U.S. patent application number 13/167908 was filed with the patent office on 2011-12-29 for solar roofing system and method of installing the same.
This patent application is currently assigned to AMERICAN ECOENERGY, INC.. Invention is credited to John Carter, Franklin D. Farmer, Daniel C. Lane.
Application Number | 20110314753 13/167908 |
Document ID | / |
Family ID | 45351185 |
Filed Date | 2011-12-29 |
United States Patent
Application |
20110314753 |
Kind Code |
A1 |
Farmer; Franklin D. ; et
al. |
December 29, 2011 |
SOLAR ROOFING SYSTEM AND METHOD OF INSTALLING THE SAME
Abstract
A solar roofing system wherein the solar panels are integrated
into the existing roof of a building in a watertight fashion,
through the use of a starter trim piece, side step flashing pieces
which are installed under each course of shingles such that they
overlap to form a barrier along the side; a step flashing cover
which seals the step flashing with the left and right sides of the
solar panels, a Z-cleat that is fastened and sealed to the top of
each solar panel, and a hood flashing which attaches to the Z-cleat
and provides a sealed, watertight transition to the regular roofing
material. The solar roofing system is watertight, and integrated
with the actual roof, such that it does not need to be replaced
when the roofing is replaced.
Inventors: |
Farmer; Franklin D.;
(Flushing, MI) ; Carter; John; (Montrose, MI)
; Lane; Daniel C.; (Holt, MI) |
Assignee: |
AMERICAN ECOENERGY, INC.
Flint
MI
|
Family ID: |
45351185 |
Appl. No.: |
13/167908 |
Filed: |
June 24, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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61358241 |
Jun 24, 2010 |
|
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Current U.S.
Class: |
52/173.3 ;
52/745.21 |
Current CPC
Class: |
Y02B 10/20 20130101;
F24S 25/40 20180501; F24S 2025/014 20180501; F24S 20/67 20180501;
Y02E 10/44 20130101; Y02E 10/50 20130101; H02S 20/23 20141201; Y02B
10/10 20130101; Y02A 30/60 20180101; Y02E 10/47 20130101 |
Class at
Publication: |
52/173.3 ;
52/745.21 |
International
Class: |
E04D 13/18 20060101
E04D013/18; E04B 1/38 20060101 E04B001/38 |
Claims
1. A solar roof assembly, comprising: a panel comprising at least
one solar energy collector unit; and a plurality of trim elements
to attach the panel to a support surface, wherein the plurality of
trim elements permit water-tight integration of the panel with an
asphalt-shingled roof, such that the solar roof assembly does not
require removal or replacement when the asphalt-shingled roof is
replaced.
2. A solar roof assembly for installation on a support surface,
comprising: at least one panel, said panel having a main body with
a solar energy collector unit thereon, two upwardly directed
flanges on opposing lateral sides of the main body, and a top edge;
a cleat having a bottom surface, a top surface and a wall
therebetween, said bottom surface affixed to the main body between
the two upwardly directed flanges, near the top edge of the panel;
and a hood, which has a bend along its length which is generally
aligned with the top edge of the at least one panel, said hood
having an upper portion above the bend which is fastened to the
support surface, and a lower portion below the bend extending from
the support surface past the top edge of the at least one panel and
affixed to the top surface of the cleat.
3. The solar roof assembly of claim 2, further comprising:
electrical wiring components electrically connected to the solar
energy collecting unit; wherein the electrical wiring components
are enclosed between the main body of the panel, the cleat and the
hood.
4. The solar roof assembly of claim 3, wherein a row of shingles is
installed over the upper portion of the hood, to provide a
watertight transition from the support surface to the solar roof
assembly.
5. The solar roof assembly of claim 4, further comprising a first
panel and a second panel, wherein the first and second panels are
placed adjacent to one another along their lateral sides.
6. The solar roof assembly of claim 5, wherein the panels have
interlocking features on adjacent upwardly directed flanges.
7. The solar roof assembly of claim 6, wherein the interlocking
features comprise an upwardly directed flange having a protrusion
on the first panel and the adjacent upwardly directed flange on the
second panel being a generally U-shaped flange with an interiorly
wrapped lip, wherein the U-shaped flange fits over the upwardly
directed flange with the protrusion, and the interiorly wrapped lip
engages the protrusion.
8. The solar roof assembly of claim 7, further comprising: clips to
secure each panel to the support structure, said clips comprising a
base which is attached to the support structure and a hook which
fits over the upwardly directed flange.
