CA2692398A1 - Building integrated solar mounting system - Google Patents

Abstract

A building integrated mounting device for installing solar modules on a sloped roof. The solar module mounting device of the present invention comprises one or more roofing panels attached to a sloped roof as part of the roof assembly into which the mounting structures for conventional solar modules are integrated or attached (the "Mounting Panels"). The Mounting Panels are affixed directly to the roof as the top cover of the roof assembly in a seamless and water-tight fashion with other Mounting Panels and adjacent roof tiles as a building integrated component.
Standard PV modules may be affixed to the Mounting Panels before or after the Mounting Panel is affixed to the roof.

Description

Description BACKGROUND OF THE INVENTION

1. Field of the Invention This invention relates generally to the field of photovoltaic generation of electricity or solar thermal water heating and more specifically to a building integrated (`BI") mounting system for solar energy devices that serves as both part of the roofing assembly and Mounting System for Solar Modules.

2. Background Art Solar photovoltaic (PV) systems convert energy from the sun's radiation directly into electricity for a multitude of end uses. Solar thermal (ST) systems convert energy from the sun's radiation into hot water which may be used for hot water supply, or water heating and cooling systems.
Mounting PV and ST Solar Modules on rooftops offers many benefits including low cost real estate, unobstructed access to sunlight, secure location, proximity to loads, and potential synergies with roofmg assemblies. There are numerous types of solar modules and means of mounting them on rooftops, the most common of which are (1) framed modules fixed via complex mounting systems comprised of separate rails or beams, flange connections, stand-offs, clamps, sliders and associated hardware that is affixed on top of existing roofmg materials, and (2) building integrated modules that may take the form of tiles or shingles incorporating `thin-film' technology or rolled thin-film material permanently affixed to a metal substrate for structural support.

Framed modules are most commonly "rack-mounted" to sloped roofs. Racks or rails are mounted on top of the existing roofing assembly by penetrating the roof to attach the rail. This often leads to leaking roofs and can void any warranty on the existing roofmg assembly.
Even if installed with care and with appropriately flashing around each penetration point, the potential to damage roofmg material and impair the water-tightness of the roofmg assembly is high.
In addition, the material and labor cost associated with installing such racking systems can be very high.
Further, most conventional asphalt shingle roofs last 10 to 15 years. Solar panels are generally warranted for 20 - 25 years and can be expected to produce useful amounts of energy for much longer periods of time. If the roof requires repair or replacement, the solar array will have to be removed and replaced at significant cost.

Building integrated technology is most commonly applied as new roofmg materials that replace an existing roof, either as a shingle comprised of thin film solar material, or thin film material rolled onto a metal roof and affixed with an adhesive. U.S. Patent 5,092,939 to Nath et al discloses a photovoltaic roof that includes panels having a galvanized steel supporting layer with side supporting flanges interconnected to form a roof assembly (a typical standing seam roof).
The mid portion of each panel has a photovoltaic surface made formed of amorphous semi-conductor material which is laminated onto the galvanized steel supporting layer. Such systems tend to be considerably less efficient than conventional crystalline technology, requiring as much as 2x or more surface area to produce the same amount of power. Questions have also been raised about the durability of thin-film roofing materials and difficulty of installing them well.

Nothing in the known prior art, either singly or in combination, disclose or suggest the present invention.

BRIEF SUMMARY OF THE INVENTION

A Solar Module Mounting System ("SMMS") of improved design, the object of which is to provide a building-integrated (`BP") SMMS whereby that Mounting System is built into or directly affixed to Mounting Panels which form an integral part of the roofmg assembly.

A further object is to provide a BI SMMS that is easier to install than other systems.

A further object of the invention is to provide an installed solar photovoltaic or thermal system that is less expensive than systems installed with different technologies.

A further object of the invention is to provide a BI SMMS that maintains the watertight integrity of the roofing assembly.

A further object of the invention is to provide a SMMS that can be seamlessly integrated with a variety of different roofmg materials, either as a new roof or addition to an existing roof. Unlike conventional solar panel installations, the improved design envisaged by the invention would be similar to a skylight, and permit re-roofing around the SMMS without removing it or impacting the watertight integrity of the roofing assembly as a whole.

A further object of the invention is to provide a design that permits the circulation of air around a BI SMMS to maintain operating efficiency.

A further object of the invention is to provide a novel integrated SMMS/stand-off mechanism of fixed but variable design.

A further object of the invention is to provide novel integrated SMMS of fixed or adjustable design.

