U.S. patent application number 13/792809 was filed with the patent office on 2013-07-25 for solar panel support structure.
The applicant listed for this patent is Gary Kassem. Invention is credited to Gary Kassem.
Application Number | 20130186017 13/792809 |
Document ID | / |
Family ID | 45811112 |
Filed Date | 2013-07-25 |
United States Patent
Application |
20130186017 |
Kind Code |
A1 |
Kassem; Gary |
July 25, 2013 |
SOLAR PANEL SUPPORT STRUCTURE
Abstract
Roof-top solar panel system that is held in place on a roof by
the solar array. The system includes a softened design including
rounded component edges that protect the roof from uplift damage by
solar panel structure components with or without mechanical
anchoring or ballast.
Inventors: |
Kassem; Gary; (Naples,
FL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Kassem; Gary |
Naples |
FL |
US |
|
|
Family ID: |
45811112 |
Appl. No.: |
13/792809 |
Filed: |
March 11, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/US2011/001562 |
Sep 9, 2011 |
|
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13792809 |
|
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61381230 |
Sep 9, 2010 |
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Current U.S.
Class: |
52/173.3 |
Current CPC
Class: |
F24S 2025/806 20180501;
F24S 25/13 20180501; Y02E 10/50 20130101; Y02B 10/10 20130101; Y02E
10/47 20130101; H02S 20/23 20141201; F24S 25/61 20180501; F24S
2025/021 20180501; Y02B 10/20 20130101; F24S 20/25 20180501; F24S
25/33 20180501 |
Class at
Publication: |
52/173.3 |
International
Class: |
F24J 2/52 20060101
F24J002/52 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 9, 2011 |
US |
PCT/US2011/001562 |
Claims
1. A solar panel support structure to mount a solar array on a roof
comprising: a pair of parallel oriented guide rails, wherein each
guide rail includes a length and a track extending substantially
the entire length of the guide rail; at least one cross member
slidably connected to the tracks of the pair of parallel oriented
guide rails, wherein the at least one cross member includes a
recess to receive a first edge of the solar array; a pair of
longitudinal members slidably connected to the tracks of the pair
of parallel oriented guide rails, wherein each longitudinal member
of the pair of longitudinal members includes a recess to receive a
second edge of the solar array, wherein a predetermined distance
between the at least one cross member and a pair of longitudinal
members defines an angle of incidence O of the solar array relative
to an upper surface of the roof.
2. The solar panel support structure according to claim 1, further
comprising a third guide rail with a length and a track extending
substantially the entire length of the third guide rail, wherein
the third guide rail is disposed between the pair of parallel
oriented guide rails and a center member slidably connected to the
track of the third guide rail.
3. The solar panel support structure according to claim 1, further
comprising a protective membrane with a perimeter, wherein the
protective membrane is disposed between the pair of parallel
oriented guide rails and the upper surface of the roof without the
use of ballast to retain the protective membrane on the roof.
4. The solar panel support structure according to claim 3, wherein
the protective membrane is not attached to the roof.
5. The solar panel support structure according to claim 3, wherein
the protective member comprises a plurality of edges along the
perimeter, wherein one or more edges of the plurality of edges of
the perimeter of the protective membrane are attached to the
roof.
6. The solar panel support structure according to claim 1, further
comprising a foot disposed under at least one guide rail of the
pair of parallel oriented guide rails.
7. The solar panel support structure according to claim 3, wherein
the protective membrane is not attached to at least one guide rail
of the pair of parallel oriented guide rails.
8. The solar panel support structure according to claim 3, wherein
the protective membrane is attached to at least one guide rail of
the pair of parallel oriented guide rails.
9. The solar panel support structure according to claim 3, further
comprising a bracket and a connector, wherein the bracket coupling
the connector to at least one guide rail of the pair of parallel
oriented guide rails, wherein the connector counteracts external
forces acting on the solar array to maintain the at least one guide
rail of the pair of parallel oriented guide rails in substantially
contact with the upper surface of the roof.
10. The roofing system according to claim 1, wherein each guide
rail of the pair of parallel oriented guide rails comprises rounded
bottom edges that prevent cutting of the roof along the rounded
bottom edges when wind causes relative motion between the roof and
the pair of parallel oriented guide rails due to uplift forces.
11. The solar panel support structure according to claim 1, further
comprising a protective membrane disposed between the guide rail
and the upper surface of the roof and a ballast to retain the
protective membrane on the roof with the use of penetrating
anchors.
12. A solar panel support structure to mount a solar array of a
plurality of PV modules on a roof comprising: a fastening bolt
having a threaded shaft and a bolt head; a support post having an
upper structure and a lower structure, wherein the upper structure
includes an aperture sized to receive the threaded shaft of the
fastening bolt; a corner base having a through hole sized to
receive the threaded shaft of the fastening bolt; and a clamp
having a base with an edge, a through hole sized to receive the
threaded shaft of the fastening bolt, and an outwardly extending
tab along the edge, wherein the outwardly extending tab includes a
bend angle a relative to the base, wherein a corner of a PV module
of the plurality of PV modules is disposed between the clamp and
the corner base and retained in place when the fastening bolt
engages the support post and the clamp without one or more rails
interconnecting the plurality of PV modules.