9. The solar roof assembly of claim 8, wherein the first panel is
secured to the support structure using clips along each lateral
side, and the U-shaped flange of the second panel fits over the
upwardly directed flange of the first panel and the clips, and the
second panel is secured to the support surface using clips along
the lateral side which is not adjacent to the first panel.
10. The solar roof assembly of claim 2, wherein a foam backing and
an underlayment are attached to the support surface beneath the
panels.
11. The solar roof assembly of claim 2, for application to a
support surface with a covering of flexible shingles, further
comprising: A panel assembly, comprising the at least one panel,
said panel assembly having a first side with a first upwardly
directed flange thereon, a second side with a second upwardly
directed flange thereon, and a bottom; A first slit in the covering
of flexible shingles adjacent to the first side of the panel
assembly and a second slit in the covering of flexible shingles
adjacent to the second side of the panel assembly; a starter trim
piece, having a cleat for the attachment of the bottom of the panel
assembly; a first plurality of side step flashing pieces, wherein
each side step flashing piece comprises an L-shaped piece with a
first leg which fits under the shingles adjacent to the first side
of the panel assembly and a second leg which extends through the
first slit and is adjacent to the first upwardly directed flange,
and wherein the side step flashing pieces are overlapping along the
first side of the panel assembly; a second plurality of side step
flashing pieces, wherein each side step flashing piece comprises an
L-shaped piece with a first leg which fits under the shingles
adjacent to the second side of the panel assembly and a second leg
which extends through the second slit and is adjacent to the second
upwardly directed flange, and wherein the side step flashing pieces
are overlapping along the second side of the panel assembly; a
first side step flashing cap, having an inverted "u" shape which
fits over the first plurality of overlapping side step flashing
pieces and the adjacent first upwardly directed flange; and a
second side step flashing cap, having an inverted "u" shape which
fits over the second plurality of overlapping side step flashing
pieces and the adjacent second upwardly directed flange.
12. The solar roof assembly of claim 2, for application to a
support surface, further comprising: a panel assembly, comprising
the at least one panel, said panel assembly having a first side
with a first upwardly directed flange thereon, a second side with a
second upwardly directed flange thereon, and a bottom; a starter
trim piece, having a cleat for the attachment of the panel assembly
and a cleat for attachment to a row of shingles; a first lineal
side channel, comprising a two-layered back section with an opening
along the bottom thereof which fits over the first upwardly
directed flange of the panel assembly, a bottom leg which lies
generally flush with the support surface, and a top leg which
extends generally parallel with the bottom leg and is at a level
sufficient to allow adjacent shingles to be installed under the top
leg; and A second lineal side channel, comprising a two-layered
back section with an opening along the bottom thereof which fits
over the second upwardly directed flange of the panel assembly, a
bottom leg which lies generally flush with the support surface, and
a top leg which extends generally parallel with the bottom leg and
is at a level sufficient to allow adjacent shingles to be installed
under the top leg.
13. A kit for installing a solar roof assembly, comprising: a
plurality of panels, each having a main body with a solar energy
collecting unit thereon and two upwardly directed flanges extending
therefrom, wherein each of the plurality of panels has features to
interlock with adjacent panels; a starter trim piece, having a
cleat for the attachment of panels; a cleat for the top of each
panel; a hood; and electrical wiring components to link the solar
collecting unit to an electrical grid.
14. The kit for installing a solar roof assembly of claim 13,
further comprising: a plurality of side step flashing pieces; and
two side step flashing caps which fit over the side step flashing
pieces and the upwardly directed flange of the panels on the
lateral edges of the solar roof assembly.
15. The kit for installing a solar roof assembly of claim 13,
further comprising: two lineal side channels; a foam backing layer;
and an underlayment for layering between the foam backing and the
panels.
16. A method of installing a solar roof assembly on a support
surface, comprising the steps of: positioning at least one panel on
the support surface, the at least one panel having a main body with
a solar energy collecting unit thereon and two upwardly-directed
flanges extending therefrom on opposing lateral sides of the main
body, and a top edge; fastening a cleat having a bottom surface,
top surface and a wall therebetween, to the main body near the top
edge thereof, so that the bottom surface is securely attached to
the main body between the upwardly directed flanges, above the
solar energy collecting unit; electrically connecting electrical
connectors for the solar energy collecting units and feeding the
electrical connectors through the support surface above the cleats;
attaching an upper portion of a hood to the support surface above
the top edge of the at least one panel; and affixing a lower
portion of the hood to the top surface of the cleat and the
upwardly directed flanges.