Other objects and advantages of the present invention will become apparent from the following descriptions and accompanying drawings, wherein by way of illustration and example, preferred and alternative embodiments of the present invention are disclosed.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 is a perspective view of a rooftop showing a modular, Building Integrated Solar Module Mounting System of the present invention with photovoltaic Solar Modules mounted thereon, the bottom row demonstrating installation on the same plane as the rooftop, the top row demonstrating the panels installed with integrated adjustable stand-offs for deployment at a greater angle to the sun than the slope of the roof.

FIG. 2 is a perspective view of a single Mounting Panel with an adjustable panel support/clamp.
FIG. 3 is a side sectional view of a single Mounting Panel with an adjustable panel support/clamp.

FIG. 4 is a side sectional view of the Mounting System integrated with the building rooftop in a watertight manner with an integral Flashing Panel at the top of a Mounting Panel.

FIG. 5 is a side sectional view of the Mounting System integrated with the building rooftop in a watertight manner with an integral Flashing Panel at the bottom of a Mounting Panel.

FIG. 6 is a side sectional view of the Mounting System integrated with the building rooftop in a watertight manner with an integral Flashing Panel at the side of a Mounting Panel.

FIG. 7 is a side-sectional view of a fixed mounting panel with a two piece fixed length standoff/panel support affixing the panel with a commercially available panel clamp.

DETAILED DESCRIPTION OF THE INVENTION

The Solar Module Mounting System of the present invention is illustrated in Fig 1. The Mounting System 20 is comprised of Mounting Panels 22, integrated Module Supports 40, 50, 60, Top Flashing Panel(s) 24, Bottom Flashing Panel(s) 25, Side Flashing Panel(s) 26, and horizontal and vertical Spacing Panels 28, 29. In practice, Spacing Panels between Solar Modules would be used primarily in larger arrays to permit access to the roof and maintenance of the system. While the present invention may be effective in any manner of roofing structure, the Mounting System is designed to incorporate proven effective roofing design elements into an integrated package that facilitates the installation of Solar Modules onto a sloped rooftop in a manner that should involve minimal incremental cost beyond the cost of installing standard roofing materials over the same area. The SMMS of the present invention is a modular design that can accommodate one or any number of Solar Modules in a roof-mounted array ("Solar Array").

In the preferred embodiment shown at 22 in Fig 2, the Mounting Panels comprise the top layer of the roofing assembly. The Mounting Panels are designed to conform to the dimensions of a single Solar Module or row of modules, extended at top, bottom and sides to provide for installation in an interlocking and over- or under-lapping manner with adjacent panels. Each Mounting Panel overlaps the Mounting Panel immediately above, below and beside it in a manner well-known to those skilled in the art to permit water to flow down the sloped roof without penetrating the roofing assembly. In alternative embodiments, the Mounting Panels may be configured and designed in different dimensions that match the dimensions of one or more Solar Modules, while facilitating structurally sound and watertight mounting to the rooftop in the circumstances.

While the Mounting Panels may be of any specification that facilitates the design elements described herein, in the preferred embodiment the Mounting Panels are corrugated or seamed, for example in the B-Deck or Rib pattern illustrated most clearly in Fig 1 and 2. Such metal roofing materials are lightweight, durable and fire resistant, and facilitate the prefabrication or integral design of mounting hardware into the panels themselves. The use of a corrugated or seamed base facilitates the flow of air between the Mounting Panel and Solar Module to reduce heat build-up and support efficient operation of the Solar Module, a major drawback to traditional BIPV designs.

Mounting Panels 22, Spacing Panels 28, 29 and Flashing Panels 24, 25, 26 are affixed to the roof in a conventional, watertight manner familiar to those skilled in the art of installing metal roofing systems.

In the preferred embodiment, the Mounting System is installed integrally with surrounding roofing materials using Flashing Panels 24, 25, 26 specifically designed for the purpose. This methodology facilitates installation in new construction, re-roof or with existing roofing materials. Roofing materials surrounding the Mounting System can be replaced without uninstalling or removing the Solar Array. Alternatively, the Flashing Panel elements described herein may be incorporated into the Mounting Panels themselves.

The Top Flashing Panel 24 depicted in Fig 1, 2 and 4, overlaps the Mounting Panel immediately below it 24.1 in a manner familiar to those skilled in the art to permit water to flow down the sloped roof without penetrating the roofing assembly. In the preferred embodiment utilizing corrugated or seamed panels, the face of the Top Flashing Panel is designed to close the open portion of the Mounting Panel to the elements 24.2. The upper skirt of the Top Flashing Panel 24.3 is designed to conform to and underlap the roofing material above the Top Flashing Panel in a manner known to those skilled in the art to permit water to flow down the sloped roof without penetrating the roofmg assembly.