13. The solar panel support structure according to claim 12,
wherein the aperture of the support post comprises a slot opening
sized to receive the threaded shaft of the fastening bolt and a
slot base sized to receive the bolt head of the fastening bolt,
wherein the slot opening is less than a width of the bolt head such
that the fastening bolt is retained in the support post.
14. The solar panel support structure according to claim 12,
wherein the aperture of the support post comprises a threaded
through hole sized to receive the threaded shaft of the fastening
bolt.
15. The solar panel support structure according to claim 12,
wherein the outwardly extending tab of the corner clamp comprises a
width to form a predetermined space between two PV modules of the
plurality of PV modules.
16. The solar panel support structure according to claim 12,
wherein the bend angle a ranges between about 120 degrees and about
150 degrees.
17. The solar panel support structure according to claim 12,
wherein the corner base comprises a constant thickness such that
the PV module has a zero degree slope.
18. The solar panel support structure according to claim 12,
wherein the corner base comprises a varying thickness such that the
PV module has a greater than zero degree slope.
19. The solar panel support structure according to claim 12,
further comprising at least two support posts, wherein heights of
the at least two support posts are the same height such that the PV
module has a zero degree slope.
20. The solar panel support structure according to claim 12,
further comprising at least two support posts, wherein heights of
the at least two support posts are different heights such that the
PV module has a greater than zero degree slope.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation In Part Application of
International Application Serial No. PCT/US2011/001562, titled:
SOLAR PANEL SUPPORT STRUCTURE, filed Sep. 9, 2011, claiming
priority of U.S. Provisional Application No: 61/381,230, titled:
SOLAR PANEL SUPPORT STRUCTURE, filed on Sep. 9, 2010, both herein
incorporated by reference.
FIELD OF THE INVENTION
[0002] This invention relates to a combination roofing system and
solar panel support structure for use with solar energy panels on
roofs and decks, in particular the array and solar panel support
structure holds the roof in place.
BACKGROUND OF THE INVENTION
[0003] Commercially available solar racks are incompatible with the
existing roof-top materials. The racks and/or supporting structure
must be fastened directly to the roof or ballasted around its
perimeter with weights. Such racks damage or slice through the
roofing materials, such as waterproof membranes, over time.
Existing solar rack systems also have disadvantages when solar rack
systems are shipped with integral roof protection membranes,
because such systems make it difficult to position the rack on the
roof and provide roof maintenance. In addition, existing membrane
systems with racks have redundant fastening mechanisms and do not
recognize and incorporate the benefits of the solar rack as
ballast. The practice of using a ballast material such as pavers,
stones, or other materials with sufficient weight to counteract
wind uplift forces are well documented in the roofing industry.
Typically, a minimum weight of 10 lbs. per square foot is required
when round river stone is utilized. This represents the minimal
condition and the ballast weights are increased in the perimeters,
corners and field of the roof in accordance with industry accepted
design guidelines. The ability of a ballasted roofing system to
withstand wind uplift forces given the relatively low weight of the
ballast versus the design uplift pressure is due to the geometry of
the stone (generally round) and the wind interaction with the
shape. Pavers or other square or rectangular flat plates usually
require an interlocking mechanism or increased weight to perform
the same function. Racking systems utilizing additional ballast
weight may exceed the safe capacity of the structure. As a result
solar rack systems that minimize the additional weight required are
desirable to the market since the structural impact is
lessened.
SUMMARY OF THE INVENTION
[0004] The present invention is a roofing membrane and integrated
solar panel support structure that is compatible with any existing
roofing substrate and that optimizes the attachment benefits of the
solar rack by providing a combination of a solar panel support
structure and a waterproofing membrane that is secured to a roof,
for example, by using the solar panel support structure and roofing
membrane as ballast, such that few or no other fastening system or
mechanism or wind reduction or pressure equalizing devices attached
thereto are needed to complete the installation of the photovoltaic
(PV) assembly to the roof. The bottom of the support rails of the
solar panel rack also have a rounded (softened) designed such that
when the roof pillows or bounces in the wind, the roof membrane is
not damaged or sliced by the rails of the solar panel structure.
The softening is extended to the panel support members (run
perpendicular to the support rails) and upright PV panel support
brackets that attach to the support rails. The protective membrane
is loosely laid on top of the existing roof and can be held in
place using the weight of the present invention and solar panel
support structure and solar panel array components attached
thereto. The protective membrane can be used to repair a
pre-existing old roof such that it is watertight. Once the new
protective member is placed on the old existing roof a two-ply
redundant roofing system is formed, and the aging of the old roof
ceases because there is no longer any Ultraviolet light exposure to
the pre-existing roof. In cases where wind uplift or seismic forces
require increased resistance to lateral or uplift forces,
connectors may be utilized to counteract the forces. The connectors
are secured to a structural element and the solar support
structure. In some cases support members of the solar rack may be
used in lieu of the existing ballast to secure a loose laid roofing
material (such as an Ethylene Propylene Diene Monomer (EPDM)
membrane ballasted with river stone) to the structure thereby
eliminating the need for pre-securing the underlying roof system.
However, some embodiments may replace penetrating anchors, such as
short or long spikes, with conventional ballast.