17. The method of installing a solar roof assembly of claim 16,
wherein there are at least three panels, further comprising the
steps of: Fastening a starter trim piece to the support surface,
the starter trim piece having a cleat for connection of the panels
installing a starter panel on the starter trim piece; installing at
least one intermediate panel adjacent to the starter panel;
installing an end panel adjacent to the at least one intermediate
panel, wherein the starter panel, intermediate panel and end panel
have interlocking features as between the panels.
18. The method of installing a solar roof assembly of claim 16 on a
support surface having a covering of flexible shingles, further
comprising the steps of: slitting the shingles along each side of
an installation site for the panels; and inserting a plurality of
side step flashing pieces having an L-shaped cross section with a
first leg and a second leg along the slit, with the first leg of
each of the plurality of side step flashing pieces under a row of
shingles and the second leg of each of the plurality of side step
flashing pieces positioned adjacent to the upwardly directed
flanges on the outer sides of the at least one panel; and
installing a side step flashing cap over the second legs and the
upwardly directed flange.
19. The method of installing a solar roof assembly of claim 16,
further comprising the steps of: laying one row of metal shingles;
installing a starter trim piece above the row of metal shingles;
and installing a first and second lineal side channel along the
upwardly directed flanges of the at least one panel that are
adjacent to the support surface.
20. A solar roof assembly, comprising: a plurality of panels laid
side-by-side on a support surface, each panel comprising a main
body with a solar energy collecting unit and two upwardly directed
flanges wherein the flanges that are adjacent to another flange
when the panels are laid side-by-side are adapted to interconnect
with the flange of the adjacent panel in a water-tight fashion; a
plurality of trim, flashing and cap elements to seal the bottom and
the sides of the plurality of panels in a water-tight fashion; a
cleat, installed between the upwardly directed flanges of each
panel, having a bottom surface affixed to the main body, a top
surface, and a wall therebetween; and a hood, having a top portion
which is attached to the support surface above the panels, and a
its bottom side which is attached to the top surfaces of the cleats
and upwardly directed flanges, said hood having a row of shingles
installed over the top portion to provide a water-tight seal.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuing non-provisional application of
co-pending United States provisional Patent Application Ser. No.
61/358,241, entitled SOLAR ROOFING SYSTEM AND METHOD OF INSTALLING
THE SAME, and filed on 24 Jun. 2010, the disclosure of which is
incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
PARTIES TO A JOINT RESEARCH AGREEMENT
[0003] Not applicable.
REFERENCE TO A SEQUENCE LISTING
[0004] Not applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention
[0006] The present invention relates to the field of solar panel
systems and their installation on roofs or other support
surfaces.
[0007] 2. Description of Related Art
[0008] Solar panels for installation on a roofing system to capture
solar energy are known in the art. Traditional solar panel systems
often included glass panels that were heavy, fragile and/or rigid,
and traditional systems are often are difficult to install on an
existing roof or must be moved when replacing shingles or other
roofing materials. The solar roofing system described in this
application, and the method of installing the same provides a
light-weight, durable, flexible alternative to traditional
glass-based solar panel systems, can be installed on existing
shingled roofs in a water-tight manner, and does not have to be
removed or replaced when re-roofing.
SUMMARY OF THE INVENTION
[0009] The invention includes a solar roofing system and a method
for installing the same such that the solar roofing system as
described herein can be installed on many types of roofs, including
a roof that is cedar shake, slate, tile, asphalt shingle or metal,
and therefore provides certain users, such as residential users,
more options for the installation of a solar roofing system. The
solar roofing system described herein can be applied on top of an
existing traditional asphalt roof and the solar panels are an
integrated part of the roofing so that the solar roofing system
does not have to be replaced when the rest of the roofing is
replaced.