The Bottom Flashing Panel 25 depicted in Fig 1,2 and 5 underlaps the Mounting Panel immediately above it in a manner known to those skilled in the art to permit water to flow down the sloped roof without penetrating the roofing assembly. The flashing/apron of the Bottom Flashing Panel 25.2 is designed to conform to and overlap the roofmg material below the Bottom Flashing Panel it in a manner known to those familiar in the art to permit water to flow down the sloped roof without penetrating the roofing assembly. In the preferred embodiment, the Bottom Flashing Panel may incorporate Closure Strips 25.3 to close the panels to the elements. The Bottom Flashing Panel is removable, permitting adjacent roofmg materials to be replaced without disassembling or uninstalling the solar panels as would be required with a conventional mounting system.

The Side Flashing Panel 26 depicted in Fig 1, 2 and 6 may cover the entire length (top to bottom) of the Mounting System on either side, or may be comprised of smaller sections that underlap the Side Flashing Panel immediately above it and overlap the Side Flashing panel immediately below it in a traditional manner familiar to those skilled in the art to permit water to flow down the sloped roof without penetrating the roofing assembly. The Side Flashing Panel is designed with a common pattern to the adjacent Mounting Panel such that it will overlap or interlock with the Mounting Panel in a manner familiar to those skilled in the art to maintain a water tight roofmg system 26.1. The skirt of the Flashing Panel at roof level 26.2 conforms to and underlaps the roofmg material on the other side of the Side Flashing Panel it in a manner known to those skilled in the art to provide a flow channel to permit water to flow down the sloped roof without penetrating the roofmg assembly. The Side Flashing Panel may be designed with a hem 26.3 bent from bottom to top to form a tight "U" shape to form a trough to prevent the ingress of water between the roofing material and flashing.

The horizontal and vertical Spacing Panels illustrated at 28 and 29 in Fig 1 and 2 may be used to provide space between mounting panels to facilitate air flow, to permit movement among the array for maintenance, including adjustment of the angle of the array and are designed to provide a secure walkway and safe access to the panels such as, but not limited to, the metal hand/foot grip 28.1 shown therein.

The Mounting, Flashing and Spacing Panels may be comprised of sheet metal, stainless steel, aluminum, galvalume, galvanized, polymer, extruded or other material of suitably rigid and waterproof construction and may be coated in paint, polymer or other finish to ensure long term resistance to wear and improve their watertight characteristics.

Traditional BIPV designs tend to conform to the slope of the roof which may not be optimal. In some locations the slope of the roof or panel support may be close enough to optimal that the Solar Modules can be installed flush with the Mounting Panel as in the bottom row of panels illustrated in Fig 1. The present invention also provides for the alternative of using fixed or adjustable (Fig 3) stand-offs or panel supports 50 upon which the Solar Modules can be mounted at higher angles to the sun to maximize the power generation capacity of the Solar Array.

FIG. 7 is a side-sectional view of a two-piece Panel Mount/Support 40. In the embodiment shown in Fig. 7, a C-shaped Mount design 42 is utilized to provide additional space between the Mounting Panel 22 and Solar Module 30 to permit additional air flow around the Solar Array.
The height of the vertical support 44 may vary depending on site conditions and need for air movement or as a stand-off to change the angle of the array to the sun to ensure optimal efficiency of the Solar Modules. In an alternative embodiment, the Panel Support may be a simple mounting bracket represented by the horizontal members of the C Mount at 43 or 45. In the preferred embodiment, the Mounting Bracket 42 is prefabricated or integrally molded to the Mounting Panel 22 to provide mechanical strength to support the Solar Module and permit it to be rigidly affixed to the Mounting Panel 22 together with the Panel Clamp 46.
If the Panel Support 42 is prefabricated as a separate component from the Mounting Panel, it can be secured to the Mounting Panel during assembly with a bolt 70 and lock nut 72. The assembly includes a rubber gasket 74, bead of silicone 76 or other means to ensure that the point where the Panel Support is affixed to the Mounting Panel in a permanently secure and watertight manner.
Mounting Bracket 41 also serves to provide mechanical strength to support the mounting of the Solar Module 30 to the Mounting Panel 22. The shape, length, width and thickness of the Mounting Brackets 41, 43 may vary as required to provide adequate structural and mechanical support to maintain the integrity of the attachment of the Mounting Panel to the Solar Module for different gauge materials and to ensure the structural integrity of the Mounting System. In an alternative embodiment, the Mounting Brackets may be affixed to the Mounting during the installation process, particularly where seam-type panels are used.