DESCRIPTION OF THE DRAWINGS
[0005] The invention is further illustrated by the following
non-limiting drawings in which,
[0006] FIG. 1 is perspective view of an embodiment of the present
invention in which the solar panel structure protection layer is
not attached to the existing membrane/roof;
[0007] FIG. 2 is a perspective view of an embodiment of the present
invention in which the solar panel structure protection layer is
partially attached to the existing membrane/roof system at the
edges;
[0008] FIG. 3 is a perspective view of an embodiment of the present
invention in which the solar panel structure protection layer is
sealed on three sides to the existing roof membrane;
[0009] FIG. 4 is a side view of an embodiment of the present
invention having the solar panel structure protection layer and a
support railing directly on a roof substrate, and with foot
supports under one rail to illustrate one embodiment of the present
invention to increase roof clearance or for additional support;
[0010] FIG. 5 is a side view of an embodiment of the present
invention having the solar panel structure protection layer and a
support railing directly on top of an existing roof membrane, and
with foot supports under one rail to illustrate one embodiment of
the present invention to increase roof clearance;
[0011] FIG. 6a is a perspective of an embodiment of the present
invention having the solar panel structure protection layer and a
connector on top of an existing roof membrane;
[0012] FIG. 6b is an illustration of a connector used to retain
support rail 30 in place;
[0013] FIGS. 7A-C are side views of embodiments of the present
invention having a connector attached to wood blocking which is in
turn attached to the structure, wherein the post penetrates the
existing roof system and new membrane requiring the installation of
flashings to both membranes in order to seal the post to water
penetration;
[0014] FIG. 8 is a side view of an embodiment of the present
invention having a connector attached directly the base structure
of the roof, wherein the post penetrates the existing roof system
and new membrane requiring the installation of filler material
around the post and flashings to both membranes in order to seal
the post to water penetration;
[0015] FIG. 9A is a perspective view of the embodiments of the
present invention shown in FIGS. 1, 2, & 3 with the solar array
attached thereto;
[0016] FIG. 9B is a perspective view of the embodiments of the
present invention shown in FIGS. 1, 2, & 3 without the solar
array attached thereto;
[0017] FIGS. 10A and 10B are illustrations of external forces and
reactive forces acting on an object, such the present
invention;
[0018] FIG. 11 is side view of an embodiment of the present
invention adjacent to a corner or edge roof wall;
[0019] FIG. 12 is an exploded view of an exemplary embodiment of an
assembly including a support post, a corner base, and a corner
clamp;
[0020] FIG. 13 is an exploded view of another exemplary embodiment
of an assembly including a support post, a corner base, and a
corner clamp;
[0021] FIG. 14A-14F are various pictorial views of components of an
assembly;
[0022] FIG. 14G is an exploded view of assembly components with PV
modules positioned for installation;
[0023] FIG. 15A is a top view of an exemplary rack system with
assemblies positioned at corners of PV modules;
[0024] FIG. 15B is a side view of the rack system of FIG. 15A
illustrating a plane P1 of zero degrees;
[0025] FIG. 16A is a top view of an exemplary rack system with
assemblies positioned at corners of PV modules; and
[0026] FIG. 16B is a side view of the rack system of FIG. 16A
illustrating a plane P2 of greater than zero degrees.
DETAILED DESCRIPTION OF THE INVENTION
[0027] FIG. 1 is a perspective plan view of an embodiment of the
present invention 1 in which the protective membrane 5 is not
fixedly attached to the existing roof membrane 10 and merely
overlays the existing roof membrane 10. Roof member 10 includes an
upper surface 10a. Two or more rows of support rails 30 can be
positioned on top of protective membrane 5 without any adhesive or
fasteners or fixturing devices used to attach or connect support
rails 30 to protective membrane 5. Alternatively, support rails 30
could sit directly on the roof membrane 10 or sit on feet or risers
31.
[0028] The protective membrane 5 of the present invention 1 also
protects an existing roof system from damage by solar panel
structure components, such as damage during maintenance to the
solar panel structure, PV panels and associated electrical system
or other roof top equipment (HVAC, exhaust fans, etc), or damage
incurred while relocating (horizontally or vertically) portions of
an existing PV system, or damage caused by abrasion to the roof
membrane 10 from "feet" or "ballast pans" that contact the roof
membrane 10 and are subject to continued thermal expansion and
contraction cycles. This abrasion can result in holes through the
membranes 10 or a severely compromised roof system. The protective
membrane 5 can be used as a new waterproofing membrane for new
construction, or can be used as a new waterproofing membrane over
an existing roof system. In the former case, an existing roof
membrane 10 in marginal condition can be waterproofed under the
solar panel structure without any preparatory repair work to the
existing roof system.
[0029] Now turning to the insert in FIG. 1, support rails 30 can be
generally trapezoidal shaped or any other geometric shape with
rounded bottom edges 32 where the rail could contact the protective
membrane 5 or roof 10. Rounded bottom edges 32 soften the contact
of the surfaces to prevent cutting or tearing or excessive wear of
the surfaces that results in relation motion between the surfaces
due to wind induced uplift. The rounding is beneficial where the
protective membrane 5 or roof 10 pillows up under a wind load and
contacts the support rails 30 causing abrasion or puncture damage.
