SYSTEMS AND METHODS FOR SOLAR PANEL MOUNTING

Systems and methods for mounting solar panels include a curb assembly coupled to a top surface of a roof. An end of a solar panel rests on a portion of the assembly. An astragal is located with a portion of the astragal extending over the edge of the solar panel. A fastener is engaged through the astragal and the curb assembly such that a portion of the astragal contacts and compressively engages the top surface of the supported solar panel edge, whereby the solar panel is mounted to the roof. Moreover, systems and methods cleaning solar panels of a solar panel system installed on an exterior surface are also described.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to solar panels, solar heating, and other solar based systems for rooftop positioning on buildings. More particularly, it relates to a system for mounting solar panel arrays of photovoltaic or heating in solar heating arrays or the like on building rooftops which have a roof formed of engaged metal rooftop panels or homes having a wood roof or similar planar rooftop installations. The system provides cooperatively engageable metal roof panels for forming a rack system with a sealed roof of the building, which so engaged, concurrently provides a plurality of vertically projecting sections of adjacent panels. These projecting sections formed as part of each adjacent roof panel form above support members for supporting a solar panel for photovoltaic or water heating or another frame-engaged array, elevated above the formed roof and form a passage therebetween. An engageable astragal is positionable (e.g., configurable) to secure the solar panels and seal the passage between projecting sections of adjacent roof panels.

2. Discussion of the Related Art

In recent years, it has become more popular in the United States and many foreign countries for building owners to install solar panels and solar heating and other solar-based devices on the rooftops of such building. Such installations of solar panel arrays generate electricity which can power the building itself or be communicated to the local grid. Many state and national governments offer tax incentives to building owners who make the financial commitment to install solar panels on such buildings.

Conventional metal roof systems, however, perform acceptable weatherproofing functions but such metal roof panels are currently configured for engagement to each other and underlaying support surfaces. However, they are not configured to incorporate solar panel attachment as part of the formed roof panels and roof structure.

Solar panel and solar heating attachment to roofs, via conventional racking, is not a designed or intended use of any other roofing system. While racked solar panel engagement to roofs is allowable, the piercing of the metal roof panels to mount the various components for holding solar panels in an array on the metal rooftop, is not desirable because the more screws and fasteners which pierce the seal of a roof panel, the more likely it is to leak over time. Further, solar system engagement mounting components and fasteners and the like are designed and sold separately from the roof panels, and the panels themselves have no structural accommodation to hold the solar panels or their mounting system.

As a consequence, solar racking systems continue to employ a conventional rail mounting system for the solar panel array, in both tilt leg and flush mount configurations. They do not, however, integrate the solar panels with the metal roof system itself and, thus, do not provide both roofing panels adapted for engagement to each other which also configure on the roof for a seamless engagement with the solar panel array.

Such a lack of integration between metal roofing panels and the solar array engaged with them has caused conventional solar panels to be mounted a distance above the underlying metal roof panels. Such causes problems such as an uplifting force from wind communicating between the solar panels and the metal roof panels which can cause significant damage. Further, conventional systems having a gap up to five inches or more between the solar panels, and roof panels allow birds and small animals to climb into the gap where they nest. This animal occupancy can wreak havoc with the mechanics of tilting solar panels along with leaves and debris which can enter the gap.

Using the solar racking system as a functional roof also allows for future expansion of the solar panel collection area or additional insulation across the entire roof. It reduces barriers to entry by lowering initial cost and allowing the owner to add and remove panels as needed to accommodate changing usage requirements, take advantage of new technology, requirements, or market conditions as needed.

The forgoing examples of related art as to solar panel and solar heating systems and their engagement to metal rooftops, and limitations related therewith, are intended to be illustrative and not exclusive, and they do not imply any limitations on the invention described and claimed herein. Various limitations of the related art will become apparent to those skilled in the art upon a reading and understanding of the specification below and the accompanying drawings.

SUMMARY

The device herein disclosed and described provides a solution to the shortcomings in prior art with regard to engaging solar panels, solar heating components, and other solar arrays to the rooftops of buildings having metal roofs. While, for convenience, the language herein is directed primarily to photovoltaic solar panels, the mounting system herein is also configurable to hold solar heating panels, and other solar-energized components on a rooftop of a metal building. As such, when the term solar panel is employed herein, any boxed or paneled component which is rooftop-mounted on a metal building is to be considered included.

The integrated metal roof and solar mounting system herein, is configured to allow conventional solar photovoltaic arrays to be installed with a metal roofing system using the same construction means and methods that are conventionally already widely used in the roofing industry. Thus, no exceptional training or tools are required for the installation of the metal roof panels herein, to the underlying structure.

One core element to the system herein is the provision of metal roofing sections, which are adapted for attachment to the underlying support surface for the roof in a conventional screw type engagement. However, rather than conventional planar opposing side edges for each metal roof panel, the opposing side edges of the metal roof panels of the system herein include the addition of vertically projecting portions running along opposing side edges. Each such metal roof panel is a unitary planar structure which on opposing sides has a bend which forms projecting side portions. One side portion extends substantially normal to the planar portion in between. The opposing side portion is adapted to slidably engage with that of an adjacent metal roof panel to allow for adjustment. By planar is meant substantially flat, although, corrugations or channels are formed in a conventional fashion which run parallel to the opposing sides of the metal roof panel and, thus, substantially parallel to the projecting portions on both sides.

Also provided is an astragal which is employable to compress and secure a solar panel to the roof formed by the metal panels. This astragal additionally forms a seal over adjacent roof panels in another particularly preferred component of the device and method herein. The formation of the metal roof panels with opposing projecting and slidably engaged side edges, and the inclusion of the astragal herein which is configured to hold the solar panels and concurrently seal the two adjacent roof panels and their respective projecting edges, effectively merges two historically different scopes of work into one, and roofing and solar panels become a solar roof system.

The roofing system herein increases the performance of the solar collection of the array, and with the system herein, the solar materials provide additional insulation factors that improve the heat loss/gain profile of the roof. This is accomplished with the system herein by its configuration which traps a layer of air between the solar panels and metal roof panels which also provide shade to the roof surface formed of the engaged metal panels herein.

Still further the system herein provides channels and gaps which protect the electrical conductors of the solar panels in the formed array. Additionally, for aesthetic reasons the system herein allows for insulation blanks to be positioned where needed to improve the seamless aesthetic of the installation of the solar array of panels along valleys and gables. Still further, by combining the solar panels and roof and underlying structure into a single function, the value of the tax credit to the building owner can increase substantially.

A system for solar panel installation is described. One or more aspects of the system include a left panel configured for coupling onto a substantially planar surface and including a left panel first end, a left panel second end opposite to the left panel first end, and a left panel middle portion connecting the left panel first end and the left panel second end. One or more aspects of the system further include a right panel configured for coupling onto the substantially planar surface and including a right panel first end, a right panel second end, and a right panel middle portion connecting the right panel first end and the second panel second end. In some aspects, the left panel first end and the right panel first end are configured to couple together to form a continuous panel joint projecting outward from the substantially planar surface, wherein the panel joint includes a left engagement contour on a left side of the continuous panel joint and a right engagement contour on a right side of the continuous panel joint. In some aspects, the left engagement contour is configured to interlock with a contoured end of a frame of a left solar module spanning over at least a portion of the left panel and the right engagement contour is configured to interlock with a contoured end of a frame of a right solar module spanning over at least a portion of the right panel.

A method for solar panel installation is described. One or more aspects of the method include coupling a left panel to a substantially planar surface, the left panel including a left panel first end, a left panel second end opposite to the left panel first end, and a left panel middle portion connecting the left panel first end and the left panel second end; and coupling a right panel to the substantially planar surface, the right panel including a right panel first end, a right panel second end, and a right panel middle portion connecting the right panel first end and the second panel second end. One or more aspects of the method further include coupling the left panel first end to the right panel first end to form a continuous panel joint projecting outward from the substantially planar surface, wherein the panel joint includes a left engagement contour on a left side of the continuous panel joint and a right engagement contour on a right side of the continuous panel joint. One or more aspects of the method further include interlocking a contoured edge of a frame of a left solar panel with the left engagement contour such that the contoured edge is coupled to the left engagement contour and the left solar panel is spanning over at least a portion of the left panel; and interlocking a contoured edge of a frame of a right solar panel with the right engagement contour such that the contoured edge is coupled to the right engagement contour and the right solar panel is spanning over at least a portion of the right panel.

A method for cleaning solar panels of a solar panel system installed on an exterior surface is described. One or more aspects of the method include attaching a solar panel cleaning system to the solar panel system, wherein the solar panel cleaning system comprises a cleaning apparatus, wherein the solar panel system includes a plurality of parallel weathercap rails, wherein the parallel rails alternate with rows of solar panels, wherein the attaching is a movable attachment whereby the solar panel cleaning system is configured for movement along the direction of the rails; moving of the solar panel cleaning system along the direction of the rails, whereby the cleaning apparatus is moved over the solar panels in one row; and activating the cleaning apparatus, whereby the solar panels in the one row are cleaned.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for designing of other roof and solar panel structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.

The objects features, and advantages of the present invention, as well as the advantages thereof over existing prior art, which will become apparent from the description to follow, are accomplished by the improvements described in this specification and hereinafter described in the following detailed description which fully discloses the invention, but should not be considered as placing limitations thereon.

Other aspects of the present invention will be more readily understood when considered in conjunction with the accompanying drawings, and the following detailed description, neither of which should be considered limiting.

DETAILED DESCRIPTION

Conventional solar panel designs (e.g., other solar panel designs not implementing one or more aspects of the present disclosure) may be insufficient. For instance, conventional solar panel designs may leave wiring exposed, may not shed water, may be difficult to clean, may be visually unappealing, may readily house animals such as pigeons and other pests that may nest in exposed structural elements, etc. In some cases, from underneath certain conventional solar panel designs, wiring and attachments may be visible and unsightly, in addition to the sky being visible through the gaps between solar panel modules. As such, when it rains, dirt and debris may accumulate (e.g., and water, dirt, and other remnants may drip onto whatever is below the solar panel design through the gaps between solar panel modules).

Various aspects of the structural beam support systems disclosed herein may advantageously reduce overall steel tonnage, increase speed of installation (e.g., by shifting significant fabrication effort into a factory setting to reduce field fabrication), and neatly encapsulate all the internal workings of the photovoltaic generation system (e.g., while efficiently shedding water and increasing electricity production through convection and reflection, while provided limited/restricted access for birds and other pests, etc.). The configuration of the structural beam support systems disclosed herein further enable and introduce new design possibilities such as radiused, tapered, curved and even complex variably recurved shapes. Moreover, as described in more detail herein, described structural support systems and associated cleaning techniques may demand little manual attention, and may require little to no downtime for corresponding solar energy facilities.

In various aspects of the present disclosure, the terms ‘solar panel,’ ‘solar module,’ and ‘solar panel module’ may be used interchangeably (e.g., to refer to a single photovoltaic panel that is an assembly of connected solar cells). Further, term ‘solar array’ may be used to describe an aggregation of solar panels/modules (e.g., that together form a discrete electrical system).

In this description, the directional prepositions of up, upwardly, down, downwardly, front, back, top, upper, bottom, lower, left, right and other such terms refer to the nose engagement device as it is oriented and appears in the drawings and are used for convenience only; they are not intended to be limiting or to imply that the device has to be used or positioned in any particular orientation.

Now referring to drawings inFIGS.1-11, wherein similar components are identified with like numerals,FIG.1shows a depiction of a sectional view of the engaged components of the device10herein, enabling the method herein ofFIGS.7-11where a rack system is formed for positioning of solar panels thereon above a metal or wood or other roof structure.

