Solar panel attachment system for a roof

BACKGROUND AND SUMMARY

0001The present application relates generally to an attachment system and more particularly to a solar panel attachment system for a roof of a building.

0002Conventional photovoltaic or solar panels are mounted to roofs of buildings through screw-in clips or the like. Examples of such conventional devices are disclosed in U.S. Patent Publication No. 2011/0088740 entitled “Photovoltaic Panel Clamp” which published to Mittan et al. on Apr. 21, 2011, and U.S. Pat. No. 6,672,018 entitled “Solar Module Mounting Method and Clip” which issued to Shingleton on Jan. 6, 2004, both of which are incorporated by reference herein. Such conventional methods cause the installer to juggle many loose fasteners while simultaneously holding heavy solar panels and/or roof mounting components, often on a tilted metal roof in unpleasant weather conditions. Furthermore, such traditional multi-piece screw or bolt arrangements take considerable time to install while also having inconsistent installation torque values, especially in the common situation where many of these solar panel mounting devices are required for each roof.

0003In accordance with the present invention, an attachment system is provided. In another aspect, a latching assembly is mounted to a building roof. Another aspect employs a moveable latch that removeably attaches an auxiliary component, such as a solar panel, to a building in a single motion and/or snap-in installation manner. A method of installing a latch assembly is additionally provided. Furthermore, a method of manufacturing a latch assembly is disclosed.

0004The present attachment system is advantagous over traditional devices. For example, in one aspect, a single motion installation is employed to engage an auxiliary roof component, such as a solar panel, for latch engagement without requiring tools. In an aspect of the present attachment system, an auxiliary roof component is quickly and easily secured to a building roof in a fast manner without requiring the installer to juggle multiple parts. In another aspect, a striker or protruding member is preassembled directly to a glass surface of a solar panel and a latch assembly is preassembled to a building roof via an easy to install roof clamp, prior to assembly of the solar panel to the latch assembly. Moreover, the auxiliary roof component can be easily detached from the latch assembly in an aspect of the present system. Another aspect allows for quick connect mounting of the auxiliary roof component to a latch assembly coupled to a tilted frame and/or by use of ballast on a horizontal surface. Another aspect of the present system is advantageous over conventional devices since this aspect uses lightweight and strong composite materials for various components of the attachment system. When installed, the latch assembly and roof clamp can optionally provide an electrical grounding path between the auxiliary roof component and the metal roof, or wires attached thereto. Additional advantageous and features of the present invention will become apparent in the following description and appended claims, taking in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

0005<figref idref="DRAWINGS">FIG. 1</figref> is a perspective view showing a first preferred embodiment attachment system securing solar panels to a building roof;

0006<figref idref="DRAWINGS">FIG. 2</figref> is an exploded perspective view showing the first preferred embodiment attachment system;

0007<figref idref="DRAWINGS">FIG. 3</figref> is a cross-sectional view, taken along line <b>3</b>-<b>3</b> of <figref idref="DRAWINGS">FIG. 4</figref>, showing the first preferred embodiment attachment system;

0008<figref idref="DRAWINGS">FIG. 4</figref> is a perspective view showing the first preferred embodiment attachment system;

0009<figref idref="DRAWINGS">FIG. 5</figref> is a partially fragmented perspective view showing the first preferred embodiment attachment system;

0010<figref idref="DRAWINGS">FIG. 6</figref> is a perspective view, generally opposite that of <figref idref="DRAWINGS">FIG. 4</figref>, showing the first preferred embodiment attachment system;

0011<figref idref="DRAWINGS">FIG. 7</figref> is a partially fragmented perspective view, like that of <figref idref="DRAWINGS">FIG. 5</figref>, showing the first preferred embodiment attachment system;

0012<figref idref="DRAWINGS">FIG. 8</figref> is a cross-sectional view, taken along line <b>8</b>-<b>8</b> of <figref idref="DRAWINGS">FIG. 7</figref>, showing the first preferred embodiment attachment system;

0013<figref idref="DRAWINGS">FIG. 9</figref> is a perspective view showing a second preferred embodiment attachment system; and

0014<figref idref="DRAWINGS">FIG. 10</figref> is a partially exploded perspective view showing a third preferred embodiment attachment system.