The overall length 36 of support rails 30 can be shorter than
length 38 of protective membrane 5. However, some embodiments of
support rails 30 can have length 36 equal to or greater than length
38 of protective membrane 5. The internal cavity 39 of support
rails 30 is configured to receive nuts, bolts, or other fasteners 9
to secure the solar panel supports (shown in FIG. 9B) to the system
1. Internal cavity 39 shown in the insert in FIG. 1 is an
illustration of a nut/bolt insert slot to engage a head 33 of
nut/bolt 9 to connect cross member 25 (FIG. 2) with support rail 30
to form the solar rack system 1 at any point along the support rail
30. The internal cavity 39 acts like a track for a variable sliding
adjustment of the cross member 25 along guide rail 30.
[0030] Now turning to FIG. 9B that illustrates an embodiment 52 of
the present invention including center upright members 97 and end
upright members 99, discussed below, also can be slideably adjusted
along guide rail 30 to any point along the length 36 (see FIG. 1)
of guide rail 30. This adjustability provides flexibility in the
selection of the solar array width and/or angle of incidence O
relative to the roof upper surface by setting a distance D between
cross member 25 and center upright members 97/end upright members
99. As distance D reduces, the angle of incidence O increases. The
desired angle of incidence O is determined based on the position of
the sun relative to the roof surface 10A, which is dependent on the
time of year and latitudinal location relative to the equator. As
mentioned above, an example of distance X that separates guide
rails 30 ranges can from 3' to 16' depending upon the layout
configuration. The longer distance X spans would accommodate more
panels side by side supported by cross members 25 and center
upright members 97 and end upright members 99. As distance X spans
longer distances, then length L3 of lip 97A and L4 of lip 25A would
be longer extrusions. The longer the lengths L3, L4 of lips 97A,
25A, respectively, the ratio of guide rails 30 to panels 55 (see
FIG. 9A) would decrease. For example, FIG. 9A illustrates 3 guide
rails 30 and 2 solar panels 55 or 3:2 ratio. As the distance X
increases and lengths L3, L4 increase, then more than 2 solar
panels 55 can be placed on lips 97A, 99A, 25A, such as 3 guide
rails with 3 solar panels making the guide rail 30 to solar panel
ratio 3:3, or 3 guide rails with 4 solar panels, 3:4 ratio, etc.
However, any configuration that retains the solar rack system 52
within support rails 30 is suitable for the contemplated
embodiments of the present invention.
[0031] Now turning to FIG. 2 and an insert of cross member 25
illustrating a through hole 11 to receive bolt 9 (see FIG. 1) to
secure cross member 25 to support rail 30. Cross member rounded
bottom edges 33 along bottom width 31 where cross member 25 could
contact the protective membrane 5 or roof 10. Rounded bottom edges
33 soften the contact of the surfaces to prevent cutting or tearing
or excessive wear of the surfaces that results in relation motion
between the surfaces due to wind induced uplift. The rounding is
beneficial where the protective membrane 5 or roof 10 pillows up
under a wind load and contacts cross member 25 causing abrasion or
puncture damage. Projections 27 and 29 form a recess 28 to attach
the solar rack system (not shown) to the present invention.
[0032] Now returning to FIG. 1, bottom surface 95A of support rail
30 or bottom surface 95B of connector 40 (FIG. 7A) can have a
surface roughness or be made of or coated with a material that has
a sufficient coefficient of friction .mu. between adjacent surface
protective membrane 5 or feet 31 (FIGS. 4 and 5) to require a
horizontal force F.sub.x greater than sliding friction F.mu. (F.mu.
a equals normal force N times coefficient of friction .mu.) before
the solar rack system 1 moves relative to the adjacent material
when external force F.sub.external is induced on solar rack system
1 (see FIGS. 10A and 10B). Coefficient of friction .mu. can be
determined based on the characteristics of the mating surfaces.
External force F.sub.external has an X component of force F.sub.x
and a Y component of force F.sub.y. Normal force N is the resultant
force of the weight of solar rack system 1 and External force Y
component (F.sub.y). FIG. 10A illustrates an external force
F.sub.external inducing a downward or negative vertical force
F.sub.y on the solar rack system 1. Therefore, normal force N is
the addition of the downward external force F.sub.y and the weight
W of solar rack system 1. FIG. 10B illustrates an external force
F.sub.external inducing an upward or positive vertical force
F.sub.y on the solar rack system 1. Therefore, normal force N is
the subtraction of the upward external force F.sub.y from weight W
of solar rack system 1. With regards to sliding friction F.mu.,
external force vertical force Fy could be beneficial (-Fy--see FIG.
10A)) or detrimental (+Fy--see FIG. 10B). With regards to
externally induced moment M, external vertical force Fy could be
beneficial (-Fy--see FIG. 10A)) or detrimental (+Fy--see FIG. 10B).
Therefore, weight W of solar rack system 1 must take into account
the upward or positive vertical force F.sub.y of the external force
F.sub.external. The protective membrane 5 is held in place normal
to the roof membrane 10 by the weight of solar rack system 1 and/or
anchors (such as short spikes 77 and long spikes 79 shown in FIGS.
7A and 7B).
[0033] Now turning to FIG. 2 illustrating a perspective view of the
protective membrane 5 partially attached to the existing membrane
10 at various (discontinuous) attachment points 15. Attachment
points 15 can be used around the entire perimeter 3 of the
protective membrane 5, or on one or more sides of protective
membrane 5, depending on the needs of the user. Attachment methods
vary with the type of membrane. A thermoplastic membrane could be
heat welded to a thermoplastic membrane, a thermoset membrane may
require an adhesive tape, and dissimilar materials could be
attached with an adhesive tape, contact adhesive, a built-up roof
(BUR) could be attached with bitumen based mastics, sealants, or
any combination thereof The guide rails 30 could sit directly on
the roof membrane 10 or sit on feet or risers 31.