BRIEF DESCRIPTION OF THE SEVERAL VIEW OF THE DRAWINGS
[0010] FIG. 1 is a perspective view of a solar roofing system;
[0011] FIG. 2 is a perspective view of a roof with a saw line,
prepared for installation of the solar roofing system;
[0012] FIG. 3 is a perspective view of the starter trim;
[0013] FIG. 4 is a perspective cutaway view of the solar roof
assembly;
[0014] FIG. 4A is an enlarged end view of the section shown as IVA
in FIG. 4;
[0015] FIG. 4B is an enlarged end view of the section shown as IVB
in FIG. 4;
[0016] FIG. 4C is an enlarged end view of the section shown as IVC
in FIG. 4;
[0017] FIG. 5 is a perspective view of the starter panel as
installed with clips;
[0018] FIG. 6 is a perspective view of the solar panel with the
step flashing installed;
[0019] FIG. 7 is a perspective view of the solar panel with the
step flashing, step flashing cap, and installed Z-cleat;
[0020] FIG. 8 is a perspective view of the hood flashing;
[0021] FIG. 9 is a perspective view of the hood flashing, as
installed, with a partial row of shingles installed over the top
portion;
[0022] FIG. 10 is a perspective view of the metal starter trim used
to install an embodiment of the solar roofing panel on a metal
roof, as installed on a roof with one row of metal shingles;
[0023] FIG. 11 is an end view of the lineal side channel installed
on the end panel; and
[0024] FIG. 12 is a perspective view of the hood transition, with a
cutaway showing the z-cleat.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] According to one preferred embodiment, the solar roofing
system 50 can be applied over an existing asphalt shingle roof 52,
a common residential roofing material (FIG. 1). Solar roofing
system 50 comprises a plurality of interconnected solar panels 80,
82, 84 secured to and bounded along their bottom edges by a starter
trim member 58 and secured to and bounded along their upper edges
by hood flashing 70, which serves not only as an upper flashing,
but also as a hood for covering the electrical wiring associated
with solar panels 80, 82, 84 (FIG. 1). The panel on the left side
of the array is starter panel 80, the panel on the right is end
panel 82, and the intermediate panels are panels 84. The location
of the solar roofing system 50 is preferably the portion of the
roof 52 with the southern-most exposure and the most sun exposure,
with no vent pipes or other roof protrusions (which may need to be
moved to place the solar roofing in the location where it will most
efficiently produce electricity).
[0026] The solar roofing system 50 can be installed so that it is
as close as approximately twelve (12) inches from the existing
starter row and as close as approximately twelve (12) inches from
the ridge. The sides of the solar roofing system 50 may also be
located as close as twelve (12) inches from the side wall or gable
ends on the roof. The size of the solar roofing system 50 will be
determined in accordance with known solar panel design principles
and calculations based upon: (1) how much energy the end user uses;
(2) the percentage of the end user's electrical needs that it
desires to meet with the solar roofing system 50; (3) what zone the
solar roofing system 50 will be installed in (to estimate the
available solar energy); and (4) the amount and orientation of the
end user's available roof space.
[0027] Once the location for the solar roofing system 50 is
located, the surface of the roof 52 is prepared by removing any
sharp protrusions such as nails, branches or other debris, and
trimming or removing curled shingles to create a smooth base for
the application of the of the solar roofing system 50.
[0028] To facilitate installation of a solar roofing system 50, the
left and right sides of the installation site can optionally be
marked using parallel vertical chalk lines. A circular saw or an
equivalent can be used to make saw cuts 56 in the first layer of
shingles on the roof along the vertical lines at the left and right
sides of the installation site (FIG. 2). The length of the cuts is
preferably between the length of the solar panels 80, 82, 84 that
will be installed and a length which is less than six (6) inches
longer than the solar panels 80, 82, 84. If any additional cutting
is required, it can be accomplished using a utility knife or the
like during the later installation phases of the flashing next to
the panels 80 or 82. Saw cuts 56 allow an installer to lift the cut
shingles and slide side fasteners and flashing under the cut
shingles.
[0029] The starter trim 58 is preferably formed of sheet metal. It
is installed along the bottom edge of the installation site (FIG.
1). The starter trim 58 can be provided "pre-trimmed," or can be
cut to fit the width of the solar roofing system. The starter trim
58 has a downwardly extending starter trim cleat 60 on the top
portion of the starter trim 58 and, preferably, an angled portion
62 along the bottom edge (to extend back toward the existing roof),
more preferably a section which angles back at approximately forty
degrees (40.degree.) (FIG. 3). Starter trim 58 is cut so that it
extends beyond each side edge of the roofing system 50 to be
installed, a distance approximately equal to the height of the left
side flange 90 of left side solar panel 80 and right side flange 92
of right side solar panel 82. A short rectangular portion is cut
from each of the upper corners of starter trim 58 from the top edge
to a point at the root 60' of starter trim cleat 60. The remaining
portion of each end of starter trim 58 which extends beyond the
width of the roofing system 50 is folded up to define an upwardly
extending flange 58a, which is approximately the same height as the
aforesaid outside flanges on solar panels 80 and 82 (FIGS. 1, 3).
Starter trim 58 is then placed so that its upper portion is
positioned between cuts 56, and it is nailed in place above cleat
60.