DETAILED DESCRIPTION

0015<figref idref="DRAWINGS">FIG. 1</figref> illustrates a building <b>21</b> having a tilted roof <b>23</b>, preferably made from sheet metal sections joined together at folded over, raised standing seams <b>25</b>. Auxiliary roof components, preferably multiple solar panel assemblies <b>27</b>, are secured to seams <b>25</b> by way of multiple attachment systems <b>29</b>. Each attachment system <b>29</b> includes a roof clamp <b>31</b> and a latch assembly <b>33</b>.

0016<figref idref="DRAWINGS">FIGS. 2 and 3</figref> depict roof clamp <b>31</b> attached to seam <b>25</b> of roof <b>23</b>. Roof clamp <b>31</b> includes a saddle <b>41</b>, a roof seam-engaging wedge <b>43</b>, and an elongated shaft or securing member <b>45</b>. An optional part includes a retaining element <b>71</b>. Securing member <b>45</b> fits into and aligns saddle <b>41</b> with wedge <b>43</b> so that upon engaging securing member <b>45</b>, camming action of roof seam-engaging wedge <b>43</b> along saddle <b>41</b> secures roof clamp <b>31</b> to roof <b>23</b>. Notably the same securing member <b>45</b> that secures roof clamp <b>31</b> to roof <b>23</b> also secures an auxiliary-retaining device, such as latch assembly <b>33</b>, to roof <b>23</b> along a top surface of saddle <b>41</b>.

0017Saddle <b>41</b> further includes a saddle bore <b>51</b>, two side walls <b>53</b>, and a camming surface <b>55</b> located on each side wall <b>53</b>. Saddle <b>41</b> has an inverted U-shape or a bifurcated yoke body. Furthermore, the saddle top surface serves as the region through which securing member <b>45</b> is advanced or retracted so that the roof seam is engaged.

0018Saddle <b>41</b> defines a slot <b>61</b> which serves in part to engage seam <b>25</b> of roof <b>23</b> and also to serve as camming surface <b>55</b>. Slot <b>61</b> includes a substantially vertical access area and is adjacent camming surface <b>55</b> to facilitate trapping or clamping the roof seam in the roof clamp.

0019Roof seam-engaging wedge <b>43</b> includes a wedge bore which allows securing member <b>45</b> to pass through wedge <b>43</b> and into saddle <b>41</b>. This operates to secure roof clamp <b>31</b> on the roof seam and to also secure latch assembly <b>33</b> using the single securing member <b>45</b> and a nut fastener <b>63</b> secured to an upper end thereof. Wedge <b>43</b> includes at least one angled surface <b>65</b> that mates with camming surface <b>55</b> so that when securing member <b>45</b> is pulled by tightening nut <b>63</b>, wedge angled surface <b>65</b> moves along camming surface <b>55</b> of saddle <b>41</b>. A polygonal head of securing member <b>45</b> is prevented from rotation by a matching recess in a bottom of wedge <b>43</b>.

0020Retaining element <b>71</b> is disposed between an interior of saddle <b>41</b> and a top surface of wedge <b>43</b>. Protrusions on the inside of saddle <b>41</b> mate with retaining element <b>71</b>. This is either by a snap fit or interference fit to prevent retaining element <b>71</b> from becoming dislodged from saddle <b>41</b> prior to wedge <b>43</b> engaging the roof seam. In another construction, the retaining element can be replaced by a leaf spring secured to the saddle and/or wedge.

0021Saddle <b>41</b>, roof seam-engaging wedge <b>43</b>, securing member <b>45</b>, and optionally retaining element <b>71</b>, are pre-assembled prior to placing roof clamp <b>31</b> in the proximity of roof seam. “Pre-assembled” for the clamp refers to the components being aligned such that securing member <b>45</b> keeps them attached together. This can be achieved either on the ground at the work site, at a remote site, or at the factory at which roof clamp <b>32</b> is manufactured. When wedge <b>43</b> is retracted to trap seam <b>25</b> between an inner foot of the wedge and the inner slot edge of saddle <b>41</b>, a portion of securing member <b>45</b> extends beyond the top surface of saddle <b>43</b> such that proximal threaded end of member <b>45</b> also provides an attachment point for latch assembly <b>33</b>.