[0034] Now turning to FIG. 3 illustrating other embodiments of
protective membrane 5 can include continuous attachment 16 on one,
two, three, or four sides 17 of the membrane perimeter 3. Three
sides 17 are shown in FIG. 3 to be continuously attached to the
existing roof membrane 10. Attachment methods vary with the type of
membrane. A thermoplastic membrane could be heat welded to a
thermoplastic membrane, a thermoset membrane may require an
adhesive tape, contact adhesive, a built-up roof (BUR) could be
attached with bitumen based mastics, sealants, or any combination
thereof. Support railings 30 can be spaced apart a distance X, for
example about 3 feet to about 16 feet. FIG. 4 is a side view of an
embodiment of the present invention having the protective membrane
5 and a support railing 30 for a solar rack system directly on a
roof substrate or system 35 (without roof membrane 10) on top of
insulation substrate 35A. The support rails 30 could sit directly
on the protective membrane 5 or sit on feet or risers 31. Some
embodiments of the protective membrane 5 will substantially cover
roof membrane 10 or roof substrate 35 when there is no roof
membrane 10 as illustrated in FIG. 11.
[0035] FIG. 5 is a side view of an embodiment of the present
invention 1 having protective membrane 5 and a support railing 30
shown on top of an existing roof membrane 10. The support rails 30
could sit directly on the protective membrane 5 or sit on feet or
risers 31.
[0036] FIG. 6a is a perspective view of an embodiment of the
present invention 1 having the protective membrane 5 and a
connector 40 on top of an existing roof membrane 10. Connector 40
can be placed directly on the roof membrane 10 when the dead load
of the solar rack system 1 requires additional support to resist
loads acting normal to the roof plane, for example, wind and
seismic forces that act downward. As discussed above and shown in
FIGS. 10A and 10B, connector 40 will remain at rest in its
predetermined position until external horizontal force Fx is
greater than sliding friction F.mu.. If resistance to lateral
forces is required, the foot 31 or a connector 40 can be attached
to the roof structure to counteract the forces. Also, base 42 of
connector 40 acts as a stabilizer to counter the moment M induced
by the external forces, wherein a larger base 42 distributes the
moment load over a greater area. Connector 40 can be solid (not
shown) or include hole 43 to receive and engage a solar array rack
system (not shown). Protective membrane 5 dimensions (width W1,
length L1) can be sized to be slightly larger than the dimensions
(width W2, length L2) of base 42. A plurality of protective
membranes 5 can be used as required under connectors 40. This
feature provides for replacement of a single protective membrane 5
from under a connector 40 of smaller size than the larger
protective membrane 5 intended to be a single, monolithic pad under
all the connectors 40 as shown in FIGS. 1-3.
[0037] FIG. 6b illustrates a connector 40 used to retain support
rail 30 (see FIG. 1) in place. Bracket 101 includes slots 103, 105
to receive an attachment device such as nuts, bolts, or other
fasteners 9 (see FIG. 1) to attach bracket 101 to connector 40 and
support rail 30 (see FIG. 1) into hole 43 of shaft 54, thereby
coupling connector 40 and support rail 30 to secure support rail
30. Connector 40 can be attached to the roof structure with an
attachment device such as short spikes 77 (see FIG. 7) through
holes 40a in base 42 or not physically attached to the roof
structure and remain a place by its own weight or ballast. Slot
103, 105 allow for variable adjustment and positioning of connector
40. Bracket 101 restrains support rail 30 from lateral and upward
movement due to external forces such as wind and seismic
activities.
[0038] FIGS. 7A-C illustrate other embodiments 2A-C of the present
invention with a connector 40 having shaft 54 penetrating hole 63
of an existing roof membrane 10 and hole 65 of protective membrane
5. FIG. 7A illustrates only first flashing 45. FIG. 7B illustrates
first flashing 45 and second flashing 47. FIG. 7C illustrates first
flashing 45, second flashing 47, and third flashing 47A. All
flashing embodiments provide a waterproof seal at the point or
along the seam of penetration of the existing roof membrane 10.
Each flashing is shown was an increasing vertical height H and
horizontal length L (see FIG. 7C). Shaft 54 includes an outer
surface 67 with a diameter smaller than or equivalent to the
diameter of hole 65 of the protective membrane 5 and smaller than
or equivalent to a hole 63 in roof membrane 10 of the roof. Roof
membrane 10 is disposed between protective membrane 5 and base 42
with thickness 49 of connector 40. Base 42 is disposed between roof
membrane 10 and wood blocking 50 or equivalent. First flashing 45
includes an inner surface 69 with a diameter larger than the
diameter of the outer surface 67 of the shaft 54 of the connector
40, wherein the flashing 45 is disposed along the outer surface 67
of the shaft 54 of the connector 40 and between the roof membrane
10 and protective membrane 5 to provide a waterproof seal between
the shaft 54 and the roof membrane 10. Second flashing 47 has an
inner surface 71 with a diameter larger than the diameter of the
outer surface 73 of the first flashing 45, wherein the second
flashing 47 is disposed along the outer surface 73 of the first
flashing 45 and along the outer surface 67 of the shaft 54 of the
connector 40 and on top of the protective membrane 5 to provide a
waterproof seal between the first flashing 45 and the protective
membrane 5. Third flashing 47A includes an inner surface 47B with a
diameter larger than the diameter of the outer surface 47C of the
second flashing 47, wherein third flashing 47A is disposed along
the outer surface 47C of second flashing 47 to provide a waterproof
seal between second flashing 47, the first flashing 45, and the
protective membrane 5.