InFIG.1is shown the novel metal roof panels12each of which is formed with side edges having formed projecting portions14. In some cases there may be only one projecting portion14along one edge of a roof portion of the roof panel12, such as shown inFIG.9in the enlarged sections. In this mode, a first roof portion12A engages a second roof portion12B along a folded edge15located on the opposite side of each from the projecting portion14thereof. Thus, the roof panel12is formed by the first roof portion12A engaged to the second roof portion12B along the folded edge15of each to form the full roof panel12.

In some installations the roof panels will be formed in a unitary structure with projecting portions14running along both side edges. In other roof panels12where more adjustment for positioning is desired, the folded edges15on the opposite sides of roof portions12A and12B from the projecting portion14, allow for a sliding engagement to adjacent roof portions to form the roof panels12and to adjust the roof panels12slightly side to side during installation. This allows for a slight adjustment of the size of the formed openings41for the solar panels22between the projecting portions14on opposite sides of the formed roof panel12. This sliding engagement of folded edges15of two roof portions12A and12B (FIG.9) also forms a secondary supporting member17(FIGS.9-11) for holding center portions of the solar panels22elevated which is particularly preferred.

The projecting portions14, along one side edge of the roof panels12, are formed by a bend in the metal material along the side edge. Each projecting portion14extends from the side edge on which it is positioned, at an angle substantially normal to the planar mid-section16of the metal roof panels12. By substantially normal is meant plus or minus 10 degrees from perpendicular.

As shown inFIG.1, each roof panel12, whether formed of two engaged roof portions or a roof panel12in one section, sits atop an underlying support structure20shown in dotted line.

Screws26engaged to the underlying support structure impart force against the support members18to hold them and to hold the metal roof panels12sandwiched under them, in position. Such underlying support structures for example include a metal roof of an existing building or a wood or shingled roof. Also shown are the support members18, which abut and overlay the projecting portions14of the adjacent roof panels12, which are positioned thereon and can support the solar panel22, thereon. The support members18may be formed in two sections as inFIG.1, or in a single section shown inFIG.1A or1Bwhich is preferred, since it positions a seal formed by the bent portions of the roof panel12over the top of the support member18leading to the projecting portion14. This positions the roof panel12in the mode ofFIGS.1A and1B, above any communication of the screw26through the underlying roof structure.

An astragal24, shown inFIG.1, is placed in operative compressive engagement with adjacent solar panels22which is particularly preferred in all modes of the system10herein. A screw26is engaged through a central portion29thereof during installation, to hold the astragal24to the underlying support surface20. This screw26can be adjusted to impart a measured compression to the astragal24, which in turn will contact and engage the edges of the solar panels22or frames surrounding them in a compressive sealed contact therewith. This compressive engagement will also impart force to the bottom side of the solar panel22against the support members18and will compressively engage projecting contact points28(FIG.2) on opposing sides of the astragal24against the perimeter edge of the solar panel22to compressibly engage it and hold it in place.

Depicted inFIG.1, also, are parallel ribs30having a gap32therebetween. This gap32is aligned with an opening34positioned between the two projecting portions14which are on one respective side of each of the two roof panels12. With the screw26operatively engaged with the underlying surface20, and the astragal24compressibly engaged against the adjacent solar panels22, the gap32and opening34between projecting portions14, align to provide the path for the screw26to be engaged with the underlying support surface20.

Additionally, the two ribs30are formed of a length projecting from the center portion29, to extend past the distal ends15of the projecting portions14when the screw26is tightened to compress the astragal24against the solar panels as inFIGS.1and1A. This forms a moisture seal to prevent fluid which might get past the compressive engagement and seal of the astragal24against the adjacent solar panels22and prevent such from getting into the opening34between adjacent roof panels12.

Also shown inFIGS.1,1A, and1B, is an engageable cap36which has side edges38which are configured to engage into recesses40in the opposing sides of the astragal24. The cap36is formed of a flexible or elastic material which allows the side edges38to temporarily when the cap36is pushed against the surfaces of the astragal24above the recesses40and deflect and then compress into the recesses40. Once the edges38engage into the recesses40they form a water tight seal over the top and sides of the astragal24.

While not shown in detail inFIG.1, the interior cavities19of the support members18or more preferable, the area within the opening34between the projecting portions14, both define passages which may be employed for positioning of wiring for both the solar panels22and any controllers or the like. The opening34works especially well since prior to positioning of the astragal24thereover, the wires are easily tucked into the opening34and then covered with the astragal24.

Shown inFIG.1B, is a unique functional aspect of the system10herein, where the solar panels22have not yet been installed or have been removed. This is particularly preferred because there are instances where solar panel installation is delayed, or where they must be removed and replaced. Using the system10herein, the support members18can be installed onto the underlying support structure, and the roof panels12can be operatively positioned with the projecting portions14extending thereabove. The astragal24can then be engaged to form a seal with the ribs30contacting the support member18by tightening the screw26. Once the solar panels become available, or are repaired and ready for replacement, the screw26may be loosened temporarily, and the solar panels22can be installed as inFIG.1A. The utility provided by the system10as shown inFIG.1Ais particularly important because there are times when solar panels are damaged and must be removed and replaced, or when the panels arrive too late for a winter installation. The ability to form the mounting system10herein which forms the racks for easy installation, and or removal and reinstallation of subsequently installed solar panels22gives the contractor an advantage.

Shown inFIG.2is an end view of the typical astragal24herein employed as inFIG.1. The projecting contact points28can be seen on the lower edges of opposing projecting ledges42projecting in opposite directions on opposing sides of the body forming the astragal24. These points28have been found to better engage with the surface of the solar panels22and form a secure contact and seal therewith. Also shown are the ribs30projecting from the center portion29a distance for surrounding the opening34between the two projecting portions14. Also depicted are the two recesses40formed into the edges of the ledges42which engage to the side edges38formed on the flexible cap36.

InFIG.3is shown one side edge of the metal roofing panel12per the device10and method herein. As depicted, the projecting portions14can extend from one or both side edges of the roof panel12. As noted, the projecting portions14run substantially normal to the planar mid section16of the panel12. As also noted, in a particularly preferred mode of the system10which uses two roof portions12A and12B (FIG.9) engaged at folded edges15which forms the secondary support members17, the opposite side edges of the formed roof panels12from the projecting portion14of each, can be configured with the folded edge15as inFIGS.9and11. When engaged over each other, the folded edges15form the secondary support member17shown inFIGS.9-11.

Where both side edges of the roof panels12have the projecting portion14and the roof panel is formed in a single sheet, support members18may be positioned on the underlying structure instead of forming the secondary support members17. However, by forming the roof panels12in a first and second portion12A and12B as noted herein, each having folded edges15such that they will engaged and form the secondary support members17, additional support is provided to the solar panels22. This additional support is provided without the need or expense for extra support members18such as shown inFIGS.9-11. Optionally the folded edges15can be formed to slide slightly upon each other, to allow for a side to side adjustment of the first and second portions12A and12B of roof panel12, (FIG.9) to provide additional function in that the size of the openings41(FIG.10) can be adjusted if needed.

FIG.4depicts the device herein in a perspective end view of the device10in an assembled mode, showing the cap36engaged along the astragal24. The astragal24is engaged by the screw26to the underlying support structure20and compressibly engages the ledges42against the solar panel22edge. An end cap46is shown engaged to the upper side edge of the astragal24using projecting prongs48(FIG.5). An end cap50is also shown covering the open ends of the support members18and the gap32and covers the opening34shown inFIG.1.

As can be seen inFIG.1andFIG.4, using the system herein, a very small gap27is formed between the rear surface23of the solar panel22and the upper surface of the roof panel12. Such is preferably between ½ to ¾ of an inch and can be smaller if the peak of the formed ridges44are less than inch above the surface of the mid section16of the roof panel12. Such prevents lift from wind and the intrusion of animals and birds underneath the solar panels22and a secondary cover not shown can be provided to cover this gap27. The gap27provides a passage for venting heat from the solar panels22.

The end cap46can be formed to fit inside the cap36on top of the solar modules. This requires that the astragal24to shortened sightly shorter than the solar modules to provide space for the end cap46. The end cap46in all modes is preferably formed of a compliant material (for example rubber or foam) and it could also serve as an expansion joint between sections of the astragal24to prevent thermal expansion stresses while concurrently eliminating any gaps.

FIG.5shows an end view of the end cap46engageable with the top portion of the astragal24as inFIG.4. The prongs48are configured to removably engage in recesses40formed in the astragal24as can be seen inFIG.1.

FIGS.6A-6Dare for reference and depict a typical prior art view of the mounting of conventional solar panel systems on rooftops, which those skilled in the art will be familiar with. As can be seen, the roof panels conventionally are separate from and form no part of the engagement system, which is mounted on purlins and rafters elevated above the roof. In conventional systems, many more holes are drilled through the support structure such as a roof and they are not covered by any sealing system such as herein.

FIGS.7-11show components of the system10herein being installed onto an existing roof of a metal or wood roof of a building to form a rack system adapted for the easy and secure positioning of solar panels thereon. As shown inFIGS.7-11the roof panels12can be formed of a first section12A and second section12B, which engage at respective folded edges15opposite respective projecting portions14thereon.

In the system10herein, in a first step, shown inFIG.7, support members18are positioned on the support structure20such as an underlying roof surface of a building. Where the roof panels12have projecting portions14on both opposing side edges, extra support members18may be installed to provide center support to overlying solar panels22if needed.

Where the roof panels12are formed in sections12A and12B, with a first side edge having the projecting portion14and the opposing second side edge having a folded edge15configured to engage over and with a similar folding edge15of an adjacent roof panel12, the engagement forms the secondary support member17. This secondary support member provides support to the solar panels22and maintains the gap32between them and the underlying support structure20.

This mode of the system10herein is preferable since it allows for smaller sections12A and12B to form the roof panels12which are easier to handle in wind and weather. It is additionally preferred since it forms an overlapping seal of the folded edges15as well as a strong secondary support member17to help support the solar panels22better.

InFIG.8is shown the positioning of portions of the roof panels12to be formed in the manner shown inFIG.9, upon the support members18shown installed inFIG.7. Each roof panel portion12B has a first side edge with the projecting portion14and an opposing second side edge with a folded edge15such as shown inFIGS.9and11where the folded edges15overlap.

This is followed by the positioning of the rest of the roof panel portions12A shown inFIG.9, wherein each of the support members18have a pair of parallel projecting portions14of adjacent roof panels12thereabove, and each of the folded edges15on the second side edges of the roof panels12are overlapped to form the secondary support members17.

Thereafter as shown inFIG.10, the solar panels22are placed within openings41formed between the support members18which have the two projecting portions14of roof panels12extending thereabove. Central areas of the openings41have the formed secondary support members17therein to support the underside of the solar panels22. The width of the formed openings41between the projecting portions14on opposing sides of each formed roof panel12is adapted for positioning the solar panels22therein.

Whether the roof panels12are formed in a single unit with projecting portions14on both opposing sides as inFIG.1, or as two roof panel portions having engaged folded edges15as inFIGS.7-11, the width of the openings41is configured to position sides of the solar panels22over the support members18and adjacent the projecting portions so they are engaged by the contact points28of the ledges42extending from the center portion29of the astragal24when the screw26is tightened.

Finally,FIG.11shows the system10herein, formed from the roof panels12ofFIGS.7-10where second sides of the roof panels12overlap and form the secondary support members17.

However, if roof panels12having projecting portions formed on both opposing side edges are employed, the assembly of the system10shown inFIG.11is substantially the same but for the positioning of additional support members18where the secondary support members17are formed by roof panels12with the folded edges15on second sides.

Referring next toFIG.12, a sectional view of a system1200to support and seal between frameless solar panels is shown in another embodiment of the present invention. Shown are engageable cap36, screw26, support member18, projecting portions14, roof panels12, underlying support structure20, frameless solar panels1202, a frameless astragal1204, parallel ribs1206, center portion1208, left shelf1210, right shelf1212, rubber gasket1214, pressure bar1216, and notches1218.