[0030] A layer of foam backing 64 is applied to the installation
site, starting at the left saw line 56 and extending to the right
saw line 56 (FIGS. 4, 4A, 4B, 4C). It is positioned so that it
overlaps the upper portion of starter trim 58, but not so far as to
overlap cleat 60. Foam backing 64 extends upward to the top edge of
where the hood flashing 70 will be installed. The foam backing 64,
which is preferably approximately one quarter inch (1/4'') thick,
can be of any type which is generally commercially available, such
as fan-fold foam backing which is traditionally used for layering
under siding. The foam backing 64 is preferably installed with
plastic, flat-topped nails 66, with such flat-topped nails 66
preferably spaced at twenty-four (24) inch on-center intervals. The
foam backing 64 can be permitted to extend beyond the right saw
line 56 during the following installation steps until just before
the flashing on the right side is installed.
[0031] Once the foam backing 64 is installed, it is covered with a
layer of underlayment material 68, with the underlayment 68
extending beyond the left saw line 56, preferably for a distance
which is approximately equal to the height of the raised side of
the panel 80, most preferably approximately one (1) inch, and with
the underlayment 68 extending from the bottom edge of foam layer 64
upward to a position which will be under where the hood 70 will be
installed as described herein. The underlayment 68 can extend
beyond these boundaries as applied, and be trimmed with a trim
knife after or as the various components are installed over it. The
underlayment 68 is fastened using nails spaced at twelve (12) inch
on-center intervals, with laps nailed every six (6) inches. The
right edge of the underlayment 68 (like the foam backing 64) can be
trimmed just before the flashing on the right side is installed,
and will also be trimmed to extend beyond the right saw line 56 a
distance approximately equal to the height of the raised left side
of the panel 82, preferably about one (1) inch past the right saw
line 56.
[0032] Once the foam backing 64 and underlayment 68 are installed,
the panels 80, 82, 84 can be installed over the underlayment 68.
Each panel 80, 82, 84 comprises a rectangular metal frame, with a
raised right side or flange 72 and raised left side or flange 74
(FIG. 4B). The flat base area 76 is covered with a flexible
photovoltaic laminate 78, preferably a flexible and durable
laminate such as that provided by United Solar Ovonic under the
UNI-SOLAR brand. The photovoltaic laminate 78 does not extend all
of the way to the top of the panels 80, 82, 84 or its sides, and
sufficient space is left on the panels 80, 82, 84 to allow for the
hood flashing 70 and other fastening items that are used to attach
the panels to the roof, as further described herein.
[0033] Each set of panels to be used will include two outer panels
(a starter panel 80 and an end panel 82), and a varying number of
interior panels 84, as required to create an overall solar roofing
system 50 of the desired size (FIG. 1). In a system designed to be
installed from left to right, each interior panel 84 will have
raised right flange 72 which is bent upwardly, preferably at an
angle of approximately ninety degrees (90.degree.) (FIGS. 4, 4A,
4B, 4C). The raised right flange 72 is further characterized by a
protrusion 86 facing the photovoltaic laminate 78. Each interior
panel 84 will have a raised left side 74 comprising an inverted
"U-shaped" member designed to fit and lock over the adjacent
panel's right side flange 72. The outer leg of the inverted "U"
extends down toward the photovoltaic laminate 78 of the adjacent
panel 84, and terminates at an interiorly wrapped lip 88 which
engages the protrusion 86 on the raised right edge flange 72 of the
adjacent panel 84.
[0034] For a solar roofing system 50 that is to be installed from
left to right, the starter panel 80 will have a right side flange
72a that is substantially the same as an interior panel's right
side flange 72, but the starter panel left side is preferably a
straight flange 90 (FIG. 4A). Similarly, the end panel 82 will have
a left side flange 74a that is substantially the same as an
interior panel's left side flange 74, but the right side of the end
panel is preferably a straight flange 92 which is bent upwards from
the base of the panel (FIG. 4C). Preferably, particularly when
provided in "kit" form, the starter panel and end panel will be
marked on the back side, or otherwise identified before delivery
for ease of installation.