0022Referring now to <figref idref="DRAWINGS">FIGS. 2-7</figref>, latch assembly <b>33</b> includes a stamped metal bracket <b>101</b>, a spring steel insert <b>103</b> and a pair of latches <b>105</b> and <b>107</b>. Bracket <b>101</b> has a generally U-end view shape defined by a generally flat bottom or base wall <b>111</b> and a pair of spaced apart and upstanding side walls <b>113</b>. Multiple slots <b>117</b> are provided in each side wall <b>113</b> which are openly accessible adjacent a top edge <b>119</b> thereof. An aperture <b>121</b> is provided in bottom wall <b>111</b> of bracket <b>101</b> to receive the threaded end of securing member <b>45</b> for nut attachment thereto.

0023Insert <b>103</b> is a stamped metal part including an outer ring <b>123</b> and a pair of tabs <b>125</b> diagonally projecting and biasing upwardly away from bottom wall <b>111</b> of bracket <b>101</b>. A generally horizontal turned flange <b>125</b> inwardly projects from each diagonal section of tab <b>123</b> within which is an internally slotted receptacle <b>127</b>. A central hole is also provided in insert <b>103</b> to receive member <b>45</b> therethrough.

0024Latches <b>105</b> and <b>107</b> are in mirrored symmetry to each other and have a generally hook-like shape defined by a somewhat radially extending engagement surface <b>141</b>. A pivot pin <b>143</b> projects laterally from each side wall <b>145</b> of latches <b>105</b> and <b>107</b>. The ends of each pin <b>143</b> have peripheral grooves therein for a compression fit into the side wall or for receiving circlips external to the side walls, such that pin is rotatably journaled within side walls <b>113</b> of bracket <b>101</b> to allow pin <b>143</b> to rotate with each associated latch. Alternately, the pivot pin can be stationarily affixed to bracket such that each latch rotates about the pin.

0025Furthermore, a central rib <b>147</b> extends from an internal ledge of each latch <b>105</b> and <b>107</b>, which is spaced apart from and between outer walls <b>145</b> in a generally parallel configuration. Alternately, each latch may be a single solid piece such that the peripheral surface continuously extends between walls <b>145</b> thereby subsuming central rib <b>147</b>. A peripheral camming surface <b>151</b> is provided on walls <b>145</b> and <b>147</b> such that each tab <b>123</b> acts as a cam follower by riding against and controlling motion of camming surface <b>151</b> for at least central wall <b>147</b>, and optionally outer walls <b>145</b>, of each latch. This camming action serves to urge each latch to either its unlatched position (as shown for latch <b>107</b>) or its latched position (as shown for latch <b>105</b>). The latches are preferably made by compressing sintered powder metal, but may alternately be cast metal which is thereafter machined.

0026A striker arm <b>201</b> protrudes from each auxiliary roof component, preferably solar panel <b>27</b>, for engagement by latch assembly <b>33</b>. More specifically, each striker <b>201</b> includes a generally cylindrical rod <b>203</b> bordered by laterally enlarged and generally circular abutment stops <b>205</b> and <b>207</b>. A curved neck <b>209</b> ends with a generally flat pad <b>211</b> which is adhesively bonded directly to a bottom surface <b>213</b> of the glass solar panel with a suitable adhesive, such as that obtained from A. Raybond Sarl as Techbond™ brand polyurethane adhesive. Thus, an expensive and heavy peripheral frame is not required to mount the solar panels <b>27</b> to the building roof <b>23</b>. The strikers <b>201</b> are preferably made by compressing sintered powder metal in the present system, but may alternately be cast metal or extruded and then cold head compression formed for the pads.

0027Each striker <b>201</b> is preassembled to the associated solar panel <b>27</b> either at the solar panel manufacturing plant or on the ground at the job site. Moreover, roof clamp <b>31</b> is preassembled onto the roof seam <b>25</b> and thereafter, latch assembly <b>33</b> is assembled to roof clamp <b>31</b> using a single securing member <b>45</b> in a top-only access manner. Subsequently, the solar panel assembly, including the preassembled striker <b>201</b>, is manually lowered by the installer through the associated slots <b>117</b> of bracket <b>101</b>. This single linear motion causes rod <b>203</b> of striker <b>201</b> to manually rotate latch <b>107</b> about pin <b>143</b> from its unlatched position to its latched position. In the latched position, a pawl <b>221</b> (see <figref idref="DRAWINGS">FIGS. 3 and 8</figref>) protrudes into receptacle slot <b>127</b> of spring tab <b>123</b>, thereby providing a locking function to secure the latch in its latching position. Hence, rod <b>203</b> of striker <b>201</b> is trapped between latch engaging surface <b>141</b> and edges of the bracket side walls defining slots <b>117</b>. This is done in a quick connect or snap-in manner without requiring tools or threaded fastener engagement.

