WO2020032985A1

WO2020032985A1 - Roof mounted solar panel system and method

Info

Publication number: WO2020032985A1
Application number: PCT/US2018/056357
Authority: WO
Inventors: Joe D BYLES
Original assignee: Byles Joe D
Priority date: 2018-08-06
Filing date: 2018-10-17
Publication date: 2020-02-13

Abstract

AA roof mounted solar panel system for use on steep sloped roofs without the need to install permanent hardware through roof penetrations. The roof mounted solar panel system comprises a solar panel, ballast plate, and non-slip pad. The non-slip pad is placed on the roof and remains in place due to frictional forces. The ballast plate is frictionally engaged with the non-slip pad and connected to a solar panel. Fluid may be added to the ballast plate to increase weight. A micro-inverter and battery storage system may fit within recessed portions of the ballast plate.

Description

Inventor: Joe D. Byles

TITLE OF THE INVENTION

Roof mounted Solar Panel System and Method

CROSS-REFERENCES TO RELATED RESEARCH

This application claims the benefit of U.S. Provisional Application Serial No. 62/283,017 filed October 17, 2017 entitled Steep Slope Roof Photovoltaic Ballasted Friction Plate Solar Panel Attachment Apparatus and Method. The contents of said application are incorporated by reference herein.

FEDERAL-SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to mounting a photovoltaic (PV) solar panel and its related electronics on a sloped roof.

Description of the Related Art

Solar energy or electricity, generated by sunlight energizing a PV cell on a solar panel, has grown exponentially within the past few decades and is an ever-increasing percentage of distributed energy production within the United States and around the world. The rise of solar energy production has allowed commercial and residential buildings to utilize roof tops as a placement location for multiple solar panels to generate electricity. In a typical installation, multiple solar panels are linked in series to form an array.

Building roof top installations of solar panel arrays are generally grouped into two categories: low slope roofs and high slope roofs. Flat or low slope roofs have a slope equal to or less than 4 over 12 (meaning that there is no more than 4 inches of rise over each 12 inches of run). Flat or low slope roofs are often found on commercial buildings. The relative low slope of these roof tops allows for a solar panel array to be installed with a racking system that is ballasted with weights to hold it down. Due to the lack of roof slope, or low angle of slope, the ballast force vector of the weight is directed down onto the roof which holds the system in place. As a result, there is no need to penetrate the roof for mounting of the racking system. The ability to install solar panel arrays without roof penetrations makes the installation cheaper, faster, and with less potential for damage. Building owners as well as installers prefer installations that do not require roof penetrations because any penetration of the roof creates a higher likelihood for a damaging water leak.

High slope roofs have a slope greater than 4 over 12. High slope roofs are often found on residential buildings. Similar to low slope roofs, solar panel arrays are installed with a racking system. Due to the steep slope, traditional ballasting of a rack system cannot be utilized because it slides off the roof. The force vector downward and parallel to the slope of the roofing surface, for steep roofs, is greater than then downward force holding it on to the roof. As result, the racking system must be attached to the underlying rafters or structure under the roof. This requires multiple roof penetrations to support the racking system. Each roof penetration requires drilling through the roof top, bolting or securing the racking system to the underlying rafters or building structure, and then flashing and waterproofing the penetration site to prevent leaks. Roof penetrations often result in the removal of shingles and the breaking of the mastic sealant which holds the rows or courses of shingles in place during high wind or storm events. Ultimately, there are numerous disadvantages of using a mechanically attached racking system that requires roof penetrations on steep slope roofing. These include increased labor for installation, the inability to easily move the solar panel array to optimize performance output, increased probability of roof and structure leaks, difficulty in removing solar panel(s) for replacement, movement, roof repair, or roof replacement.

Another trend in solar panel systems is the addition of battery means to store the electricity produced in times when the produced electricity exceeds the electricity load requirement. In many states and systems, the excess produced electricity is credited to the solar panel system owner at some rate in a process known as net-metering. The addition of a battery allows for the solar panel system owner to self-consume the electricity at a later time when load is higher than the electricity produced by the solar panel system, eliminating the need for net-metering. The problem with adding batteries to solar panel systems is that they are heavy and require additional space in a separate area like a garage or separate room. Presently, no solar panel system exists in which a battery or micro inverter is located within the solar panel assembly. The addition of a battery and the positioning of the battery and/or micro inverter within the system reduces the labor costs associated with installation. Furthermore, even if the battery or micro inverter is not initially installed, the components may be added at a later date to an installed system without significant installation costs.