[0035] To install the starter panel 80, the starter panel 80 is
positioned so that it is immediately to the inside of the portion
of the starter trim 58 that was bent upwards, with the bottom edge
of the starter panel 80 hooked around the starter trim cleat 60,
and a screw is inserted through the top of the panel 80 (above the
photovoltaic laminate 78 on the panel 80) to prevent the panel 80
from sliding downward. The underlayment 68 is folded upwards along
the straight raised edge flange 90 on the left side of the starter
panel 80, and trimmed as necessary. Clips 94 are then fastened at
intervals along the raised left side flange 90 and right side
flange 72 of the starter panel 80 (FIG. 5), preferably at
twenty-four (24) inch on-center intervals, to secure the panel 80
to the existing roofing 52. The clips 94 have a U-shaped portion 96
that fits over the straight raised edge flange 90 of the starter
panel 80 and the right side of the starter panel 80 with the
protrusion 86, and a tab 98 that extends laterally at approximately
a ninety degree (90.degree.) angle from the U-shaped portion 96,
such that it rests flush against the existing roof 52. Preferably,
two (2) screws 100 are used to fasten the tab 98 of each clip 94 to
the roof 52 to provide maximum stability and wind resistance. For
the clips 94 that are fastened on the left side of the starter
panel 80, the course of shingles next to each clip 94 is folded
upwards, and the clip 94 is fastened into the roof 52 below the
shingle, so that the clips 94 and the screws 100 that they are
attached with are covered by the shingle when it is in its normal
position.
[0036] The interior panel 84 immediately to the right of the
starter panel 80 is installed by sliding the U-shaped left side 74
of the panel 84 over the right side flange 72 of the starter panel
80, such that the U-shaped left side 74 is locked onto the
protrusion 86 on the right side of the starter panel 80. Clips 94
are then fastened at intervals along the raised right side 72 of
the interior panel 84, preferably at twenty-four (24) inch
intervals, to fasten the right side of the panel 84 to the roof 52.
To ensure that there is no damage to the next panel 84, the screws
100 should be tightened down so that they are flat and will not
protrude into the neighboring panel 84. Subsequent panels 84 are
installed by repeating this process, and sliding the U-shaped left
side 74 of each panel 84 over the right side 72 of the previously
installed panel 84, and then fastening the right side 72 of each
panel with clips 94, preferably spaced at twenty-four (24) inch
intervals.
[0037] To install the end panel 82, its U-shaped left side 74 is
slid over the right side 72 of the neighboring panel 84, and the
raised right flange 92 of the end panel 82 will line up with the
second saw line 56 in the roofing 52. The foam backing 64 and the
underlayment 68 can be trimmed and then the clips 94 are installed
on the straight right edge 92 of the end panel 82, with the tabs 98
inserted and fastened underneath the neighboring course of shingles
in the same manner as those on the left side of the starter panel
80.
[0038] Once the panels 80, 82, 84 are fastened to the existing roof
52, L-shaped step flashing segments 102 are installed on the left
side of the starter panel 80 and the right side of the end panel 82
by sliding each piece of step flashing 102 up under a course of
shingles, such that one leg of the "L" is below the shingle, and
the other leg is flush with the straight side flange 90 of the
starter panel 80 or the straight side flange 92 of end panel 82
(FIG. 6). Each flashing segment 102 has a width approximately the
same as that of a shingle, and succeeding segments 102 are arranged
in overlapping fashion as one proceeds from the top to the bottom
of the solar roofing system 50. Once overlapping step flashing 102
is installed along the entire length of the starter panel 80 and
end panel 82, a U-shaped step flashing clips can optionally be
installed over the step flashing and the raised edge flange 90 or
92 of the panel 80 or 82. Then, a U-shaped step flashing cap, 104
with interiorly wrapped lips on each side of the "U" (FIG. 7) is
placed over the step flashing 102 and the raised straight sides 90
and 92 of the starter panel 80 and end panel 82, by starting the
step flashing cap 104 at the top, and forcing it down along the
flanges 90 and 92 and the step flashing 102. Zip screws or similar
fastening devices are then fastened, preferably at twenty-four (24)
inch intervals along the length of the step flashing cap
[0039] Lengths of Z-cleat 106 having a vertical leg 106a and
oppositely extending top and bottom legs 106b and 106c are
installed across the top of each of the panels 80, 82, 84,
preferably at a distance of approximately three (3) inches from the
top of each panel 80, 82, 84, and above the top edge of the
photovoltaic laminate 78 (FIG. 7). Z-cleat 106 is adhered to the
panels 80, 82, 84 by placing a bead of sealant on the bottom of the
flat surface 106c and the sides of the Z-cleat 106 so that the
Z-cleat 106 is sealed to the base area 76 of each panel 80, 82, 84
and the raised edges 72, 74 on each side thereof to form a
water-tight barrier. Each Z-cleat 106 has a length which is able to
fit snugly within the raised edges of each panel 80, 82, 84. A
screw or similar fastening device is installed on the outside of
each piece of Z-cleat 106, outside the photovoltaic laminate 78.