System1200is configured to support frameless solar panels. As shown frameless solar panels1202are thinner than the framed solar panels22. The height of the panels above the roof is affected by the amount of space required underneath the solar panels1202for microinverters, optimizers, wiring, and/or other elements located between the solar panels1202and the roofing.

The frameless astragal1204includes two vertical, substantially parallel ribs1206that bear on and are supported by the support member18. By substantially is meant a maximum angular difference of less than 10 degrees.

A center, substantially horizontal portion1208is interposed between the two ribs to form an H-shape. A left shelf1210extends horizontally outward from the left side of the astragal1204, and a right shelf1212extends horizontally outward from the right side of the astragal1204. The left shelf1210and the right shelf1212are located at the same height. An edge of each solar panel1202bears on and is supported by the proximate shelf1210,1212. Each shelf1210,1212and rib1206has a width and thickness suitable for required strength and serviceability requirements for structural support of the frameless solar panel1202. In some embodiments the rubber gasket1214is interposed between the frameless solar panels1202and the frameless astragal1204. The rubber gasket1314protects the unprotected glass edge of the solar panels1202from breakage.

The continuous pressure bar1216is seated on top of the frameless astragal1204. The pressure bar1216includes two downward-facing notches1218configured to receive the upper ends of the parallel ribs1206. The pressure bar1216extends outward on each side, generally parallel to the proximate shelf1210,1212, to cover a portion of the proximate frameless solar panel1202end. Each side end of the pressure bar1216includes the recess for receiving the engageable cap36. In some embodiments the pressure bar1216is aluminum, but may be of any suitable material. The pressure bar1216received the solar panels1202and secures them to the frameless astragal1204and the support member18. The pressure bar1216also provides an anchor point for the engageable weathercap36. The generally vertical screw26is engaged through a central portion of the pressure bar1216and the central portion1208of the frameless astragal1204and is secured into the support member18below. Screw26as shown in the illustration secures the entire assembly to the underlying roof deck, as well as securing the pressure bar1216to the underlying strut1204however additional shorter fasteners such as self-tapping screws could be used to secure the pressure bar1216to the underlying frameless astragal1204as needed to pinch the frameless glass edge of the solar panel1202between the frameless astragal1204and the pressure bar1216to make sure that the solar panel1202is firmly secured.

The screw26can be adjusted to both secure the frameless astragal1204to the support member18and to provide compress the pressure bar1216to the top of the frameless solar panel1202. The screw couples the pressure bar to the frameless astragal, whereby the frameless solar panel is constrained against vertical movement by being interposed between the frameless astragal shelf and the corresponding side portion of the pressure bar. As the bottom edge of the solar panel1202is supported by the corresponding shelf1210,1212, the downward pressure applied to the frameless solar panel by the screw26adjustment will provide additional restraint to the connection by engaging the edges of the solar panels1202or frames surrounding them in a compressive sealed contact between the frameless astragal1204and the pressure bar1208. In this way the frameless solar panels1202are compressibly engaged and held in place.

As described with respect to previous embodiments the system1200similarly allows the support members18to be installed onto the underlying support structure, and the roof panels12can be operatively positioned with the projecting portions14extending thereabove before installation of the frameless astragal1204. The frameless astragal1204is then later installed. When solar panels1202are repaired or replaced the screw26may be loosened temporarily, and the solar panels22can be reinstalled.

In other embodiments the frameless astragal1204or the astragal24can be combined with various embodiments of solar panels and/or roof panels to result in a system that is more suitable for the structural characteristics of the glass-based solar panels and is more efficient in the use of materials. For example, the roof panel system may be narrower and include simpler astragal and roofing profiles. The revised roof panel system may be used in conjunction with frameless or mini-frame solar panels.

Referring next toFIG.13, a sectional view of a system1300to support and seal between solar panels including a rail extension is shown in another embodiment of the present invention. Shown are screw26, support member18, projecting portions14, roof panels12, solar panels22, astragal24, engageable cap1302, rail extension1304, head1306, and web1308.

The embodiment shown inFIG.13includes the engageable cap1302with the rail extension1304coupled to and extending upward from the engageable cap1304. The engageable cap1302may include aspects of engageable cap36shown inFIGS.1,1A, and1B. The rail extension1304includes the head1306and the generally vertical web1308extending downward from the head1306, with an end of the web1308distal to the head1306coupled to the engageable cap1302. In some embodiments the rail extension1304is integral with the engageable cap1302.

The rail extension1304is configured to support and allow for linear movement along the rail extension1304for a building accessory or accessories. In some embodiments the rail is configured for an automated solar panel cleaning apparatus. The solar panel cleaning apparatus would grip onto the rail extension1302and work its way around the solar panels by sliding along the rail extension1302using either a dry process or a wet process to clean the solar panels. For smaller solar panel arrays a simple, hand-operated mechanical apparatus would be suitable, and for larger commercial arrays, an electrically powered and/or automated cleaning apparatus would be more suitable. Cleaning of solar panels installed on a roof or parking structure is typically difficult to clean with ground-based equipment such as up-and-over manlifts, hand-held pressure washers, long pool brushes, and squeegees. The addition of the rail extension is advantageous in that it allows a secure attachment point and guidance needed for manual/automated, roof-based cleaning equipment for the solar panels. In some embodiments the roofing/solar panel system includes a charging location where the automated solar panel cleaning apparatus would be stored for charging while not in operation. Additionally, the location of the rail extension can assist in hiding the visibility of the attachments for aesthetic purposes.

In other embodiments the rail extension1304is configured for operation of other types of modules. In yet another embodiment, the rail extension can be coupled to other linear building elements. For example, a rail extension could be used in conjunction with a curtainwall structure for window cleaning operations (instead of hanging people off of the side of high rise buildings). The rail extension could be added by replacing an engageable cap of existing curtainwall systems. While the rail extension cross-sectional shape is shown inFIG.13as similar to a traditional rail shape, it should be understood that the cross-sectional shape may be of any suitable shape for the attached apparatus.

In some embodiments the rail extension1304is formed specifically to engage a cleaning apparatus which may be friction or power driven manual or robotic and guided along the rail over the solar panels. Furthermore and importantly the continuous rail provides an anchor point for cleaning apparatuses which currently is not available as a feature of solar panel racking. The rail can be formed in various ways to facilitate cleaning by different devices.

The continuous cap is a unique and distinguishing feature of the system and provides numerous advantages over current systems. The continuous engageable cap as disclosed in various embodiments herein also provides a primary flashing to direct water flows over the solar panels rather than under them. The engageable cap also prevents buildup of dust in the gaps between the panels. The engageable cap also improves the visual appeal of the system by eliminating visual obstructions and presenting a solar array, as one item rather than many disparate items cobbled together.

In other embodiments of the system to support and seal between solar panels a wiring gutter box/channel may be installed between the roofing panel and the underside of the solar panel, with the gutter box/channel running perpendicular to the roofing seams. The gutter box/channel in some embodiments is used for wiring for the solar panel system and can be placed to facilitate placement of vent penetrations where needed. In some embodiments the gutter box/channel includes a snap-on cover and/or has a formed vinyl seal below the gutter box/channel.

In other embodiments of the system to support and seal between solar panels, low-rise plumbing vent terminations are configured to be installed in and operate in conjunction with the system. The low-rise plumbing vent terminations are specially adapted to work with the roof system by being formed low to the roof so not to interfere with the placement of solar modules.

In other embodiments of the system to support and seal between solar panels, low-rise integrated water and HVAC heater vent or supply air weatherheads are configured to be installed in and operate in conjunction with the system.

In other embodiments of the system to support and seal between solar panels, the system is configured to allow for installation of low profile solar panels specifically adapted for engagement to the roofing system and sized, finished and configured to appear similar to the solar panels commercially available for electricity production. In this way both solar water heating and solar photovoltaic electricity production can be accomplished on a single rooftop, with minimal to no negative aesthetic impact.

Referring next toFIG.14, a perspective end view of a system1400including a support curb is shown in yet another embodiment of the present invention. Shown are the solar panels22, astragal24, screw26, engageable cover36, a curb assembly1402, a shaped steel plate1404, a foam filler1406, a waterproof membrane skirt1408, roof membrane1410, and roof assembly1412. A perspective cross-sectional view of the curb assembly is shown inFIG.15

The system1400shown inFIG.14includes the curb assembly1402comprising the shaped steel plate1404, foam filler1406, and the waterproof membrane skirt1408. The roof assembly1412is fully constructed and waterproofed with the rolled waterproofed membrane1412prior to installation of the curb assembly1402. The curb assembly1402is coupled to the roof and is shaped in a general inverted T-shape, with the flanges of the T-shape forming a lower rectangular portion1420with two shelf surfaces14141416(one on either side of the curb assembly) and a stem of the tee1418extending upward vertically between the two shelf surfaces14141416. A solar panel22end is supported by each lower shelf surface14141416. The astragal24is coupled to the stem1418via the fastener26, which fastens the solar panels22to the roof1412as previously described. The curb assembly1402is in some embodiments continuous under the solar panels22in order to provide continuous support to the solar panels22.

As previously described, the curb assembly1402forms the general inverted T-shape including the generally rectangular curb1420forming the flange of the inverted T-shape and the centered upward center projection1418forming the web. The shaped steel plate1404is shaped to provide the exterior shape of the curb assembly1402. The shaped steel plate1404also includes the side extensions1422extending generally horizontally outward from the lower edge of the rectangular curb portion1420. While the curb assembly shown is with reference to the curb assembly1402ofFIG.14It will be understood that the description also applies to the curb assembly1500ofFIG.15.

The foam filling1406is shaped to match the interior surface of the shaped steel plate1404and configured such that when the foam filling1406is coupled to the steel plate, the underside surface of the foam filling1406generally matches the underside surfaces of the side extensions1422(i.e. the underside of the curb assembly1402is generally flat). A strip of waterproof membrane, the waterproof membrane skirt1408, is juxtaposed with the underside surfaces of the foam filling1406and the extensions1422. The waterproof membrane skirt1408extends horizontally past the extent of the extensions1422such that there is sufficient weld length to the underlying roofing system. In some embodiments the length past the extent of the extensions1504is between 2″ and 6″. The waterproof membrane skirt1408in some embodiments is permanently coupled to the steel plate1404. In some embodiments the coupling is by heat or adhesive coupling. The foam filling1406is of sufficient firmness to engage with the other components. In some embodiment the foam filling comprises FPS foam with a 2.5 lb density.

FIG.15shows a system1500, which is an alternative embodiment of the system ofFIG.14. In the embodiment ofFIG.15a continuous metal clip1510snaps over the vertical tee-stem projection of a curb assembly1504. The curb assembly1504comprises a steel plate1506and a foam filling1508. The curb assembly1504is shaped and designed to receive the metal clip1510. The clip1510creates a firm ledge for attachment of the solar panel22, which when tightened to the astragal24(which is shortened and spaced along the clip1510in this embodiment) further secures the attachment of the solar panel22to the underlying curb assembly1504. In the embodiment ofFIG.15screws are placed through the foam curb prior to overlaying the roofing membrane material and the continuous clip1510is engaged when screwed to the astragal24above by the fastener26and compressed by the solar modules/panels24to attach more tightly to the curb assembly1504. In some applications using a clip instead of the continuous astragal provides a cost reduction while still providing sufficient mounting structure. Additionally, use of the intermittent clip can make it easier to remove the engageable cover and to replace solar panels if necessary.

The embodiments of attachment ofFIGS.14and15use existing means and methods for sealing roof membranes such that it can be used with all commercially available roofing systems. All roofing systems provide for the installation of curbs and flashing on the roof surface and the curb assemblies14021504provide for a specially adapted curb and flashing to engage with solar modules/panels22in the way substantially described previously.