An additional issue with roof mounted solar panel systems is overheating of related electronic components. Module level micro-inverters are utilized to invert the DC power produced by the PV cells to AC power that is directly consumable by the user. The module level electronics, along with the PV cells, suffer from degraded performance in the rooftop mounted situation as their performance is reduced by increasing temperature, known as the temperature coefficient of performance. To avoid this performance degradation, a sizable air gap of 3 to 6 inches is typically required to allow for cooling air to moderate the high temperature effects of the rooftop environment, which can easily climb to 160 degrees F.

Despite the known difficulties and limitations of installing solar panels on a steep slope roof, installations continue to rise as the cost of the solar panel module, inverter, and racking system have decreased rapidly. As a result of the price decrease, the majority cost for installation of a solar panel array on a high sloped roof is the labor to install the system. There are currently no methods of mounting a solar panel array on a steep slope roof that is cost effective, eliminates the need for roof penetrations, provides a means for temperature cooling of the solar panel and/or the module level micro-electronics, or provides an integral mounting location for battery storage and micro-inverters.

It is therefore a general objective of the current invention to overcome the above-described limitations and constraints associated with prior art solutions to mounting solar panels on steep slope roofs alone or with battery storage and micro-inverter installations.

SUMMARY OF THE INVENTION

The present roof mounted solar panel system invention permits the mounting of one or more solar panels on a sloped roof without creating any roof penetrations or using permanent mounting hardware. The system comprises a solar panel, a ballast plate, and anon-slip pad. Recessed portions of the ballast plate accommodate a micro-inverter, battery, junction box associated with solar panel, and the related wiring. The ballast plate has an internal cavity which may be filled with high heat capacity fluid to provide ballast. The non-slip pad lays flat against the roof of a home with the ballast plate positioned on top of it. The battery and micro-inverter are placed within a recess portion of the ballast plate. A solar panel is then positioned on top of the ballast plate and connected to the ballast plate with mounting hardware that engages the frame of the solar panel. The properties of the non-slip pad combined with the weight of the ballast plate, battery, micro-inverter, and solar panel, or alternatively the solar panel alone with any combination of micro-inverter or battery, pushing down on the non-slip pad prevent the mounting system from sliding down a roof, regardless of how steep the roof is. The roof mounted solar panel system resists seismic activity, wind, rain, and snow loading once installed.

An array of solar panels may be created by positioning more than one roof mounted solar panel units on a roof and connecting them in series. Each roof mounted solar panel unit may be easily removed from the roof or repositioned on the roof without the need to repair any holes or roof penetrations.

The roof mounted solar panel system when installed has the following advantages:

No racking mounting holes or penetrations need to be made in the roof for the roof mounted solar panel system.

The roof mounted solar panel system may be installed on the steep slope roof surface in a much quicker time as they are just placed in the preferred location and connected up.

All wiring and assembly of the roof mounted solar panel system may be done in an on ground location or building/warehouse where it is much safe and comfortable to work and there is quick and easy access to tools, without requiring substantial wiring and assembly on a dangerous and steep roof surface.

Re-configuration of the installed roof mounted solar panel system is easier as there is no lag bolts or racking hardware to unscrew, disassemble and move in order to change location or orientation. The roof mounted solar panel system may simply be picked up and moved to the new desired location on the steep slope roof.

Ultimate removal of the roof mounted solar panel system is simple as the roof mounted solar panel system is lifted up and removed with no need to do extensive roof repairs and re-roofing over the many (up to 100) holes/penetrations typically associated with state of the art steep slope solar panel installations.

No separate battery installation or inverter space is required to achieve battery storage.

The integrated assembly (micro-inverter, battery, ballast plate, non-slip pad) is fairly light and does not get the bulk of its ballasting weight until it is filled with fluid up on the roof at its final location. The amount of ballast weight gained through addition of the fluid may be varied according to need by controlling the amount of fluid.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a top view of an embodiment of the ballast plate.

Fig. 2 is a bottom view of an embodiment of the ballast plate.

Fig. 3 is an isometric view of an embodiment of the ballast plate.

Fig. 4 is a side profile view of the first short side of an embodiment of the ballast plate.

Fig. 5 is a side profile view of the second short side of an embodiment of the ballast plate.

Fig. 6 is a cross section of the line 6-6 in Fig. 3.

Fig. 7 is a side profile of an embodiment of the roof mounted solar panel system.

Fig. 8 is an exploded view of an embodiment of the roof mounted solar panel system.

