metal roofs with clamps that tighten against the seam alone but do not simultaneously rest on the flat portion of the metal roof. The mounting brackets 30, 30′, and 30″ illustrated in FIGS. 1 through 3 advantageously set firmly against the flat portion of a seemed roof so as to remain perpendicular to the roof without rotating or twisting or allowing the solar modules, when installed, to shift as with typical clamps that are only attached to the standing seam of the metal roof. The mounting brackets 30, 30′, and 30″ have a generally rectangular central vertical extension portion or rail with a hollow central area or channel therethrough defined by a plurality of cross members. An upper slot or groove for attaching a bolt (e.g., a hex head bolt) and/or nuts, is provided on the top of the mounting brackets 30, 30′, and 30″. It should be noted that the exemplary dimensions provided in FIGS. 1-3 are for illustrational purposes, and that other dimensions and brackets sizes may be used in different embodiments. The hollow channels in the vertical upper rail portion extend laterally therethrough, and may be used for routing electrical wiring, for example, if desired.

Flanges or extensions at the bottom of the mounting brackets 30, 30′, and 30″ extend outwardly away from the central portion so as to sit flat on the rooftop or roof deck upon installation. Serrations or other surface features may optionally be included on the top and/or bottom of the central portion (and flanges), if desired. The serrations may advantageously provide for improved electrical grounding with the frame of the module, as well as increased grip or friction, for example. A pad of or other insulating material may optionally be included on the bottom of the flanges to protect the standing seam metal roof from being damaged by the flanges.

In the illustrated example, the mounting brackets or feet 30, 30′, and 30″ clamp and hold the solar modules via bolts which screw downward through end and mid clamps into nuts located in the top rails, as seen in FIGS. 7 and 8, for example.

A first row of panels 90 (FIG. 9) may then be attached on the roof by clamping to the existing standing seams on standing seam metal roofs as shown in FIGS. 4-6 for the mounting brackets 30, 30′, and 30″, respectively. Again, an end-clamp may be used as demonstrated in FIG. 7. A next row of modules may then be attached with additional mounting brackets 30, 30′, or 30″ on the bottom of the second row modules with a mid-clamp, as shown in FIG. 8. It should be noted that different mounting brackets 30, 30′, and 30″ may be used during an installation, that this, not all of the same type of mounting bracket need by used in a given installation, but rather they may be intermixed.

The above steps may be repeated for each row of modules to be installed, until the last row of modules is in place. The last module of each row may be attached to the mounting brackets 30, 30′, and 30″ using end-clamps as discussed above.

It should be noted that the mounting brackets 30, 30′, and 30″ need not be hollow in all embodiments, and that different shapes beside a rectangular shape may also be used in some embodiments. Example materials for the foot 30 may include aluminum, which may be extruded into the desired shape, although other suitable materials may also be used in different embodiments. For example, composite materials (e.g., fiber-reinforced polymer, etc.) may be used in some applications, which may also provide an added benefit with respect to electrical grounding, for example. The various locking mechanisms may be made of metal components, such as stainless steel, aluminum, etc.

It should also be noted that the above-described mounting feet or brackets may be used with a variety of standing seam profiles.

In addition to being used for standing seam metal roofs as described above, the same part can be used with or without the chamfer in the base to mount solar panels to flush mount roofs by attaching them to the decking with decking screws through mounting holes on each side of the vertical upper rail portion of the mount. As a result, the bracket mount may be more versatile than typical brackets, as it may be used for both standing seam metal roofs and flush mount roof applications. More particularly, the bracket may be used for composition shingle mount roofs, flat roofs, and sheet metal roofs with screws or other suitable mounting hardware (e.g., bolts, etc.) designed for such decking, for example.

Example embodiments of brackets 130, 230 without the standing seam chamfer are shown in FIGS. 16-20. The bracket 230 has central holes or openings drilled or formed in the center of the vertical upper rail portion for centering them over roof rafters for mounting with longer wood screws (see FIGS. 18-20). While it may typically be easier to install a bracket using only decking screws on the flanges to either side of the vertical upper rail portion, some local building codes may require that solar fixtures be secured to trusses or rafters, as opposed to decking alone, and the rafter screw holes may be used in such jurisdictions. Decking screws may still be installed through peripheral mounting holes on each side of the upper portion of the rail to provide added strength and stability, if desired. Accordingly, in different embodiments, holes for rafter screws or decking screws, or both, may be provided on the bracket, with or without a chamfer for a standing seam. Moreover, different numbers of rafter screw holes and decking screw holes may be used in different embodiments.

It should be noted that other base shapes besides those shown in the illustrated examples noted above may also be used. For example, instead of a generally rectangular/square shape, the base may take other shapes such as a circle, oval, polygon, etc.