Referring again toFIGS.14and15, in operation the curb assembly1402is placed on top of the waterproof membrane1410, which has been previously installed, so that the waterproof membrane skirt1408is juxtaposed with the waterproof membrane as shown inFIG.14. The waterproof membrane skirt1408is coupled to the waterproof membrane1410using a method approved by the manufacturer of the waterproofing materials. As located, the curb assembly1402provides the two side shelves1506. Similarly to the previous embodiments, a solar panel22end is supported on each shelf1506and the astragal24is provided such that it is supported by the top of the solar panels22. During installation screws26are engaged through the central portion29of the astragal24, through the curb assembly1402, and secured into the roof assembly1412, whereby the curb is coupled to the roof assembly1412.

Large commercial roofs use rolled materials as the waterproofing element. The solar panel support system integrates with rolled waterproofing materials using the specially designed curb assembly1402that interlocks with the astragal24and supports the solar panel modules22while providing a surface to adhere and flash the roofing material in a manner that allows for use of existing installation means and methods without significant changes.

The curb assembly1402comes with the pre-attached waterproofing skirt1408which is secured to the underlying surface of the waterproofing membrane1410using a method approved by the manufacturer of the waterproofing material. For instance, when using TPO, Thermoplastic Olefin sheet material the installer would simply secure the curb assembly1410to the roof assembly1412with screws26and then run a seamer (an automated heat gun) around the perimeter of the skirting1408.

Referring again toFIGS.1,1A, and9-17, the mounting systems disclosed include continuous secondary support members to support the underside of the solar panels, which allows in combination with the support along the long sides of the solar panels a structural rigidity to the system such that it may be walked on in much the same way as common roofing materials may be walked on without causing damage to the solar module or to the roof. Current racking and mounting systems for solar modules typical to the industry as shown inFIGS.6A-6Dare too flimsy to accommodate being walked on—but are essentially no-go areas on the roof because the array of multiple panels only has rigid support at the points of attachment, which are spaced out along the length of the racking where roof framing members are available for attachment (usually at intervals from 8 to 10 feet).

By integrating solar panel support shelves/ledges into the underlying material and enclosing the perimeter of the module into the roof panel with a secure attachment via the astragal or clips and continuous engageable cap, these systems can be walked on by service and installation personnel with the ordinary care associated with other roofing systems. This walkability factor has significant potential benefits/implications for firefighting as well, since building departments place restrictions on the placement of solar panels because they require fire access to roofs. As a result of this safety requirement large portions of the roof are not available for installation of solar panels. Fire services require a path to ventilate the roof to cut a large hole at various locations. Currently they do not allow solar panels in this path or at potential ventilation areas for safety reasons. There are some electrical hazards which cause this requirement, but with current systems these have been overcome (rapid shutdown is required) and the only remaining hazard is walkability which is overcome with these systems, thus potentially rendering the entire roof available as a solar collection area without restriction for Fire access.

Referring next toFIG.16, a perspective end view of a system1600including a structural beam as a support member is shown in yet another embodiment of the present invention. Shown are the solar panels22, astragal24, screw26, engageable cover36, a structural beam1602, structural roof deck1604, hat flashing1606, and deck support beam1608.

In the system1600shown inFIG.16, in lieu of a light-gage support member, a structural beam is used for the solar panel support member. In the embodiment shown inFIG.16, structural beam1602is a rectangular hollow steel section (HSS) having a generally rectangular cross-sectional perimeter shaped, and having a top outer surface1610, a left outer surface, a right outer surface1614, and an underside outer surface. It will be apparent to those of ordinary skill in the art that other suitable steel sections, such as wide flange or tee sections, may be used. The hat flashing1606is seated on the top outer surface of the beam1602and is shaped to generally conform to and juxtapose with the outer surface of the beam1602, such that the hat flashing1606extends across the top surface of the beam and down each of the generally vertical left outer surfaces and right outer surfaces. The hat flashing1606also includes a generally horizontal flange1616extending outward and away from each of the left outer surface and the right outer surface. A lip1618extends generally upward from each flange

The deck support beam1608is coupled to the underside surface of the structural beam1602and a longitudinal axis of the deck support beam1608is oriented generally perpendicular to a longitudinal axis of the structural beam1602. The roof deck1604rests on and is supported by the deck support beam1608on each side of the structural beam1602. A portion of the roof deck1604proximate to the structural beam1602overlaps the proximate lip1618and flange1616of the hat flashing, thus providing closure for and preventing water intrusion between the roof deck1604and the structural beam1602.

The deck support beam1608members shown are channel sections, although any suitable shape may be used. It will be understood that a plurality of parallel deck support members1608are typically required to provide the required roof deck support.

Similarly to the embodiments previously shown, the solar panels22are seated on the structural beam1602(similarly to the support member18), with a top portion of the hat flashing1606interposed between the solar panel and the structural beam1602. The astragal24and engageable cap36are installed between the two solar panels22, with the screw26anchoring the astragal24to the hat flashing1606and the structural beam1602. In this way the solar panels are compressibly coupled to the structural beam, as previously described.

In the embodiment shown inFIG.16, the use of the structural beam1602instead of an additional support member allows the system1600to be thinner, as instead of a separate support member for the solar panels and a structural beam, the two have been combined into the single structural beam1602that performs both the function of a structural support of the roof system and a curb and support for the solar panels22.

Referring next toFIG.17, a perspective end view of a system1700including a beam as a support member is shown in yet another embodiment of the present invention. An open HSS beam1702is shown. Internal stiffeners (not shown) may be provided to the HSS beam1702as required.

Referring next toFIG.18, a perspective view of a roof panel overlap at the secondary support member17is shown in yet another embodiment of the present invention. Shown are the first roof portion12A, second roof portion12B, folded edges15, secondary support17, underlying support surface20, hem1800, clip1802, hem fasteners1804, fastener lip1806, and lip fasteners1808.

Shown inFIG.18is an alternative embodiment of the roof panel overlap shown inFIGS.9and11. In the embodiment shown inFIG.18, first roof portion12A includes the horizontal folded hem1800which is juxtaposed with the underlying roofing surface20. Prior to installation of the roof panels12A and12B, a plurality of clips1802are coupled to the roof surface20using the plurality of fasteners1804in locations to receive and couple the hem1800to the clips1802and thus to the roof surface20.

In the embodiment shown inFIG.18, the fastener lip1806of the second roof panel12B is folded outward, i.e. extends outward in the direction toward the first roof panels12A (instead of extending inward back toward roof panel12B, as shown inFIGS.9and11). During installation, second roof panel12B is coupled to the underlying roof surface20by installing the lip fasteners1808through the exposed fastener lip1806. Prior to installation of the first roof portion12A, the plurality of clips1802are coupled to the roof surface20using the clip fasteners1804in locations to receive the hem1800of the first roof portion12A. Then the first roof portion12A is installed with the folded edges15of the first roof portion12A over the folded edges15of the second roof portion12B by coupling the hem1800to the plurality of clips1802. This same system can be used with expansion roof panels that allows for installation of solar modules/panels in a landscape orientation.

The roof panel overlap embodiment ofFIG.18retains the advantageous features of the embodiment shown inFIGS.9and11, such as being adjustable to receive solar panels of varying widths while still forming an appropriately flashed roof system forming a rain-tight seal. The embodiment ofFIG.18allows the clip fasteners1804to be fully concealed, unlike the roof overlap ofFIGS.9and18, which requires exposed fasteners. Additionally, the use of clips is superior to using other direct fasteners such as face screws, as face screws create stress points at the fastener locations due to thermal movement of the metal roofing material. Use of clips allows for thermal movement of the roofing panels, reducing stress on the roofing material and reducing potential for compromising of the waterproofing of the roof. Additionally, the overlapping part of the profile allows for the system of attachment to be adapted to solar modules in various standard/typical sizes.

Referring next toFIG.19, a sectional view of a system1900to support and seal between frameless solar panels is shown in another embodiment of the present invention. Shown are screw26, support member18, projecting portions14, roof panels12, solar panels22, astragal24, astragal center portion29, parallel ribs30, engageable cap36, seal1902, seal center portion1904, and seal legs1906.

The system1900includes the seal1902. The seal1902is in an inverted U-shape, comprising the horizontal center portion interposed between two legs1906generally normal to the center portion1904and extending downward from the center portion1904. The seal1902dimensions are such that each leg1906of the seal is interposed between the generally vertical projection14and the proximate generally vertical astragal parallel rib30. As shown inFIG.19, when installed in the system1900, the center portion1904is located beneath the astragal center portion29. The seal1902comprises a waterproof material. In some embodiments the seal1902is a waterproof vinyl seal.

For additional weatherproofing and protection, and/or when there is a scheduling gap between dry-in status of the roof and installation of the solar modules, the seal1902can be installed under the center portion29of the astragal24. The seal1902provides an extra layer of water intrusion protection at the gap between the astragal leg30and the projection14, and/or when the solar panels22have not yet been installed. If dissimilar metal contact is deemed to be a problem, then the seal1902also provides electrical isolation between the coated roofing material and the aluminum astragal24. Thus the seal1902advantageously provides both electrical isolation and additional weather sealing properties.

FIG.20shows an example of a structural view of a solar panel support system according to aspects of the present disclosure. Solar panel installation system2000is an example of, or includes aspects of, the corresponding element described with reference toFIGS.21-24,27-38,40, and41. In one aspect, solar panel installation system2000includes beam2005, roof panel portion2010, fold2015, clamp2020, astragal clip2025, flashing panel2030, left solar panel module2035, and right solar panel module2040.

Beam2005is an example of, or includes aspects of, the corresponding element described with reference toFIG.21. Roof panel portion2010is an example of, or includes aspects of, the corresponding element described with reference toFIG.21. Fold2015is an example of, or includes aspects of, the corresponding element described with reference toFIGS.21and38. Clamp2020is an example of, or includes aspects of, the corresponding element described with reference toFIG.21. Astragal clip2025is an example of, or includes aspects of, the corresponding element described with reference toFIGS.21-23,27,28,30, and34-36. Flashing panel2030is an example of, or includes aspects of, the corresponding element described with reference toFIG.21. Left solar panel module2035is an example of, or includes aspects of, the corresponding element described with reference toFIGS.21-23,27,28,30,31,34,37,38,40,41, and43. Right solar panel module2040is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,30,34,37,38,40, and41.

FIG.21shows an example of a perspective view of a solar panel support system according to aspects of the present disclosure. Solar panel installation system2100is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,22-24,27-38,40, and41. In one aspect, solar panel installation system2100includes beam2105, roof panel portion2110, fold2115, clamp2120, astragal clip2125, flashing panel2130, and solar panel module2135.

Beam2105is an example of, or includes aspects of, the corresponding element described with reference toFIG.20. Roof panel portion2110is an example of, or includes aspects of, the corresponding element described with reference toFIG.20. Fold2115is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20and38. Clamp2120is an example of, or includes aspects of, the corresponding element described with reference toFIG.20. Astragal clip2125is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,22,23,27,28,30, and34-36. Flashing panel2130is an example of, or includes aspects of, the corresponding element described with reference toFIG.20. Solar panel module2135is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,22,23,27,28,30,31,34,37,38,40,41, and43.

InFIGS.20and21, a sectional view and a perspective view of a solar panel support system using a structural beam2105as a support member is shown in another example embodiment of the present invention.

One or more aspects of the solar panel support system shown inFIGS.20and21may be related to the structural beam2105support system shown inFIGS.16and17. For instance, elements ofFIGS.20and21may be examples of, or include aspects of, corresponding elements shown and described with reference toFIGS.16and17.