[0039] Continuing with FIGS. 7A-C, wood blocking 50 having at least
the same surface area 50A or foot print as base 42 of connector 40
is integrated within roof substrate 35, which are both attached to
base structure 37 and used to provide a stable attachment point for
connector 40. Attachment of connector 40 to wood blocking 50 and
wood blocking 50 to base structure 37 can be accomplished by any
conventional means. FIGS. 7A-C illustrates one embodiment of the
attachment device being short spikes 77 and long spikes 79,
respectively. Alternatively, conventional ballast (not shown) can
replace the penetrating anchors, short spikes 77 and long spikes
79. Connector 40 provides resistance to external forces, such as
wind or seismic forces, by transmitting the external loads through
connector 40 to wood blocking 50 to structure 37. These adjacent
components also act as a dampening system as well as a load
transfer or load path system. The material of each component, such
as metal or wood, has insulating or energy absorption
characteristics to dampen the resonance frequency induced by the
external forces. The thickness, length and/or width of the
components can be adjusted to tune the dampening system, here being
the connector 40, wooden blocking 50, and structure 37. The
combination of energy transfer and dampening mechanisms provide for
a system that is capable of efficient operation through the varying
spectrum of vibrations because the system does not need to
eliminate all vibrations. There only needs to be sufficient
reduction in the vibrational modes such that the relative movement
of the protective membrane 5/flashings 45, 47, 47A and the
underlayment (the roof membrane 10 or roof substrate 35) at the
contact edges or seams does not form a gap or fluid pathway
therebetween to maintain integrity of the watertight seal.
[0040] Now turning to FIG. 8 that illustrates another embodiment of
the present invention 1 having recess 53 with depth 51
substantially equivalent to thickness 49 of base 42 of connector 40
plus thickness 83 of filler material 81, such that top surface 59
of filler material 81 (such as insulation, gypsum board, and foam)
is substantially flush or level with top surface 61 of roof
substrate 35. The fit of base 42 within recess 53 is sufficient
prevent substantial relative movement of base 42 within recess 53
to resist external forces dislodging connector 40 from recess 53.
Additional, attachment devices (such as bolts or spikes) can be
used to secure base 42 of connector 40 to base structure 37 of the
roof. Flashings 45, 47, 47A and protective membrane 5 are attached
by the same method as described above for the embodiment of FIGS.
7A-C.
[0041] Now turning to FIG. 9A that illustrates one embodiment of
the present invention 1 being an array of the PV assemblies 55
positioned loosely on base structure 37 (see FIGS. 7A-C and 8),
typically a horizontal roof. Solar array 55 installed on the solar
panel structure protective layer 5 can be placed on either roof
membrane 10 or roof substrate 35. Mounting of solar rack system 1
can be accomplished (1) without the need for fasteners and (2)
without the need for wind reduction or pressure equalizing devices
attached thereto.
[0042] Now turning to FIG. 9B that illustrates a perspective view
of the embodiments of the present invention shown in FIGS. 1, 2,
& 3 without the solar array attached thereto, as illustrated in
FIG. 9A. The assembled frame 96 includes cross section members 25,
center upright members 97, and end upright members 99 in slidable
engagement with support rails 30 to adjust for varying widths of PV
assemblies 55 (see FIG. 9A). Nuts, bolts, or other fasteners 9 (see
FIG. 1) can be used to secure center upright members 97 and end
upright members 99, as well as cross section members 25 discussed
above. A center upright member 97 and a pair of end upright or
longitudinal members 99 are generally aligned in same longitudinal
plane such that back edge 55a (see FIG. 9A) of PV assemblies 55
rest on lips 97a, 99a of center upright members 97 and end upright
members 99, respectively. Cross section member 25 is generally
aligned with front edge 55b of (see FIG. 9A) of PV assemblies 55
such that front edge 55b rests in lips 25a of cross section member
25. One embodiment to the heights H1 of lips 97a, 99a of center
upright members 97 and end upright members 99 from support rails 30
is greater than the height H2 of lips 25a of cross section member
25 from support rails 30 to create an angle of incidence O of PV
assemblies 55 (see FIG. 9A) above the roof
[0043] FIG. 11 is a side view of an embodiment 100 of the present
invention adjacent to or mating with a corner or edge roof wall 90
of building 98. Protective membrane 5 includes an integrally formed
side wall 92 with height 94 such that the projected maximum height
of sustainable water on the roof is less than height 92. The
overall dimensions of embodiment 100 will be equivalent to the
dimensions of the rooftop for a watertight seal around the entire
interior perimeter 96 of the roof. Alternative embodiments do not
include the side wall 92 such that perimeter 3 (see FIG. 2) of the
protective membrane 5 is substantially adjacent corner or edge 102
of roof wall 90.