0028When it is desired to service or remove solar panels <b>27</b>, the user can install an elongated tool, such as a flat bladed screw driver, within a gap <b>223</b> (see <figref idref="DRAWINGS">FIG. 6</figref>) between solar panels <b>27</b>. The screw driver is then pushed against an extending end of tab <b>125</b> between latches <b>105</b> and <b>107</b>. This tab depression unlocks pawl <b>221</b> which allows the user to then manually pull up on the solar panel which, in turn, causes counter rotation of the associated latch toward its unlatched position.

0029<figref idref="DRAWINGS">FIG. 9</figref> illustrates another configuration of the latch assembly <b>301</b>. The bracket <b>101</b>, insert <b>103</b> (not shown), latches <b>105</b> and <b>107</b>, and strikers <b>201</b> are the same as the prior embodiment. However, an elongated rail <b>303</b> is employed instead of a roof clamp. The bracket and latches are secured within an upper section of rail <b>303</b> and upwardly accessible access slots are additionally provided in side walls of rail <b>303</b> to match those in bracket <b>101</b>. Rail <b>303</b> has a generally H-end view shape with a bottom flange <b>305</b> laterally extending therefrom. A polarity of holes <b>307</b> are located in flange <b>305</b> such that screws <b>309</b>, rivets or other fasteners can be inserted therein for attachment to a structural rack or frame <b>311</b>. Frame <b>311</b> is provided with an offset angled configuration relative to a flat or tilted building roof, building side wall, or even on the ground.

0030Referring now to <figref idref="DRAWINGS">FIG. 10</figref>, another embodiment attachment system <b>351</b> includes a latch assembly <b>33</b> like that of the first embodiment discussed hereinabove. An elongated rail <b>353</b>, however, secures bracket <b>101</b> therein and includes a laterally extending lower flange <b>355</b>. Heavy weighted ballast members <b>357</b>, such as cement blocks, are positioned on flange <b>355</b> to hold attachment system <b>351</b> onto a flat roof surface <b>359</b> without the need for other fasteners or clamps. Additionally, a solar panel or other auxiliary roof component <b>361</b>, such as a snow guard, pipe, wire conduit, ladder, or the like, can be adhered or otherwise attached onto strikers <b>201</b>.

0031It is alternately envisioned that rails <b>303</b> and <b>353</b>, or even bracket <b>101</b>, are made from a composite material including one or more sheets of long strand (e.g., longer than one inch) fiberglass or carbon fiber, either of a woven or random fiber orientation, in polymeric resin such as epoxy. In one version, a pultrusion process is employed to make this composite material prior to its molding, extruding or shaping into the desired configurations. The edges and slots are cut from the sheets before or after curing, and before or after molding. This process and material advantageously provides a lightweight and very durable component for the attachment system. In another alternate configuration, rails <b>303</b> and <b>353</b> have a single upstanding wall in the upper segment upon which bracket <b>101</b> is clamped between a downwardly open slot edge of the bracket and a camming wedge similar to wedge <b>43</b>; this would eliminate the need to cut the slots in the pultruded rails.

0032While various aspects of the present attachment system have been disclosed, it should be appreciated that modifications can be made. For example, the present accessory mounting brackets can be secured to conventional roof clamps such as those disclosed in the following U.S. Pat. Nos. 7,758,011 entitled “Adjustable Mounting Assembly for Standing Seam Panels” which issued to Haddock on Jul. 20, 2010; 7,386,922 entitled “Snow-Guard Clamping Unit” which issued to Taylor et al. on Jun. 17, 2008; and 5,715,640 entitled “Mounting Device for Controlling Uplift of a Metal Roof” which issued to Haddock on Feb. 10, 1998; except many of the present advantages will not be realized. These patents are incorporated by reference herein. Moreover, more or less latches can be attached to a single bracket. It is also envisioned that the attachment system is attachable to an exterior side of a building, although various advantages may not be achieved. Furthermore, the latches can have differing camming and/or striker engaging surfaces, such as internally elongated slots, however, various advantages may not be obtained. The striker can also have different shapes, such as a U-shape, although certain advantages may not be observed. In an alternate embodiment, bracket <b>101</b> is integrated into saddle <b>41</b> as a single piece. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the present invention.