A support beam2105(e.g., a U-shaped support beam2105) is shown supporting a roof panel portion2110, where the roof panel portion2110has a fold2115extending upward along the length of the support beam2105. A U-shaped clamp2120is screwed to the fold2115via set screws. The astragal clip2125is fastened to the u-shaped clamp2120by a vertical fastener (e.g., such that the astragal clip2125is not anchored directly to the support beam2105). The astragal clip2125is installed between two solar panel modules (e.g., as described in more detail herein).

The composite structural shape comprising the nesting combination of the U-shaped support beam2105and the overlying roof panel portion2110provides additional strength (e.g., double the strength) in the axis supporting the most load by creating a double thickness in the vertical elements of the structural member. The dimensions (e.g., gauge) of these vertically-oriented structural members can be altered (e.g., tapered from a centerline to a leading edge of the system) as well (e.g., to eliminate additional weight or to optimize structural or cost performance of the total assembly).

Additionally, in some examples, the void inside the composite structural shape created inside the two parts (e.g., inside the U-shaped support beam2105and the roof panel portion2110) may incorporate stiffening members (e.g., as needed based on weight of the system, safety thresholds, etc.). This void enables the composite structural shape to be supplemented with a wide variety of internal stiffening members thereby providing a wide range of options to adapt to site specific design requirements such as enhanced spans, elevated seismic, wind or snow load requirements, etc. In some examples, stiffening members that may be integrated include, but are not limited to, a square tube steel, a metal truss, a channel, an I beam, a solid metal bar, a fiberglass reinforced structural foam, a braced metal strut, etc. In some cases (e.g., in cases demanding enhanced fire-resistance), stiffening members that may be integrated include composite wooden beams which resist deformation in high heat better than a metal equivalent could be specified.

Generally, the solar panel support system shown inFIGS.20and21may be implemented with a wide range of potential structural adaptations, which can be optimized across a wide range of scenarios and site requirements to maximize efficiency and minimize cost in a wide variety of applications (e.g., by optimizing overall steel tonnage, on site labor, overall installation costs, etc.). Further, any suitable material with sufficient structural material properties may be used for the various elements described herein. For instance, to further save weight, the flashing panel2130that spans between sections may be made out of plastic, metal or fiberglass or any other material with suitable properties. As an example, one or more aspects of structural beam2105systems described herein may be utilized in solar carport systems (e.g., solar carport systems installed at office parks, supermarkets, airports, etc.).

The configuration of support systems disclosed herein (e.g., structural beam2105based support systems) may further enable and introduce new design possibilities such as radiused, tapered, curved and even complex variably recurved shapes. Furthermore, the flashing panel2130used on the underside of the system may be finished in a variety of textures, materials and patterns to achieve aesthetic effects that are not presently feasible.

FIG.22shows an example of a perspective view of a solar panel installation system2200according to aspects of the present disclosure, wherein adjacent panels snap together. Solar panel installation system2200is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,21,23,24,27-38,40, and41. In one aspect, solar panel installation system2200includes spacer block2205, left roof panel2210, right roof panel2215, continuous panel joint2220, astragal clip2225, standing seam clip2230, set screws2235, fastener2240, and solar panel module2245.

Spacer block2205is an example of, or includes aspects of, the corresponding element described with reference toFIGS.25,27,28, and35. Left roof panel2210is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,31-34,38, and40-42. Right roof panel2215is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,31-34,38,40, and41. Continuous panel joint2220is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,24,26-28,31-33,35,36,38, and41. Astragal clip2225is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,21,23,27,28,30, and34-36. Standing seam clip2230is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,26-28, and34-36. Set screws2235is an example of, or includes aspects of, the corresponding element described with reference toFIGS.24, and26-28. Fastener2240is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,25,27,28, and30. Solar panel module2245is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,21,23,27,28,30,31,34,37,38,40,41, and43.

FIG.23shows an example of a sectional view of a solar panel installation system2300according to aspects of the present disclosure. Solar panel installation system2300is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-22,24,27-38,40, and41. In one aspect, solar panel installation system2300includes left roof panel2305, right roof panel2310, continuous panel joint2315, astragal clip2320, standing seam clip2325, fastener2330, left solar panel module2335, right solar panel module2340, and weathercap2345.

Left roof panel2305is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,27,28,31-34,38, and40-42. Right roof panel2310is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,27,28,31-34,38,40, and41. Continuous panel joint2315is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,24,26-28,31-33,35,36,38, and41. Astragal clip2320is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-22,27,28,30, and34-36. Standing seam clip2325is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,26-28, and34-36. Fastener2330is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,25,27,28, and30. Left solar panel module2335is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-22,27,28,30,31,34,37,38,40,41, and43. Right solar panel module2340is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,27,28,30,34,37,38,40, and41. Weathercap2345is an example of, or includes aspects of, the corresponding element described with reference toFIGS.27,28,30,34, and37.

InFIGS.22-24, a perspective view, a sectional view, and a plan view of a system for attaching a solar panel module to a snap-lock standing seam roof are shown, respectively.

A snap-lock standing seam metal roofing (or cladding) may utilize a folded seam between adjacent panels to provide a raintight attachment between panels (e.g., between left roof panel2305and right roof panel2310). The standing seam embodiment shown is an example of a snap-lock standing seam joint (e.g., a snap-lock continuous panel join), where the seam is formed by pre-formed edge geometries being snap-locked together to form the seam joint.

In an example, the roof panels may also include the solar panel module support shelf formed in the panel such that the seam is formed at the shelf elevation. A spacer block may be fastened to the roof below (e.g., below the standing seam). Further, the spacer block may provide the support and attachment for the panels (the left roof panel2305and the right roof panel2310) and the solar panel modules to the roof below. The spacer block is described in more detail herein, for example, with reference toFIG.25.

As the two roof panels (the left roof panel2305and the right roof panel2310) form the standing seam near the center of the support shelf, an additional element (e.g., a standing seam clip2325) may be integrated. In some aspects, the standing seam clip2325may pass the loading from the astragal clip2320to the spacer block, and ultimately pass the load to the roof structure. The geometry of the standing seam clip2325can be described as, for example, two inverted U-shapes connected by a center strip joining the bases of the U-shape. When installed, such may result in four downward facing “legs” joined by the center strip at the top (e.g., as shown inFIGS.22and23).

When installed, the astragal clip2320is seated with the center portion of the astragal clip2320located above the center strip and a press-in stud may be coupled to the center strip such that a threaded shaft of the stud extends upwards and through the corresponding hole in the astragal clip2320. In some examples, a washer and nut may be installed to the stud above the astragal clip2320to fasten the astragal clip2320to the standing seam clip2325. In some cases, other suitable types of connection between the astragal clip2320and the standing seam clip2325may be used by analogy, without departing from the scope of the present disclosure.

Each vertical leg of the astragal clip2320may fit between the corresponding standing seam clip2325legs on that side of the standing seam clip2325. In the example ofFIGS.22-24, there is an opening between the standing seam clip2325legs that receives the astragal clip2320leg. In other examples, the standing seam clip2325legs may be connected to form a continuous side to the seam clip, and the side of the seam clip may have a recess to receive the astragal clip2320(e.g., as shown, for example, inFIG.26).

In some examples, set screws (e.g., set screws2235) may be used to couple the standing seam clip2325to the standing seam. For instance, in the example ofFIG.22, one set screw2235is threaded through a hole in each standing seam clip2230leg proximate to the end of each seam clip leg. Where the snap-lock standing seam has an indentation (e.g., on the right side of the standing seam inFIG.23), the hole and set screw may be located such that the set screw extends into the indentation. In some examples, the set screws may be threaded through holes that are offset from each other on opposite sides of the continuous panel join (e.g., so that when the screws are tightened, the screws mutually deform the comparatively light-gauge metal of the continuous panel join, which may add a zigzag crimp shape in the continuous panel joint2315at the point of attachment). Such deformation or crimp may bind the continuous panel joint2315together with the clip (e.g., the standing seam clip2325) and the mount to increase the reliability, structural value, and efficiency of installation labor associated with the connection by electrically and structurally bonding all of the adjacent components together. Further, the set screws (e.g., and the resulting deformation or crimp) may securely attach the roofing material to a structure while passing the compressive load imposed by the module mount directly to the seam clip, preventing the slippage of the solar panel module mount (and thus the solar panel module which it secures) down the slope of the roof. This advantageous offset deformation of the roofing material may be utilized in wall mount systems as well.

In the examples ofFIGS.22-24, the standing seam clip2325may be stamped from a sheet of metal and then formed. In general, a variety of manufacturing methods may be used to manufacture the astragals/astragal clips2320, roof/wall panels, accessories, clips and clamps disclosed herein to accomplish the same purpose by analogy, without departing from the scope of the present disclosure. Although some elements are shown as being formed as an extruded metal (e.g. aluminum) part, in some instances the same function for the part could be achieved at lower cost or of other material (e.g., by using a stamped embodiment).

FIG.24shows an example of a plan view of a solar panel installation system2400according to aspects of the present disclosure. Solar panel installation system2400is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27-38,40, and41. In one aspect, solar panel installation system2400includes continuous panel joint2405, set screws2410, slot for module clip2415, and stud2420.

Continuous panel joint2405is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26-28,31-33,35,36,38, and41. Set screws2410is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22, and26-28. Stud2420is an example of, or includes aspects of, the corresponding element described with reference toFIG.26.

FIG.25shows an example of a spacer block assembly2500according to aspects of the present disclosure. InFIG.25, an example of a spacer block assembly2500is shown. A spacer block assembly2500may include spacer block2505, spacer block clip2510, and a plurality of fasteners2515. In one aspect, spacer block assembly2500includes spacer block2505, spacer block clip2510, and fastener2515.

Spacer block2505is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,27,28, and35. Fastener2515is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28, and30.

The spacer block2505may provide a support structure for the raised shelf that supports the solar panel modules (e.g., above roof elevations). Additionally, the spacer block2505may provide an additional attachment point to the roofing panels. In some examples, the spacer block2505may be implemented without the spacer block clip2510.

In some examples, the spacer block2505has two generally vertical leg portions and a generally horizontal center portion (e.g., forming a general U-shape, for example, as shown inFIG.25). In some aspects, a flange may extend outward from the end (e.g., bottom) of each leg. The spacer block clip2510has a lower horizontal flange and a generally vertical portion which terminates in a clip-shape configured to interlock with a snap-lock standing seam. Generally, the snap-lock/spacer block clip2510locking geometry may be of any suitable shape and the flange of the spacer block clip2510may be securely fastened to the horizontal portion of the spacer block2505by any fastening method adequate for the anticipated service and loading requirements (e.g., such as any welding, adhesive, or mechanical fastening). In the example ofFIG.25, for instance, the spacer block clip2510may be attached to the spacer block2505by spot welding. In some cases, the vertical clip may be a lighter gauge designed to resist a tensile load and to be thin enough to fit within a shape of the nesting roof panel seam clip profile. The spacer block2505may be designed to resist a compressive load imposed by the module clamp to the module frame which is communicated through the roofing panel to the clip. In some cases, roof clips for metal roofs may be used in tension to secure the roof to an underlying roof structure (e.g., such as plywood sheeting to keep the roof from blowing off, counteracting wind uplift and slippage, all without exposed fasteners2515). According to the techniques and designs described herein, in addition to similarly concealing the fasteners2515and keeping the roof from blowing off, the spacer block clips2510also are designed to withstand the forces necessary to keep the solar panel modules secured to the roof.

In the example ofFIGS.23and25, a spacer block assembly2500may be fastened to a roof underlayment/structure below. The folded edge portion of the interior edge of the snap-lock standing seam first roof panel is fitted from below into the upper clip portion of the spacer block clip2510. Then the space in the folded edge portion of the exterior edge of the snap-lock standing seam second roof panel may be snapped over the upper clip portion of the spacer block clip2510(e.g., resulting in the assembly ofFIG.23).