[0044] Additionally, the protective membrane 5 can act as a "photon
reflector" to increase energy production when provided in a white
or reflective color. Special reflective color coatings may be used
in lieu of white or light colored materials. The protective
membrane 5 may be manufactured with reflective properties to
increase the solar radiation on PV panels or solar thermal. The
membranes of the invention can be a single ply membrane, polyester
or polypropylene mats of varying weight, polymeric foam, or any
combination thereof Additionally, the membrane material may be
reinforced internally or externally. Also preferably, the membrane
is made of a material that is resistant to puncture. Some
commercially available products are thermoplastic and thermoset
membranes with highly reflective properties in the infra-red
spectrum. The membranes are available in various thicknesses.
[0045] In operation, a method of installing one embodiment of a
solar array rack on top of a roof comprises the steps of: providing
a support rail with rounded bottom edges and a cavity to receive
the solar array rack and a membrane; laying the membrane on the top
of the roof in a predetermined location without fixedly attaching
the membrane to the roof; placing the support rail on the membrane
without fixedly attaching the support rail to the membrane, wherein
the membrane is disposed between the support rail and the top of
the roof; and attaching the solar array rack to the support rail,
wherein the membrane is retained in place on the roof by the
combined weight of the support rail, the solar array rack, and the
membrane without the use of attachments devices, such as fasteners
and adhesives.
[0046] In operation, another method of installing another
embodiment of a solar array rack on top of a roof comprising the
steps of: positioning a connector with shaft on an optional wood
blocking (the connector may also be attached directly to the
structure) embedded in a roof substrate and attaching to the
structure; disposing a roof membrane onto a base of the connector
and a portion of the roof substrate and attaching the roof membrane
to the portion of the roof substrate; placing a first flashing over
an outer surface of the shaft of the connector and lowering the
first flashing onto the roof membrane and attaching the first
flashing to the roof membrane; disposing a roofing system and solar
panel support structure layer over the first flashing and a portion
of the roof membrane roof membrane without fixedly attaching the
roofing system and solar panel structure protection layer to the
first flashing or the portion of the roof membrane; placing a
second flashing over an outer surface of the shaft of the connector
and lowering the second flashing onto the roof system and solar
panel support structure and attaching the second flashing to the
roof membrane; and attaching the solar array rack to the connector,
wherein the solar array rack is retained in place on the roof by
the combined weight of the connector, the solar array rack, and the
roofing system and solar panel structure protection layer without
the use of attachments devices. The connector provides lateral
resistance to forces in this configuration. A similar procedure is
followed when using only one flashing or more than two
flashings.
[0047] Also discussed above is that the protective membrane 5 is
laid over the existing roof membrane 10 prior to installation of
the PV system, for an existing roof An existing roof in marginal
condition can receive a new solar panel structure by installing the
waterproof membrane over the roof prior to installation of the
solar panel structure. If there is no existing roof membrane 10,
the protective membrane 5 may be placed directly on the roof
substrate 35. The protective membrane 5 may be installed before the
PV system installation, for example during any scheduled or
unscheduled maintenance that requires disassembly or relocation of
the existing solar panel structure. The protective membrane 5 may
be loose laid, partially attached at the edges and/or interior, or
fully adhered depending on the type of solar panel structure
utilized. For example as shown in FIGS. 9A and 9B, a solar panel
structure 52 including PV panel 55 can be held in place by the
weight to the structure 52 with PV panel 55, protective membrane 5,
support rails 30, and other components of the solar rack system may
not require attachment of the membrane or ballast weights since the
weight will prevent movement or slippage of the system 1 relative
to the roof upper surface, for example roof membrane 10 or roof
substrate 35.
[0048] The use of a membrane is a desirable preventive measure in
cases where the PV array is installed on a roof and prevents access
to maintain or replace the underlying substrate or roof system. If
the array has to be disassembled along with the racking system the
electrical system has to be taken off line, resulting in a loss of
generation. The inclusion of a protection system such as the
membranes of the invention minimizes damage to a roof system and
lowers the lifecycle costs of the renewable energy production
plant.
[0049] FIGS. 12-16B illustrate other embodiments of a rack system
100A, 100B that eliminates cross members 25 and support rails 30 or
otherwise without any rails interconnecting the PV modules. Rack
system 100 utilizes assemblies 102A, 102B with support posts 104A,
104B, corner bases 106, corner clamps 108, and fastening bolts 110
to retain PV modules 112 forming a unitary structure. Support posts
104A, 104B are installed on the rooftop and, as required, properly
terminated into or secured on to the roof system. Corner base 106
is placed on top of support post 104A, 104B. PV modules 112 are set
in place and secured using corner clamp 108 and fastening bolt 110.
Spacing tab 114 of corner clamp 108 set spacing between PV modules
112. Installers can mix and match support posts 104A, 104B in the
pattern or use the same support post for the entire pattern.
[0050] Now turning to FIG. 12 illustrating an exploded view of an
exemplary embodiment of an assembly 102A including support post
104A, corner base 106, corner clamp 108, and fastening bolt 110.
Support post 104A includes a base 120C with a bottom surface 116
having a recess 118. One embodiment of the present invention may
include an adhesive or equivalent being applied to bottom surface
116 filling recess 118 to fixedly connect support post 104A to the
roof system. Support post 104A also includes an upper structure
120C that can include a bolt drop 120 with a slot opening 120A
sized to receive threaded shaft 126 of bolt 110 and slot base 120B
sized to receive bolt head 122 of bolt 110. Corner base 106 can
include hole 124 sized to receive threaded shaft 126 of bolt 110.