Fig. 9 is a view of an array of roof mounted solar panel systems on a roof.

Fig. 10 is a bottom view of a second embodiment of the ballast plate.

Fig. 11 is a side profile of a second embodiment of the roof mounted solar panel system.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As seen in FIGS. 7-9, the roof mounted solar panel system 1 comprises a solar panel 10, ballast plate 30, and a non-slip pad 80.

As seen in FIGS. 1 -6, the ballast plate 30 is generally rectangular in shape having a plurality of sidewalls comprising atop 31, bottom 33, first long side 35, second long side 36, first short side 37 and second short side 39. As seen in FIGS.3 and 6, the ballast plate 30 is generally hollow having a cavity 45 defined by the top 31, bottom 33, first long side 35, second long side 36, first short side 37 and second short side 39. Support cylinders 46 connect the top 31 to the bottom 33 through the cavity 45 and provide additional structural support in addition to the long side 35, second long side 36, first short side 37, and second short side 39. As seen in FIGS. 4 and 5, a filling port 42 is positioned on the first short side surface 38 of the first short side 37 and on the second short side surface 40 of the second short side 39. The filling port 42 provides access to the cavity 45 for addition or removal of fluid. In the preferred embodiment a high heat capacity fluid 60 may be added to the cavity to add ballast or weight. A handle 43 is positioned within the first long side 35 proximal to the center line.

A first recessed area 50 and second recessed area 51 are positioned within the top surface 32 of the top 31. The first recessed area 50 is generally rectangular in shape and extends from the first short side 37. The second recessed area 51 is generally rectangular in shape and is positioned at the center of the top 31. An accessory attachment channel 70, comprising a narrow opening 71 and broad opening 72 extends through the first recessed area 50 parallel to the first short side 37.

A first recessed channel 52 extends between the first recessed area 50 and the second recessed area 51. Extending laterally on each side of the first recessed area 50 are a first short recessed channel

53 and a second short recessed channel 54. The first short recessed channel 53 extends to the first long side 35 and the second short recessed channel 54 extends to the second long side 36. A first peaked recessed channel 55 begins at the first long side 35, closer to the second short side 39 and extends across the top to the second long side 36. The point of the first peaked recessed channel 55 points toward the first short side 37. The depth of the first recessed area 50 and second recessed area 51 are generally the same.

As seen on FIG. 2, a second peaked recessed channel 56 and athird peaked recessed channel 57 extend through the bottom surface 34 of the bottom 33. The second peaked recessed channel 56 begins at the first long side 35, closer to the first short side 37 and extends across the bottom 33 to the second long side 36. The third peaked recessed channel 57 begins at the first long side 35, closer to the second short side 39 and extends across the bottom 33 to the second long side 36. The point of the second peaked recessed channel 56 and third peaked recessed channel 57 point toward each other. The second peaked recessed channel 56 is generally aligned with the first short recessed channel 53 and the second short recessed channel 54 positioned on the top 31. The third peaked recessed channel 57 is generally aligned with the first peaked recessed channel 55 on the top 31.

The depth of the first recessed channel 52, the first short recessed channel 53, the second short recessed channel 54, the first peaked recessed channel 55, the second peaked recessed channel 56, and the third peaked recessed channel 57 are generally equal to each other and shallower than the depth of the first recessed area 50 and second recessed area 51. Two solar panel connectors 41 are positioned on the first long side 35 where the first short recessed channel 53 and the first peaked recessed channel 55 terminate. Two solar panel connectors 41 are positioned on the second long side 36 where the second short recessed channel 54 and the first peaked recessed channel 55 terminate.

As seen in FIGS. 7-9, the solar panel 10 is a traditional rectangular solar panel having a top 11, bottom 12, and a metal frame having two short sides 13 and two long sides 14. At least one PV cell is affixed in the top 11 of the solar panel 10. Solar panel 10 further includes two connectors 16 positioned along each long side 14 capable of connecting to the solar panel connectors 41 of the ballast plate 30. In the disclosed figures the solar panel 10 comprises a traditional 60 PV cell solar panel but other sizes may be utilized such as a 72 PV cell. As known in the art, the solar panel 10 also contains a junction box located on the bottom 12 which contains various electronic connectors and circuitry. The first recessed area 50 and second recessed area 51 are of sufficient depth to accommodate the thickness of the junction box such that the bottom of the solar panel 10 may be flush with the top surface 32 of the ballast plate 30.