For example, lower flanges of a spacer block2505may be seated on underlying roofing, and the lower flanges may be attached by any fastening method (e.g., any fastening method suitable for anticipated service and loading requirements, such as by welding methods, adhesive methods, mechanical fastening methods, etc.). In the example ofFIG.25, a fastening method may include at least one threaded fastener2515screwed through the flange (e.g., and into an underlying roofing structure below).

FIG.26shows an example of a standing seam clip according to aspects of the present disclosure. The example shown includes continuous panel joint2600, standing seam clip2605, stud2615, and set screws2620.

Continuous panel joint2600is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,27,28,31-33,35,36,38, and41. Standing seam clip2605is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28, and34-36. In one aspect, standing seam clip2605includes recessed portion2610. Stud2615is an example of, or includes aspects of, the corresponding element described with reference toFIG.24. Set screws2620is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,24,27, and28.

In some examples, a seam clip may include continuous sides (e.g., as shown inFIG.26). In the example ofFIG.26, the U-shape (e.g., the inverted U-shape) of the seam clip is continuous along the length of the standing seam clip2605, with a middle recessed portion2610on each exterior side face. The recessed portion2610on each side of the seam clip may be configured to serve as a guide for, and to receive, a corresponding leg of an astragal clip. In some aspects, the example ofFIG.16may result in the same functionality with an extruded and milled part (e.g., rather than a stamp formed metal part). Depending on the roofing material or performance requirements, different materials may be selected to perform the desired function by analogy, without departing from the scope of the present disclosure.

FIG.27shows an example of a solar panel installation system2700according to aspects of the present disclosure. Solar panel installation system2700is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,28-38,40, and41. In one aspect, solar panel installation system2700includes spacer block2705, left roof panel2710, right roof panel2715, continuous panel joint2720, astragal clip2725, standing seam clip2730, set screws2735, fastener2740, left solar panel module2745, right solar panel module2750, and weathercap2755.

Spacer block2705is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,25,28, and35. Left roof panel2710is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,28,31-34,38, and40-42. Right roof panel2715is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,28,31-34,38,40, and41. Continuous panel joint2720is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26,28,31-33,35,36,38, and41. Astragal clip2725is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,28,30, and34-36. Standing seam clip2730is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26,28, and34-36. Set screws2735is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,24,26, and28. Fastener2740is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,25,28, and30. Left solar panel module2745is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,28,30,31,34,37,38,40,41, and43. Right solar panel module2750is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,28,30,34,37,38,40, and41. Weathercap2755is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,28,30,34, and37.

FIG.27shows another example of a standing seam clip2730(e.g., where the standing seam clip2730may be used with a standing seam). In this example embodiment, a spacer block2705assembly may include only a spacer block2705and one or more fasteners2740.

In some examples of a standing seam continuous panel joint2720, joined edges of the roof panels are folded over to one side. For instance, in the example ofFIG.27, joined edges of the left roof panel2710and the right roof panel2715are folded over to the left side (e.g., joined edges are folded over towards the left roof panel2710). As such, in some cases, the standing seam may be offset from the center of the spacer block2705in order to align the centerline of the astragal clip2725and the standing seam clip2730with the centerline of the spacer block2705.

In some examples, a standing seam clip2730may have a H-shaped cross-section, with the cross-section consistent (e.g., continuous) throughout the length of the clip (e.g., although portions of the sides may be cut out and/or the standing seam clip2730may be in an inverted-U shape, such as in the example ofFIG.22).

The standing seam clip2730may include one or more holes in the left lower side of the H-shape, and each hole may be configured to receive a set screw. One or more set screws2735may be tightened to secure the standing seam between the set screw and the opposite H-leg of the standing seam clip2730(e.g., as shown inFIG.27). The securing of the standing seam between the set screw and the H-leg may fasten the assembly of the astragal clip2725/standing seam clip2730to the roof assembly, where the connection may restrain against both vertical and horizontal movement and forces.

In some examples, the astragal clip2725may be located (e.g., configured) above the standing seam clip2730, with the standing seam clip2730located between the two astragal clip2725vertical ribs. A vertically-oriented threaded fastener2740may pass through a hole in the center portion of the astragal clip2725and the horizontal cross-portion of the standing seam clip2730. A nut at the end of the threaded fastener2740may secure the astragal clip2725to the standing seam clip2730.

By tightening the nut, the astragal clip2725may be placed in operative compressive engagement with the solar panel modules, as described in more detail herein.

FIG.28shows an example of a solar panel installation system2800according to aspects of the present disclosure. Solar panel installation system2800is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27,29-38,40, and41. In one aspect, solar panel installation system2800includes spacer block2805, left roof panel2810, right roof panel2815, continuous panel joint2820, astragal clip2825, standing seam clip2830, set screws2835, fastener2840, left solar panel module2845, right solar panel module2850, and weathercap2855.

Spacer block2805is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,25,27, and35. Left roof panel2810is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,31-34,38, and40-42. Right roof panel2815is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,31-34,38,40, and41. Continuous panel joint2820is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26,27,31-33,35,36,38, and41. Astragal clip2825is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,30, and34-36. Standing seam clip2830is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26,27, and34-36. Set screws2835is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,24,26, and27. Fastener2840is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,25,27, and30. Left solar panel module2845is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,30,31,34,37,38,40,41, and43. Right solar panel module2850is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,30,34,37,38,40, and41. Weathercap2855is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,30,34, and37.

FIG.28shows one or more aspects of an example astragal clip2825that may be stamped from a sheet of material and formed into the astragal shape. For instance, a stamped portion may include a middle rectangular portion interposed between two lower legs and two upper legs. The lower legs and the upper legs may then be bent downward (e.g., to form an inverted-U shape). For instance,FIG.28may illustrate two lower legs extending downward from the horizontal middle portion of the astragal clip2825, where each leg may include a notch forming the ledges of the astragal clip2825.

In the example ofFIG.28, a weathercap2855may also be formed from a single stamped piece. For instance, a flat piece of weathercap2855may be bent on each side to form the side edges that engage with the recesses of the astragal clip2825.

FIG.29shows an example of a sectional view of an example standing seam roof overlap according to aspects of the present disclosure. Solar panel installation system2900is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27,28,30-38,40, and41. In one aspect, solar panel installation system2900includes secondary support member2905, lower roof panel2910, screw2925, upper roof panel2930, and sheeting2940.

In one aspect, lower roof panel2910includes lower flange2915and narrow folded portion2920. In one aspect, upper roof panel2930includes wide folded portion2935.

FIG.29illustrates a sectional view of an example standing seam roof overlap. The standing seam roof overlap illustrates one or more aspects of roof overlaps described herein (e.g., with reference toFIGS.9,11, and18).

In some examples, a secondary support member2905may be formed by the overlap of the standing seam roof panels and the lower panel may have a narrow folded portion2920that is then enclosed by the wide folded portion2935of the upper panel. The wide folded portion2935of the upper panel is thereby supported by the narrow folded portion2920of the lower panel. In some cases, a lower flange2915extending horizontally from the end of the narrow folded portion2920may be coupled to the underlying sheeting2940by a screw2925.

FIG.30shows an example of a solar panel installation system3000according to aspects of the present disclosure. Solar panel installation system3000is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-29,31-38,40, and41. In one aspect, solar panel installation system3000includes mounting curb3005, astragal clip3025, curb clip3030, fastener3035, left solar panel module3040, right solar panel module3045, and weathercap3050.

In one aspect, mounting curb3005includes shaped portion3010, membrane cap3015, and profile dip3020. Astragal clip3025is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28, and34-36. Fastener3035is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,25,27, and28. Left solar panel module3040is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,31,34,37,38,40,41, and43. Right solar panel module3045is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,34,37,38,40, and41. Weathercap3050is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,34, and37.

Some roofing systems (e.g., such as some commercial roofs) may utilize a membrane of some type, for instance, to weatherize the roof. When a solar panel module is installed on such roofing systems, the solar panel module may be held in place (e.g., primarily by counterweight (ballast), which in some cases may exceed the bearing capacity of the structure). As such, some roofing systems (e.g., including some large commercial roofs) may not have sizable solar installations on them, as building structures may not have been designed to support additional loads that may be associated with such solar installations.

In some examples, to lessen the requirement for ballast, a solar installation may be secured with mounts (e.g., “hard mounts”) including bolts and screws that may penetrate through the roof membrane to attach to structural members. However, such installations may significantly complicate and/or void the roof warranties (e.g., due to penetration of roof membranes that may compromise weather proofing). Further, roof leak risks may be undesirable due to large associated repair costs (e.g., and roofers may be demanded to keep leaks from occurring). As such, solar installations that pokes holes in a roofing system (e.g., in a membrane) or solar installations that significantly alter/impact a roofing system (e.g., for installing solar panel module/solar array support structures) may void roofing warranties. Therefore, such solar installations may be undesirable or inefficient for implementation on most roofing systems.

Alternatively, membrane designs described herein (e.g., such as the membrane design ofFIG.30) place the solid portion projection that is secured to the structure underneath the membrane instead of on top of it, thus facilitating secure and effective structural attachment without penetrations. Such allows for significant weight reduction in a roofing solar panel systems (e.g., from about 8 pounds per square foot down to less than 2.5 pounds per square foot), among other advantages. For instance, such techniques and designs may be applicable to larger roofing systems since no ballast is required. Further, such techniques and designs may provide significantly faster installation times for solar installers (e.g., as installation may be performed without identification and utilization of framing members, as such installations may be attached to sheeting only). Moreover, such techniques and designs may eliminate solar panel installation related warranty issues, since most manufacturers already have provisions for equipment mounting curbs3005, and seams and metal cap flashing in their approved installation instructions.

InFIG.30, a section of an example solar panel installation (e.g., using a curb assembly) is shown. The curb assembly comprises a shaped portion3010and a membrane cap3015. In some embodiments the shaped portion3010comprises foam (e.g., such as expanded polystyrene or extruded polystyrene, as foam may be a cost-efficient material and applicable for roofing applications). Other suitable materials for the shaped portion3010that have the suitable properties may also be implemented by analogy, without departing from the scope of the present disclosure. While the example ofFIG.30is illustrated as being solid, the shaped portion3010may also include one or more internal voids (e.g., in other examples).

The membrane cap3015in some embodiments comprises a detailing membrane (e.g., where the membrane caps3015may be between 30-60 mils). In some examples, the shape of the membrane cap3015may be pre-shaped (e.g., with heat) so that once the mounting curb3005is mechanically secured the membrane cap3015may be fitted precisely over the mounting curb3005(e.g., and then heat sealed to the primary roof membrane before the application of the curb clip3030, module clamps, and weathercap3050).

In some examples, the shape of a mounting curb3005may include a general inverted tee shape with a stem extending upwards and a lower shelf extending outwards on each side. The portion of the stem above the shelf level may include a wedge shape (e.g., wider at the top and tapering downward to the intersection with the shelfs). In some examples, the intersection between the base of the stem and the shelf may be rounded, the base of each shelf may taper outwards as it meets the roofing below, the outer surface of the mounting curb3005may form a first profile, etc. (e.g., aspects of which are shown in the example ofFIG.30).

The membrane cap3015may form a second profile that is similar to, but not exactly the same as, the first profile. For instance, the second profile may closely follow the first profile at the outward shelf tapers, the horizontal shelf surfaces, and the sides of the stem (e.g., but in other locations the profile may form a gap between the membrane cap3015and the mounting curb3005, as shown in the example ofFIG.30). For instance, the gaps may be placed (e.g., designed) to allow the membrane room to conform to the shape of the mounting curb3005as the continuous curb clip3030is first placed over it, providing an initial squeeze to form it over the mounting curb3005(e.g., and then later, when the modules are secured, the membrane cap3015may be further compressed before the outer skirt portions are heat welded to the primary roof membrane).