The screws must be placed outside the photovoltaic laminate 78,
because if they puncture the laminate 78 the laminate 78 will not
function properly.
[0040] Once the Z-cleat 106 has been installed on the top of each
panel 80, 82, 84, the wiring 108 associated with the photovoltaic
layers 78 are connected in a daisy chain fashion. The wiring 108 of
each panel 80, 82, 84 connecting to the one next to it, with a
maximum of approximately 400 Volts per grouping, and then feeding
the wires 108 through the roof 52 and into the attic or building
through a hole drilled in the roof 52. Exceeding the maximum
voltage will increase the risk of fire or system failure for the
solar roofing system 50. Some examples of acceptable combinations
of panels are shown below in Table 1.
TABLE-US-00001 TABLE 1 Electrical Connection of Solar Panels System
Size Number of Panels String Order PVL 136 (Panel Length 18 feet)
1.3 KW 10 2 strings of 5 2.4 KW 18 3 strings of 6 3.2 KW 24 3
strings of 8 4.1 KW 30 3 strings of 10 5.4 KW 40 4 strings of 10
6.1 KW 45 5 strings of 9 PVL 68 (Panel Length 10 feet) 1.3 KW 20 2
strings of 10 2.4 KW 36 3 strings of 12 3.2 KW 48 3 strings of 16
4.1 KW 60 3 strings of 20 5.4 KW 80 4 strings of 20 6.1 KW 90 5
strings of 18
[0041] Each panel 80, 82, 84 is also equipped with a ground lug
109, which will be interconnected with a ground wire 111, which
traditionally terminates at an existing ground bar in an inverter.
One type of ground lug 109 which is preferable for use is a
grounding lug with a stainless steel self-tap, such as the Ilsco
grounding lug model GBL-4 DBT-14-10-32. As with the other wiring
108, the grounding lug 109 is fastened to the panels 80, 82, 84
above the photovoltaic layers 78, to avoid penetration of the
photovoltaic layers 78.
[0042] After the panels 80, 82, 84 are wired through to the
building, a hood flashing 70 is used to cover the wiring 108 and
provide a waterproof covering for the solar roofing system 50
(FIGS. 8, 9). The hood flashing 70 is a generally rectangular
shaped piece, with an end cleat 110 along one side that locks onto
the top flange 106b of Z-cleat 106 and a bend 112 that extends
along its length so that a portion 70a of the hood flashing 70 will
begin at the raised height of the Z-cleat flange 106b and extend
towards the roof 52, and the portion 70b on the other side of the
bend 112 will lay flush against the roof 52 above the solar panels
80, 82, 84 (FIG. 8).
[0043] The hood flashing 70 is cut to the width of the combined
solar panels 80, 82, 84 with overlap on each side sufficient to
allow the hood flashing 70 to fold over the raised outer edges of
the panels 80, 82. As shown in FIG. 8, a short cut 114 is then made
on each of the right and left sides of the hood flashing 70 at bend
112, with a length that is approximately equal to the height of the
raised edges on the outside of the starter panel 80 and the end
panel 82. The outer edges of the lower portion 70a of the hood
flashing 70 are then folded down on each side. A diagonal fold 70c
is then made from the interior end of the short cut 114 to the
outer edge of the folded hood flashing 70 (FIG. 9).
[0044] The hood flashing 70 is then installed so that end cleat 110
locks over the edge of Z-cleat flange 106b, and the triangles that
were folded into each edge form seals along the left and right
sides of the hood flashing 70. When installed, the top portion 70b
of the hood flashing 70 is flush against the roof 52. To seal the
top portion of the hood flashing 70 so that it is water tight, a
course of shingles is installed over the hood flashing portion 70b,
according to the shingle manufacturer's instructions, and another
course of shingles is installed above and overlapping the course of
shingles that is installed over the hood flashing 70 to ensure a
water-tight seal (FIG. 9).
[0045] The panels 80, 82, 84, wiring 108, flashing and trim
elements 58, 70, 102, 104, 106, clips 94, foam backing 64,
underlayment 68 and various other elements as described in each
embodiment may be supplied in pre-packaged kit form, to facilitate
installation of the solar panel system 50 on a traditional roof 52
such that it is an integrated part of the roof 52. Selling the
components of the solar roofing system 50 as a kit will also
eliminate the need for the installer to separately calculate the
number of solar panels 80, 82, 84 required, purchase parts and
determine which parts will be suitable for use in combination with
each other. The pre-packaged kits can preferably be prepared and
packaged to meet certain desirable or commonly used system sizes
for residential use, or for larger commercial uses, such as those
shown in Table 1.