Furthermore, the base may have different non-linear profiles in different embodiments. Referring now to FIG. 21, in accordance with another example embodiment of the bracket 330, the base has a curved or arcuate shape (i.e., when viewed from the side as or cross-section shown) that may be helpful for installations on corrugated roofs, barrel tile roofs, etc. Another similar example of the bracket 430 is shown in FIG. 22, in which the base has downward pointing wings or flanges which may also be helpful for such three-dimensional (3D) roof types. Other similar 3D profiles for the base may also be used that are appropriate for a given roof type, as will be appreciated by those skilled in the art.

Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.

Claims

1. A system for mounting at least one solar panel on a roof comprising: a plurality of panel mounting brackets each comprising a base to be positioned on the roof having at least one first opening therein, anda vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends,wherein the distal end defines a fastener channel having a fastener slot opening vertically aligned with the at least one first opening in the base,wherein the central portion comprises at least one cross member defining at least one second opening therein vertically aligned with the fastener slot opening and the at least one first opening in the base;at least one bracket fastener to be inserted through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupled to the roof; anda plurality of clamps and corresponding clamp fasteners configured to couple the at least one solar panel with the fastener channel of a respective panel mounting bracket so that each clamp fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel.

2. The system of claim 1 wherein the at least one first opening comprises a plurality of spaced-apart first openings, wherein the at least one second opening comprises a plurality of second spaced-apart openings, and wherein the at least one bracket fastener comprises a plurality of bracket fasteners for each panel mounting bracket.

3. The system of claim 1 wherein the at least one cross member comprises a plurality of cross members vertically spaced apart from one another.

4. The system of claim 1 wherein the at least one first opening comprises a central opening in the base; and wherein the base further defines a plurality of peripheral openings laterally spaced apart from the central opening.

5. The system of claim 1 wherein the base has a non-linear cross section.

6. The system of claim 1 wherein the base has an arcuate cross section.

7. The system of claim 1 wherein the base has a bottom surface to be positioned on the roof; and wherein each bracket further comprises a pad coupled to the bottom surface.

8. A panel mounting bracket for mounting at least one solar panel on a roof, the panel mounting bracket comprising: a base to be positioned on the roof having at least one first opening therein; anda vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends;wherein the distal end defines a fastener channel having a fastener slot opening vertically aligned with the at least one first opening in the base,wherein the central portion comprises at least one cross member defining at least one second opening therein vertically aligned with the fastener slot opening and the at least one first opening in the base for at least one bracket fastener to be inserted through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupled to the roof;wherein the fastener channel is configured to receive a clamp fastener to couple the at least one solar panel with the fastener channel so that the clamp fastener is retained within the fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel.

9. The panel mounting bracket of claim 8 wherein the at least one first opening comprises a plurality of spaced-apart first openings, wherein the at least one second opening comprises a plurality of second spaced-apart openings.

10. The panel mounting bracket of claim 8 wherein the at least one cross member comprises a plurality of cross members vertically spaced apart from one another.

11. The panel mounting bracket of claim 8 wherein the at least one first opening comprises a central opening in the base; and wherein the base further defines a plurality of peripheral openings laterally spaced apart from the central opening.

12. The panel mounting bracket of claim 8 wherein the base has a non-linear cross section.

13. The panel mounting bracket of claim 8 wherein the base has an arcuate cross section.

14. A method for mounting at least one solar panel on a roof comprising: arranging a plurality of panel mounting brackets on the roof and each comprising a base positioned on the roof having at least one first opening therein, anda vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends,wherein the distal end defines a fastener channel having a fastener slot opening vertically aligned with the at least one first opening in the base,wherein the central portion comprises at least one cross member defining at least one second opening therein vertically aligned with the fastener slot opening and the at least one first opening in the base;inserting at least one bracket fastener through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupling the bracket fastener to the roof; andcoupling a plurality of clamps and corresponding clamp fasteners to the at least one solar panel so that each fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel.

15. The method of claim 14 wherein the at least one first opening comprises a plurality of spaced-apart first openings, wherein the at least one second opening comprises a plurality of second spaced-apart openings, and wherein the at least one bracket fastener comprises a plurality of bracket fasteners for each panel mounting bracket.

16. The method of claim 14 wherein the at least one cross member comprises a plurality of cross members vertically spaced apart from one another.

17. The method of claim 14 wherein the at least one first opening comprises a central opening in the base; and wherein the base further defines a plurality of peripheral openings laterally spaced apart from the central opening.

18. The method of claim 14 wherein the base has a non-linear cross section.

19. The method of claim 14 wherein the base has an arcuate cross section.

20. The method of claim 14 wherein the base has a bottom surface to be positioned on the roof; and wherein each bracket further comprises a pad coupled to the bottom surface.