During installation, the mounting curb3005may be fastened to the roofing/structure below using the vertical fastener3035screwed downwards through the mounting curb3005and into the roof sheeting below. Then the membrane cap3015may be installed over a solid portion of the mounting curb3005. Prior to installation of the astragal clip3025, the continuous curb clip3030may be snap-fit onto the mounting curb3005over the membrane cap3015, thereby securing the curb clip3030and the membrane cap3015to the mounting curb3005attached to the membrane cap3015below. In some examples, the curb clip3030may extend the length of the mounting curb3005(e.g., or a substantial portion of the length of the mounting curb3005) and may extend beyond the termination of the mounting curb3005below to the edge of the solar panel module which is attached to it above. As an example, the mounting curb3005may terminate by sloping at about a 45 degree angle (e.g., using standard means and methods to seal the membrane) inside a dripline of the solar panel module above where the detailing membrane is split, folded and heat welded. Underneath the solar array, provisions for conduit runs and water flows running against the direction of the mounting curbs3005may be created similarly by creating breaks in the mounting curb3005underneath the curb clip3030(e.g., using the same method used at the perimeter terminations). In some examples, such gaps underneath the solar panel module/solar array may be as wide as 6 feet (e.g., given the dimensions and spanning/mounting demands of standard aluminum framed solar panel modules).

The curb clip3030may include the lower legs in the wedge-shape configured to snap-lock to the similarly-shaped stem. The upper portion of the curb clip3030may have a raised center portion configured to provide a space to receive the lower portion of the astragal fastener3035without contacting the sheet metal outer covering below.

The astragal clip3025(e.g., which, in the example ofFIG.30may be of a short length and may be spaced along the curb clip3030) may be coupled to the curb clip3030by the astragal fastener3035which is screwed into the curb clip3030below, as shown in the example ofFIG.30. Thus, the astragal clip3025may be placed (e.g., configured) in operative compressive engagement with the solar panel modules, as described in more detail herein (e.g., with reference toFIGS.1-20). The astragal clip3025in the example ofFIG.30may have shorter ribs extending downwards (e.g., in order to not interfere with the curb clip3030below). The astragal ribs (e.g., the ribs of the astragal clip3025) may be spaced apart to allow the center portion of the curb clip3030to fit between the astragal ribs and to provide positive alignment to orient the astragal clips3025to facilitate installation of the weathercap3050.

FIG.31shows an example of an intersection between a roof panel of existing roofing and a standing seam solar roof3110according to aspects of the present disclosure. Solar panel installation system3100is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-30,32-38,40, and41. In one aspect, solar panel installation system3100includes existing roof3105, standing seam solar roof3110, and solar panel module3130.

In one aspect, standing seam solar roof3110includes left roof panel3115, right roof panel3120, and continuous panel joint3125. Left roof panel3115is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,32-34,38, and40-42. Right roof panel3120is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,32-34,38,40, and41. Continuous panel joint3125is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,32,33,35,36,38, and41. Solar panel module3130is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,34,37,38,40,41, and43.

FIG.31illustrates an intersection between a roof panel of existing roofing and a standing seam solar roof3110(e.g., before an inventive transition flashing is installed). In the example ofFIG.31, at the edge of the solar panel roof assembly comprising the right roof panel3120and the left roof panel3115joined together with the standing seam, the raised portions of the roof panels that form the support shelves and the standing seam terminate above the existing roofing surface (e.g., such that a transition may be implemented that provides a waterproof seal to roof panel portions that are located above the existing roofing).

FIG.32shows an example of a roof transition with transition flashing3205installed according to aspects of the present disclosure. Solar panel installation system3200is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-31,33-38,40, and41. In one aspect, solar panel installation system3200includes transition flashing3205, left roof panel3225, right roof panel3230, support shelf3235, and continuous panel joint3240.

Transition flashing3205is an example of, or includes aspects of, the corresponding element described with reference toFIG.33. In one aspect, transition flashing3205includes notch3210, flat portion3215, and contoured portion3220. Notch3210is an example of, or includes aspects of, the corresponding element described with reference toFIG.33. Flat portion3215is an example of, or includes aspects of, the corresponding element described with reference toFIG.33. Contoured portion3220is an example of, or includes aspects of, the corresponding element described with reference toFIG.33. eft roof panel3225is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31,33,34,38, and40-42. Right roof panel3230is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31,33,34,38,40, and41. Support shelf3235is an example of, or includes aspects of, the corresponding element described with reference toFIGS.34,40, and41. Continuous panel joint3240is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31,33,35,36,38, and41.

FIG.33shows an example of a roof transition with transition flashing3305installed according to aspects of the present disclosure. Solar panel installation system3300is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-32,34-38,40, and41. In one aspect, solar panel installation system3300includes transition flashing3305, left roof panel3325, right roof panel3330, and continuous panel joint3335.

Transition flashing3305is an example of, or includes aspects of, the corresponding element described with reference toFIG.32. In one aspect, transition flashing3305includes notch3310, flat portion3315, and contoured portion3320. Notch3310is an example of, or includes aspects of, the corresponding element described with reference toFIG.32. Flat portion3315is an example of, or includes aspects of, the corresponding element described with reference toFIG.32. Contoured portion3320is an example of, or includes aspects of, the corresponding element described with reference toFIG.32. Left roof panel3325is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31,32,34,38, and40-42. Right roof panel3330is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31,32,34,38,40, and41. Continuous panel joint3335is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31,32,35,36,38, and41.

FIGS.32and33show an example roof transition with transition flashing3305installed. The transition flashing3305has a flat portion3315configured to align with the roof surface, and a contoured portion3320that matches the contour of the standing seam and the support shelf below. Beyond the end of the standing seam and the support shelf, the contoured portion3320may taper down to the flat portion3315(e.g., as shown in the example ofFIG.32). In order to accommodate the contoured portion3320, a notch3310may be cut in the existing roofing material as shown. To install the transition flashing3305, the notch3310may be cut in the existing roofing. The forward edge of the transition flashing3305may be slid under the roofing edge, with the rear end of the transition flashing3305angled upwards. The rear end may then be lowered and the contoured portion3320may be snap-locked onto the seam/support shelf. Additionally (or alternatively), the transition may be screwed to the roofing/structure below.

Such roof transition flashing3305may be formed specifically to accommodate roof type transition applications where solar panel systems described herein may be implemented with (e.g., tied into) existing roofing systems (e.g., such that one or more aspects of the improved solar panel systems described herein may be implemented alongside existing roofing). This enables solar installers to use the solar panel systems quickly and effectively as a substitute for industry standard dedicated solar-only racking. In circumstances where the solar panel support system is installed as solar racking (e.g., only under the extent of the solar array), the transition between the existing roofing and the new solar panel roof system may be constructed in a manner consistent with industry accepted means and methods which demand flashing in order comply with code. Although some racking systems offer flashings for use at points of attachment for racking systems where lag bolts are driven through the roof into structural members below, in practice such flashings may not be desirable due to installation difficulties, and penetrations are instead weatherized only with sealant (e.g., which may not be an accepted means of weatherizing a penetration, may void warranties and/or insurance, etc.). The transition flashing3305techniques and designs described herein may provide an easily installed flashing in accordance with industry-standard flashing requirements.

FIG.34shows an example of a solar panel support system using standing seam structural insulated panels according to aspects of the present disclosure. Solar panel installation system3400is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-33,35-38,40, and41. In one aspect, solar panel installation system3400includes left solar panel module3405, right solar panel module3410, left roof panel3415, right roof panel3420, weathercap3425, astragal clip3430, standing seam clip3435, support shelf3440, sheet metal extension3445, male profile3450, female profile3455, and sealant gap3460.

Left solar panel module3405is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,37,38,40,41, and43. Right solar panel module3410is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,30,37,38,40, and41. Left roof panel3415is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-33,38, and40-42. Right roof panel3420is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-33,38,40, and41. Weathercap3425is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,30, and37. Astragal clip3430is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,35, and36. Standing seam clip3435is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26-28,35, and36. Support shelf3440is an example of, or includes aspects of, the corresponding element described with reference toFIGS.32,40, and41.

Referring next toFIGS.34A,34B and34C, a solar panel support system using standing seam structural insulated panels (SIP) is shown (e.g., in three sectional views).

In some examples, insulated panels may have a male profile3450at one end and a female profile3455at the other end (e.g., where the male profile3450and female profile3455are configured to interlock, with the standing seam version also including a sheet metal extension3445at each end). The sheet metal extensions3445may be seamed in the field or snap locked, for instance, depending on a manufacturer's configuration of the lap to form a standing seam.

In the example shown inFIGS.34A,34B and34C, the top profile of the insulated panel at the standing seam interlock may be adapted to serve as a support shelf3440for solar panel modules. An astragal clip3430, standing seam clip3435, and weathercap3425may be installed to attach the solar panel modules to the insulated panels (e.g., as described in more detail elsewhere herein).

As shown inFIGS.34A and34C, the end of each insulated panel distal to the solar panel support location may have a profile that allows for lateral adjustment with the abutting panel. The example profiles shown inFIGS.34A and34Care interlocking toothed profiles, however other types of connections that allow for variation in solar panel widths may be implemented by analogy, without departing from the scope of the present disclosure. In some examples, a sealant gap3460may be formed at an underside of the abutting panels.

FIG.35shows an example of a perspective view of a solar panel system installed in a one example of a non-roof application according to aspects of the present disclosure. Solar panel installation system3500is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-34,36-38,40, and41. In one aspect, solar panel installation system3500includes spacer block3505, standing seam clip3510, flange3515, astragal clip3520, and continuous panel joint3525.

Spacer block3505is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,25,27, and28. Standing seam clip3510is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26-28,34, and36. Flange3515is an example of, or includes aspects of, the corresponding element described with reference toFIG.36. Astragal clip3520is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,34, and36. Continuous panel joint3525is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31-33,36,38, and41.

FIG.35shows a perspective view of a solar panel system installed in a one example of a non-roof application. That is, one or more aspects of solar support systems described herein may also be implemented in various non-roof applications. One or more aspects of inventive elements and systems described herein with regard to roofing systems are also applicable to non-roof exterior building elements, examples of which are described in more detail herein. For instance, solar panel systems may be installed as a wall cladding system, over existing exterior wall systems, etc.

An example solar panel support system supporting a solar panel module over a vertical standing seam metal wall panel system is shown inFIG.35. As shown, the astragal clip3520, standing seam clip3510, and spacer block3505may be installed according to techniques described herein (e.g., as previously described with respect to standing seam roof embodiments, with the solar panel module edge compressively attached between the astragal clip3520and the spacer block3505).

In the example ofFIG.35, the standing seam clip3510includes additional edge flanges3515extending outwards from the U-shaped portion of the standing seam clip3510. The flanges3515serve to separate the compressive force securing the module to the clip from the forces resulting from securing the clip to the cladding. These flanges3515and the perpendicular tabs (e.g., shown inFIG.36) may provide positive placement and additional compressive engagement capacity to secure the module to the clip.

In some aspects, the clip design may provide the modules to be securely fastened to the vertical surface, such that the modules are held not only by the compressive force of the astragal clip3520/standing seam clip3510connection, but also by the shelf support provided by the flange3515(e.g., as shown inFIG.36). Firstly, the opposing offset set screw pattern (e.g., the offset set screw pattern described in more detail herein, for example, with reference toFIGS.22-24) may crimp all the components together securely in the vertical dimension without puncturing the structure's weatherizing envelope system. Secondly, the astragal clip3520/standing seam clip3510assembly compressively engages the module to itself. Thirdly, the flange3515provides a point of mechanical attachment (e.g., such as a screw to the module through a hole provided in the flange3515) as well as additional security against slippage provided by setting the module on a shelf/ledge/flange3515(e.g., as shown inFIG.36).