The non-slip pad 80 is generally rectangular shape having a top 81, bottom 83, two long sides 85, and two short sides 86. The non-slip pad 80 is generally uniform in construction and made from a material which provides a high coefficient of friction such as expanded polymeric polyurethane foam. The size and shape of the non-slip pad 80 is generally identical to the rectangular shape of the ballast plate 30. The non-slip 80 may be permanently attached to the bottom surface of the ballast plate 30 through glue or other chemical means.

In a preferred embodiment, the roof mounted solar panel system 1 further comprises a micro inverter 73, having an attachment rail 74 and connectors 75, and a battery 76 having an attachment rail 77 and connectors 78. The depth and width of the micro inverter 73 and battery 76 are designed to fit within the first recessed area 50 of the ballast plate 30. In the preferred embodiment, a bolt attaches to the attachment rails 74, 77 with the head of the bolt positioned down. The head of the bolt may enter the broad opening 72 of the accessory attachment channel 70 and slide into the narrow opening 71. A fastener then clamps the attachment rails 74, 77 and the bolt to hold the micro inverter 73 and battery 76 within the first recessed area 50.

The connectors 75, 78 may connect to wires that run to the building to supply power. The various wires and connectors may be placed within the first recessed channel 52, the first short recessed channel 53, the second short recessed channel 54, and/or the first peaked recessed channel 55 to prevent the solar panel 10 from resting on top of the wires. Furthermore, the first recessed channel 52, the first short recessed channel 53, the second short recessed channel 54, the first peaked recessed channel 55, the second peaked recessed channel 56, and the third peaked recessed channel 57 permit the wires to exit the roof mounted solar panel unit to attach to another the roof mounted solar panel unit or the buildings power supply without the solar panel 10 crushing the wires or causing the solar panel 10 to not be flush with the top surface 32 of the ballast plate 30. The assembly of the roof mounted solar panel system 1 is discussed in reference to FIGS. 7-9. The non-slip pad 80 may be permanently attached to the bottom surface 34 of the ballast plate 30 through adhesive or other means. Alternatively, the non-slip pad 80 may be positioned under the ballast plate 30 such that the top surface 82 of the non-slip pad 80 is flush with the bottom surface 34 of the ballast plate 30. The solar panel 10 is secured to the ballast plate 30 through the solar panel connectors 41 and connectors 16 by way of frictional engagement or interlocking hardware. Prior to securing the solar panel 10 ion place, the micro inverter 73 and battery are secured within the first recessed area 50 on the ballast plate 30. Once in place, the top surface 32 of the ballast plate 30 is flush with the bottom of the solar panel 10. In the preferred embodiment, the solar panel 10, the ballast plate 30, and the non- slip 80 have generally the same length and width. The assembly of the roof mounted solar panel system 1 may occur at a manufacturing facility or may occur at the building location. The high heat capacity fluid 60 may be added to the ballast plate 30 at the manufacturing facility or at the building location. Preferably, due to shipping weight, the high heat capacity fluid 60 should be added at the building location after the roof mounted solar panel system 1 is positioned on the roof.

The ballast plate 30 may be constructed of extrusion blow molded plastic. Other materials such as high density foams may be suitable so long as the ballast plate 30 does not leak, lose its form, or weaken due to weight. In an exemplary embodiment, the ballast plate 30 is approximately 2 inches thick. The weight of the ballast plate 30 without any fluid or other electrical components is generally less than 10 pounds depending on the size of the solar panel it is designed to accommodate. In an exemplary embodiment, the non-slip pad may have a thickness of one inch but may compress fifty percent under a weight load.

As seen in FIG. 9, the roof mounted solar panel system 1 is placed onto the roof 2 of a structure. The bottom 83 of the non-slip pad 80 is flush with the shingles 3. The polymeric polyurethane foam material grips the mineral granules of the composite asphalt shingles. The high heat capacity fluid 60 may then be added to the ballast plate 30 through the filling port 42. The weight of the ballast point 30 with high heat capacity fluid 60, the micro inverter 73, battery 76, and solar panel 10 combine to provide a resistive downward force parallel to the shingles or other roofing material. The overall ballasted weight may equal approximately 10 pounds per square feet but may vary higher or lower depending on the steepness of the roof. In operation, the high heat capacity fluid absorbs the heat from the roof 2, solar panel 10, and various electronic components including the micro inverter 73 and battery 76. This helps keep the micro inverter 73, battery 76, and solar panel 10 cooler, preventing overheating, and allowing for more efficient operation and higher power generation.