The Panel Support illustrated in Fig 7 is designed to integrate with a Panel Clamp 46, the vertical face of which may vary in lengths to accommodate various Solar Modules with different dimensions. In this embodiment, the Mounting Assembly 40 is specified such that the Mounting Bolt 70 is of a height consistent with the dimensions of the Mounting Bracket 42 and Panel Clamp 46 to permit the Mounting Bracket and Panel Clamp 46 to be connected at the desired pressure and locked into place via gasket 74 and lock nut 72. The Panel Clamp itself has a horizontal bracket 47 connecting it to the Mounting Bracket 42. The vertical face of the Clamp 48 is designed with a dimension that is less than the thickness of the solar Module 30 to permit the Panel Clamp to affix the Solar Module firmly to the Mounting Bracket 42.
The upper horizontal clip of the Panel Clamp 49 is designed to hold the Solar Module 30 securely to the Mounting Bracket 42 and is of a dimension that is less than the width of the frame of the Solar Module such that the Panel Clamp does not touch or block the active area of the Solar Module 30.

FIG. 3 is a side-sectional view of an adjustable Standoff/Panel Support 50 affixing the Solar Module to the Mounting Panel. The adjustable arm may serve as a standoff to the Mounting Panel in alternative to a fixed standoff as illustrated at 44 in Figure 7. The invention disclosed herein is intended to cover any alternative embodiment of adjustable Panel Support/Arm that serves the purpose.

As illustrated in Fig 3, the adjustable Panel Support 50 is a hinge-type Panel Support which locks into position at a steeper angle when engaged. In an alternative embodiment, the adjustable Panel Support may have multiple positions supporting the installation of the Solar Module at different angles. In the preferred embodiment, the adjustable Panel Support will facilitate the manual, mechanical or electronic adjustment of the Panel Support up to 90 degrees as required to optimize the angle of the Solar Modules to the sun from season to season and in different weather conditions. For example, the optimal angle of a Solar Module to the sun in extreme Northern and Southern locations can be nearly 90 degrees from solstice to solstice. To facilitate the use of a fixed or adjustable upper Panel Support/Clamp, the bottom Panel Support/Clamp is designed to be hinged 60 to facilitate the Solar Module being affixed to the Mounting Panel at a different angle.

In the preferred embodiment, as shown in Figures 1 and 2, the Panel Supports are prefabricated into the Mounting Panel or affixed thereto in a dimension appropriate to the Solar Module being used. Depending on the size and weight of the Solar Module, a minimum of four Panel Support/Clamp assemblies are required per module, two at on the bottom of the Solar Module 60 and at the Top of the Solar Module 50. Where a Mounting Panel supports a row of Solar Modules, two-side Panel Mounts may support both a top and bottom Solar Module.

Claims (10)

1. A building integrated mounting system for photovoltaic (PV) or solar thermal (ST) modules for installation on a sloped roof, said Mounting System comprising a roofing panel of metal or other suitably rigid and waterproof material which serves as a primary waterproofing structure in the roofing assembly, and into which the mounting structures for solar PV or ST modules (individually or collectively "Solar Modules") may be integrated (the "Mounting Panel").

2. A plurality of Mounting Panels of claim 1 in which additional Mounting Panels, spacing panels and flashing panels are installed as an integrated roofing system, vertically and/or horizontally in an interlocking or overlapping manner (the "Mounting System").

3. A Mounting Panel of claim 1 which corresponds dimensionally to one or more Solar Modules to facilitate and optimize installation.

4. A Mounting Panel or panels of claim 1 in which the panel(s) are corrugated or seamed to facilitate watertight installation.

5. A Mounting Panel claim 4 in which the panel is corrugated or seamed such that the Mounting Panel serves as an integral standoff permitting the flow of air beneath the Solar Modules.

6. A Mounting Panel of claim 4 into which the mounting structures ("Panel Clamps") for the Solar Modules may be integrated or affixed.

7. A Mounting Panel of claim 6 in which the mounting structure may include an integrated stand-off to facilitate integration of a photovoltaic module at an steeper or shallower angle than the roof upon which the mounting panel is installed.

8. A Mounting Panel of claim 7 in which a stand-off at the top end of the Mounting Panel may be of fixed or variable length and the mounting components at the bottom end of the Mounting Panel may be hinged.

9. A Mounting System of claim 2 in which certain panels that comprise the Mounting System are used solely as roofing panels to adjust the distance between Solar Modules or provide for a walkway among the solar array ("Spacing Panels") or to integrate the Mounting System with adjacent roofing materials ("Flashing Panels").

10. A Mounting System of claim 9 in which Mounting Panels or separate Flashing Panels may have a thin edge that rests directly upon the rooftop and extends in a fashion to overlap and/or underlap adjacent roofing material to act as an integrated flashing to maintain a watertight roofing assembly together with other materials that commonly comprise a roofing assembly.