Corner clamp 108 can include threaded hole 128 sized to receive
threaded shaft 126 of bolt 110.
[0051] Now turning to FIG. 13 illustrating an exploded view of
another exemplary embodiment of an assembly 102B including support
post 104B, corner base 106, corner clamp 108, fastening bolt 110,
and attachment devices 134. Support post 104B includes a base 136
with holes 132 sized to receive attachment devices 134 to fixedly
connect support base 104B to the roof system. Support post 104B can
include an upper structure 130A having a threaded hole 130 sized to
receive threaded shaft 126 of bolt 110. Corner base 106 can include
hole 124 sized to receive threaded shaft 126 of bolt 110. Corner
clamp 108 can include threaded or unthreaded hole 128 sized to
receive threaded shaft 126 of bolt 110.
[0052] Now turning to FIG. 14A that illustrates various views of a
perimeter clamp 140 having an attachment hole 142 in base 144 sized
to receive fastening bolt 110 for connecting perimeter clamp 104 to
support post 104A, 104B (FIG. 14G). Perimeter clamp 140 can include
one or more bends to form base 144, intermediate side 146, and lip
148. Bend angles .theta. and .beta. can be any suitable angle
greater than zero degrees and less than 180 degrees, wherein one
embodiment of the present invention bend angles .theta. and .beta.
each range from 85 degrees to 95 degrees. Lip 148 of perimeter
clamp 140 retains PV module 112 between perimeter clamp 140 and
corner base 106.
[0053] Now turning to FIG. 14B that illustrates various views of a
corner clamp 108 having attachment hole 124 in base 150 sized to
receive fastening bolt 110 for connecting corner clamp 108 to
support post 104A, 104B (FIG. 14G) to retain PV module 112 between
corner clamp 108 and corner base 106. Corner clamp 108 can include
spacing tab 114 along edges 152 of base 150 of corner clamp 108 to
set the space between PV modules 112. A corner 162 of PV module 160
will be disposed under corner clamp 108 in shaded area 151. Spacing
tab 114 includes width W1 and can be bend an angle .alpha.. Bend
angle a can be any suitable angle greater than 90 degrees and less
than 180 degrees, wherein one embodiment of the present invention
bend angle .alpha. ranges from 120 degrees to 150 degrees. One
embodiment of spacing tab 114 can be about 0.25 inches determined
based on the expansion coefficient of the material.
[0054] Now turning to FIG. 14C that illustrates a top view of
corner base 106 having projections 154 that act as contact surfaces
to place PV modules 112 on for retention purposes as discussed
above. Corner base 106 can include an attachment hole 124 sized to
receive fastening bolt 110 for connecting corner base 106 to
support post 104A, 104B (FIG. 14G). A corner 162 of PV module 160
will be disposed on top of corner base 106 in shaded area 155.
[0055] Now turning to FIG. 14D that illustrates two embodiments of
corner base 106 having different thicknesses. The 0 degree
embodiment 156 of corner base 106 has a constant thickness T1. The
1 degree embodiment 158 of corner base 106 has a varying thickness
from T1 to T2. The 1 degree embodiment 158 is for illustrations
purposes only and not meant to limit the invention. The actual
degrees of slope can be anything greater than 0 degrees.
[0056] Now turning to FIG. 14E that illustrates a front view and a
side view of support post 104A as discussed above in FIG. 12.
[0057] Now turning to FIG. 14F that illustrates a front view of
support post 104B as discussed above in FIG. 13.
[0058] Now turning to FIG. 14G that illustrates an exploded side
view of rack system 100A, 100B with plane P that can have a zero
degree slope (P1, FIG. 15B) or greater than zero degree slope (P2,
FIG. 16B). Assemblies 160 of either perimeter clamp 140, corner
base 106, and support posts 104A, 104B or corner clamp 108, corner
base 106, and support posts 104A, 104B are shown to retain PV
modules 112 in place on a roof system. The height H1 of support
posts 104A, 104B are the same as shown in FIG. 14G such that the PV
module 112 has a zero slope or is flat. However, the heights of
support posts 104A, 104B can vary such that the PV module 112 has a
greater than zero slope or is not flat.
[0059] Now turning to FIG. 15A that illustrates a top view of rack
system 100A with assemblies 160 positioned in proximity of corners
162 of PV modules 112. Rack system 100A includes support posts
104a, 104B having the same height H1 for all assemblies 160,
thereby resulting in plane P1 with a zero degree slope as
illustrated in FIG. 15B.
[0060] Now turning to FIG. 16A that illustrates a top view of rack
system 100B with assemblies 160 positioned in proximity of corners
162 of PV modules 112. Rack system 100B includes support posts
104a, 104B having the different heights H1, H2 for assemblies 160,
thereby resulting in plane P2 with a greater than zero degree slope
as illustrated in FIG. 16B.
[0061] While the disclosure has been described in detail and with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made therein without departing from the spirit and scope of the
embodiments. Thus, it is intended that the present disclosure cover
the modifications and variations of this disclosure provided they
come within the scope of the appended claims and their
equivalents.
* * * * *