In certain conditions such as expected heavy storms, it may be advantageous to add more fluid to the ballast plate 30 to add increased weight. If the roof mounted solar panel system 1 needs to be moved based on positioning of the sun during the seasonal change, or for roof repair or replacement, the fluid may be removed from the ballast plate 30 reducing its weight for easy movement. Once placed in the correct position, the fluid may be added to provide the necessary weight.

FIGS. 10 and 11 show another embodiment of the roof mounted solar panel system 1. In this embodiment, the non-slip surface 100 is integral with the ballast plate 30. The thickness of the non- slip surface 100 may vary depending on the anticipated weight of the ballast plate and solar panel as well as the slope of the roof. An integral non-slip surface 100 on the ballast plate 30 reduces installation time as it reduces the number of components necessary for install.

In another embodiment, metal plates may be positioned or attached within the ballast plate 30, preferably on or near the bottom surface 34. Once the roof mounted solar panel system 1 is positioned on top of the roof, strong magnets are positioned on the underside of the roof and aligned with the steel plates. The strong magnets further force the ballast plate 30 towards the roof. A metal plate may be used to provide all of the ballast weight in place of the hollow blow mold extruded shell base.

In another embodiment, a thin film PV module can be directly mounted to the ballast plate through use of an appropriate adhesive material. This form would create a building integrated PV look very similar to a shingle.

The description of the present invention has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the invention in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments were chosen and described in order to best explain the principles of the invention, the practical application, and to enable others of ordinary skill in the art to understand the invention for various embodiments with various modifications as are suited to the particular use contemplated. It will be understood by one of ordinary skill in the art that numerous variations will be possible to the disclosed embodiments without going outside the scope of the invention as disclosed in the claims.

Claims

CLAIMSim:

1. A roof mounted solar panel system comprising:

a solar panel having top surface, bottom surface, and at least one photovoltaic cell on the top surface;

a ballast plate having top surface and bottom surface connected to the solar panel wherein the top surface of the ballast plate is facing the bottom surface of the solar panel; and

a pad having a non-slip top surface and a non-slip bottom surface wherein the non- slip top surface is frictionally engaged with the bottom surface of the ballast plate.

2. The roof mounted solar panel system of claim 1 wherein the ballast plate further comprises sidewalls defining a cavity and an access port in fluid communication with the cavity.

3. The roof mounted solar panel system of claim 1 wherein the cavity is at least partially full of fluid.

4. The roof mounted solar panel system of claim 1 wherein the ballast plate further comprises at least one recessed portion within the top surface.

5. The roof mounted solar panel system of claim 4 further comprises a micro inverter

positioned within the at least one recessed portion.

6. The roof mounted solar panel system of claim 4 further comprises a battery positioned

within the at least one recessed portion.

7. The roof mounted solar panel system of claim 4 further comprises a micro inverter and battery positioned within the at least one recessed portion.

8. A roof mounted solar panel system comprising:

a solar panel having top surface, bottom surface, and at least one photovoltaic cell on the top surface; and

a ballast plate having top surface and a non-slip bottom surface connected to the solar panel wherein the top surface of the ballast plate is facing the bottom surface of the solar panel.

9. The roof mounted solar panel system of claim 8 wherein the ballast plate further comprises sidewalls defining a cavity and an access port in fluid communication with the cavity.

10. The roof mounted solar panel system of claim 8 wherein the cavity is at least partially full of fluid.

11. The roof mounted solar panel system of claim 8 wherein the ballast plate further comprises at least one recessed portion within the top surface.

12. The roof mounted solar panel system of claim 11 further comprises a micro inverter

positioned within the at least one recessed portion.

13. The roof mounted solar panel system of claim 11 further comprises a battery positioned within the at least one recessed portion.

14. The roof mounted solar panel system of claim 11 further comprises a micro inverter and battery positioned within the at least one recessed portion.

15. A method for mounting a solar panel on a sloped roof comprising the steps of:

assembling a roof mounted solar panel unit comprising:

a ballast plate having top surface and bottom surface connected to the solar panel wherein the top surface of the ballast plate is facing the bottom surface of the solar panel;

the ballast plate further comprising sidewalls defining a cavity and an access port in fluid communication with the cavity; and

a pad having a non-slip top surface and a non-slip bottom surface wherein the non-slip top surface is frictionally engaged with the bottom surface of the ballast plate;

positioning the roof mounted solar panel unit on a sloped roof wherein the non-slip bottom surface of the pad is frictionally engaged to the sloped roof;

filing the cavity of the ballast plate with fluid.