[0046] In another preferred embodiment, a metal solar roofing
system 50' can be installed on a roof that will also have metal
shingles 202 installed thereon (FIG. 10). However, when two
different metals are in contact and subject to a corrosive or
conductive environment (such as one that might be experienced on
the roof of a building) a current flow may be initiated between the
metals. Therefore, a non-absorbent insulating layer must be used
between rows of dissimilar metals, preferably an insulating
synthetic underlayment material. The method of installing a solar
roofing system 50' is similar to that used to install the solar
roofing system 50 on an asphalt shingle or other roof 52, although
some modifications to the flashing elements are made to seal the
solar roofing system 50' to the metal roof 202.
[0047] To install a solar roofing system 50' with metal shingles
202, at least one (1) row of the metal shingles 202 must be
installed first. Then, the metal starter strip 204 is attached
(FIG. 10). Starter strip has a shingle cleat 206 and a panel cleat
208. The shingle cleat 206 is at the bottom of the metal starter
strip 204, and is used to hook over and thereby anchor the metal
starter strip 204 to the metal shingles 202. The panel cleat 208 is
along a midline of the metal starter strip 204, and is used to
anchor the panels 80, 82, 84 to the metal starter strip 204, by
hooking the bottom lip of panels 80, 82, 84 over cleat 208. Once
the metal starter strip 204 is in place, the solar roofing panels
80, 82, 84 can be installed generally as described above with
respect to the installation on an asphalt roof 52.
[0048] A lineal side channel 218, is used on each side of the solar
roofing system 50' in place of the step flashing 102 and flashing
cover 104 as described above (FIG. 11). The lineal side channel has
three sections: (a) a bottom section 214, which lies flush with the
roof and has a side cleat 216 to fasten adjacent metal shingles
202, (b) a two-layered back section 218, which is oriented
perpendicular to the roof and has an opening from the bottom which
is sized to fit over the straight raised edge flanges 90 and 92 of
the starter and end panels 80 and 82, and (c) a top section 220,
which extends outward from the metal solar roofing system 50 to fit
over the adjacent metal shingles 202. On the left and right sides
of the outside panels 80 and 82 the lineal side channel 212 is
installed by sliding the back 218 over the straight raised left and
right side flanges 90 and 92, such that the top 220 and bottom 214
of the lineal side channels 212 extend outwardly from the solar
roofing system 50'. The lineal side channel 212 is cut to a length
longer than the panels 80 or 82, such that it extends to the bottom
of the metal starter trim 204 on each side, approximately three (3)
inches below the raised side flange 90 or 92 of the panel 80 or 82
that is being capped. The lineal side channel 212 is fastened to
the roof 202 by nailing through the bottom section 214 at intervals
along its length.
[0049] Once the lineal side channel 212 is installed, metal
shingles 202 can be installed along the sides of the solar roofing
system 50, where they are inserted into the lineal side channel 212
(FIG. 11). A Z-cleat 106 is then installed on the top of each panel
80, 82, 84, and the panels are electrically connected as described
above, with the wires routed down into the building. A metal hood
transition piece 222 is then installed in the same manner as the
hood flashing 70 described above (FIG. 12). The metal hood
transition piece 222 is generally similar to the hood flashing 70
except that is has an additional transitional cleat 224 along the
top for the installation of metal shingles 202, by hooking them
over cleat 224. Metal shingles 202 can then be installed over the
metal hood transition piece 222, with a bead of sealant placed at
the lap of the shingle 202 and the metal hood transition piece 222.
It may be necessary in some instances to install a siding starter
on the metal hood transition piece 222 so that the shingles 202
line up evenly.
[0050] The elements of the embodiment of the solar roofing system
50' as described for use with metal roofing can also be supplied in
pre-fabricated "kit" form, for ease and efficiency of installation
of the solar roofing system 50', as described above with relation
to solar roofing system 50.
[0051] It will be apparent to those skilled in the pertinent arts
that still other embodiments of solar roofing assemblies in
accordance with the invention can be designed, as well as
variations to the method of installing the same. That is the
principles of an assembly and method of installing it in accordance
with the invention are not limited to the specific embodiments
described herein. Accordingly, it will be apparent to those skilled
in the art that modifications and other variations of the
above-described illustrative embodiments of the invention may be
effected without departing from the spirit and scope of the novel
concepts of the invention.
* * * * *