While a vertical wall system is shown in the example ofFIGS.35and36, it will be understood that the system may also be used for over or under vertical/curved/radiused walls, steeply sloped roofs, etc.

FIG.36shows an example of a perspective view of a solar panel system installed in a one example of a non-roof application according to aspects of the present disclosure. Solar panel installation system3600is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-35,37,38,40, and41. In one aspect, solar panel installation system3600includes standing seam clip3605, flange3610, perpendicular tab3615, astragal clip3620, and continuous panel joint3625.

Standing seam clip3605is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,26-28,34, and35. Flange3610is an example of, or includes aspects of, the corresponding element described with reference toFIG.35. Astragal clip3620is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,34, and35. Continuous panel joint3625is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31-33,35,38, and41.

InFIG.36, a perspective view of a solar panel system installed in a second example of a non-roof application is shown.

In some aspects, the example shown inFIG.36is similar to (or analogous to) the example shown inFIG.35(e.g., with the exception of the standing seam clip3605). InFIG.36, the flanges3610of the standing seam clip3605are extended and each flange3610includes a perpendicular tab3615with a hole. In addition to the advantages described with respect toFIG.35, the perpendicular tab3615ofFIG.36may facilitate (e.g., speed up) installation. Further, the perpendicular tab3615ofFIG.36may simplify the layout (e.g., by making it easy to see where modules will rest when the mounts are positioned and secured), may facilitate installation (e.g., by providing a place to rest the modules as they are installed), may assure positive permanent positioning with a provision for mechanical attachment of the module to the clip (e.g., screw hole), etc.

FIG.37shows an example of a perspective of a weathercap3715installed on a solar panel support system according to aspects of the present disclosure. Solar panel installation system3700is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-36,38,40, and41. In one aspect, solar panel installation system3700includes left solar panel module3705, right solar panel module3710, and weathercap3715.

Left solar panel module3705is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,34,38,40,41, and43. Right solar panel module3710is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,30,34,38,40, and41. Weathercap3715is an example of, or includes aspects of, the corresponding element described with reference toFIGS.23,27,28,30, and34.

FIG.37illustrates a perspective of a weathercap3715installed on a solar panel support system (e.g., a weathercap3715installed on a solar panel support system of the examples ofFIGS.35and36). As shown inFIG.37, a weathercap3715(e.g., as described in more detail herein) may also be installed in non-roofing applications. Generally, the weathercap3715—astragal/astragal clip assembly may be any suitable combination of weathercap3715and astragal/astragal clip described herein.

FIG.38shows an example of a solar panel attachment system according to aspects of the present disclosure. Solar panel installation system3800is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-37,40, and41. In one aspect, solar panel installation system3800includes left roof panel3805, right roof panel3815, continuous panel joint3820, left solar panel module3830, and right solar panel module3855.

Left roof panel3805is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34, and40-42. Right roof panel3815is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,40, and41. In one aspect, left roof panel3805and right roof panel3815each include a bulb3810. Continuous panel joint3820is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31-33,35,36, and41. In one aspect, continuous panel joint3820includes fold3825. Fold3825is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20and21. Left solar panel module3830is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,34,37,40,41, and43. Right solar panel module3855is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,30,34,37,40, and41. In one aspect, left solar panel module3830and right solar panel module3855each include a groove3835, a bottom edge3840, and a support structure3845. In one aspect, support structures3845include a foot3850.

In some examples, a solar panel module (e.g., left solar panel module3830, right solar panel module3855, etc.) may have a unique attachment edge including a groove3835configured to receive a roofing panel bulb3810(e.g., a bulb3810formed by a left roof panel3805and a right roof panel3815at fold3825). In some examples a solar panel of this type may be manufactured with a frame specifically adapted for a particular roof profile. The groove3835may be continuous along the edge of the solar panel module, and the solar panel module may also include a continuous support structure3845extending downwards from a bottom edge3840of the solar panel module. In some cases, the support structure3845may include a “foot”3850element configured to sit on a roof panel below and to provide support for the solar panel module. In some cases, the solar panel module may be fastened to the roof bulb3810by a snap-lock connection where the support structure3845and lower portion of the solar panel end slides past the bulb3810until the bulb3810is received by the groove3835, locking that edge of the solar panel module in place. The bulb3810and groove3835may be located above the roof and relative to each other such that the foot3850rests on and is supported by the roof panel while the solar panel module is locked to the bulb3810. In some aspects, a solar panel module may be removed by completing the opposite action (e.g., pushing the lower portion of the solar panel module end up past the bulb3810so that the solar panel module edge moves upward past the bulb3810and the groove3835is uncoupled from the bulb3810).

The bulb3810for coupling the solar panel modules to the roof may be formed by the intersection of the two standing seam roofing panels (e.g., the left roof panel3805and the right roof panel3815). In some cases, each roofing panel ends with a vertical portion, and the ends of the two vertical portions may be folded over each other to form the standing seam (e.g., the fold3825). In the example ofFIG.38, the vertical portions of the standing seam are long enough such that the fold3825is located high enough above the installed solar panel modules to allow installation of the solar panel modules (e.g., such that the top edge of the solar panel modules clear the fold3825during installation). The vertical portion of the standing seam also includes a semi-circular bulb3810formed by curving the vertical portion. Two semicircles (e.g., of the bulbs3810) may be located next to each other so that they form, or nearly form, a circle (e.g., as shown in the example ofFIG.38), which may help the strength of the connection. Each bulb3810is then received by the corresponding groove3835of the solar panel module for a tool-less connection of a solar panel module to a roofing system. As shown inFIG.38, the lower portion and the support structure3845may be sloped downward away from the seam to allow for the lower portion of the solar panel end to clear the bulb3810as the solar panel end is lowered into place.

In the example ofFIG.38, the bulb3810and corresponding groove3835are shown to be circular.

However, generally the bulb3810and corresponding groove3835may be elliptical, triangular, diamond-shaped, or any other shape suitable for the connection by analogy, without departing from the scope of the present disclosure.

In some aspects, the width of the solar panel module may be dependent on the width of the standing seam profile (e.g., the spacing between adjacent roof panel folds3825). In one example implementation, the spacing of the roof panel folds3825may be approximately 4 feet and the width of the solar panel modules may be approximately 20 inches. In some example implementations, the spacing of the roof panel folds3825may match, or closely match, a width of a number of side-by-side standard solar panel modules (e.g., 1, 2, 3, 4, etc.). The solar panel module frames have end portions that may be shorter than the other portions of the frame, which may allow for water and wiring to transition underneath the solar panel modules at the shorter end portions.

In some aspects, the example ofFIG.38may simplify the roofing profile (e.g., by eliminating the ledge in the metal roofing panel that is used in conventional solar panel designs). As described, the solar panel modules may simply snap into a metal roof profile (e.g., after a roofing system is installed). This may effectively and advantageously separate the two scopes of installation/maintenance work, roofing system installation/maintenance and solar panel system installation/maintenance. Additionally, no special tools are required for the solar panel installation aspects described. Although in some embodiments, adhesive may be applied between the groove3835and the bulb3810. Further, in some cases, the area underneath the panel may be used as a chase for running wires.

In some aspects, the configuration of the left roof panel3805end and the right roof panel3815end to couple together to form a continuous panel joint3820projecting outward from the substantially planar surface further comprises folding of an edge of the left roof panel3805end with and edge of the right roof panel3815end to form a continuous seam (e.g., as described in more detail herein, for example, with reference toFIG.38).

FIG.39shows an example of a method3900for solar energy systems according to aspects of the present disclosure. In some examples, these operations are performed by a system including a processor executing a set of codes to control functional elements of an apparatus.

At operation3905, the system couples a left panel to a substantially planar surface, the left panel including a left panel first end, a left panel second end opposite to the left panel first end, and a left panel middle portion connecting the left panel first end and the left panel second end. In some cases, the operations of this step refer to, or may be performed by, a left roof panel as described with reference toFIGS.22,23,27,28,31-34,38, and40-42.

At operation3910, the system couples a right panel to the substantially planar surface, the right panel including a right panel first end, a right panel second end, and a right panel middle portion connecting the right panel first end and the second panel second end. In some cases, the operations of this step refer to, or may be performed by, a right roof panel as described with reference toFIGS.22,23,27,28,31-34,38,40, and41.

At operation3915, the system couples the left panel first end to the right panel first end to form a continuous panel joint projecting outward from the substantially planar surface, where the panel joint includes a left engagement contour on a left side of the continuous panel joint and a right engagement contour on a right side of the continuous panel joint. In some cases, the operations of this step refer to, or may be performed by, an engagement contour as described with reference toFIGS.40,41, and44. In some cases, the operations of this step refer to, or may be performed by, a continuous panel joint as described with reference toFIGS.22-24,26-28,31-33,35,36,38, and41.

At operation3920, the system interlocks a contoured edge of a frame of a left solar panel with the left engagement contour such that the contoured edge is coupled to the left engagement contour and the left solar panel is spanning over at least a portion of the left panel. In some cases, the operations of this step refer to, or may be performed by, a contoured edge as described with reference toFIGS.40,41, and43. In some cases, the operations of this step refer to, or may be performed by, a left solar panel module as described with reference toFIGS.20-23,27,28,30,31,34,37,38,40,41, and43.

At operation3925, the system interlocks a contoured edge of a frame of a right solar panel with the right engagement contour such that the contoured edge is coupled to the right engagement contour and the right solar panel is spanning over at least a portion of the right panel. In some cases, the operations of this step refer to, or may be performed by, a contoured edge as described with reference toFIGS.40,41, and43. In some cases, the operations of this step refer to, or may be performed by, a right solar panel module as described with reference toFIGS.20,23,27,28,30,34,37,38,40, and41.

FIG.40shows an example of a perspective view of a solar support system according to aspects of the present disclosure. Solar panel installation system4000is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-38, and41. In one aspect, solar panel installation system4000includes left roof panel4005, right roof panel4010, third roof panel4015, support shelf4020, left solar panel module4025, right solar panel module4030, third solar panel module4035, engagement contour4040, and contoured edge4045.

Left roof panel4005is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,38,41, and42. Right roof panel4010is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,38, and41. Support shelf4020is an example of, or includes aspects of, the corresponding element described with reference toFIGS.32,34, and41. Left solar panel module4025is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,34,37,38,41, and43. Right solar panel module4030is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,30,34,37,38, and41. Engagement contour4040is an example of, or includes aspects of, the corresponding element described with reference toFIGS.41and44. Contoured edge4045is an example of, or includes aspects of, the corresponding element described with reference toFIGS.41and43.

A perspective view of a toolless solar support system is shown in the example ofFIG.40. Shown are a first roof panel (e.g., left roof panel4005), a second roof panel (e.g., right roof panel4010), a third roof panel4015, a first solar panel (e.g., left solar panel module4025), a second solar panel (e.g., right solar panel module4030), a third solar panel, a plurality of support shelves, and a plurality of panel-receiving engagement contours4040.

Shown inFIG.40are aspects of a corrugated roof panel system, wherein each roof panel end may be configured to overlap and snap-lock to the adjacent roof panel. The roof panel ends may be formed such that when they are snap-locked (e.g., such that the panel ends overlap), a support shelf4020and a panel-receiving concave engagement contour4040may be located on each side of the overlapped portion, as described in more detail herein (e.g., with respect toFIG.41).

FIG.41shows an example of a detailed view of a panel support location according to aspects of the present disclosure. Solar panel installation system4100is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-24,27-38, and40. In one aspect, solar panel installation system4100includes left roof panel4105, right roof panel4125, continuous panel joint4140, left solar panel module4150, right solar panel module4160, and planar surface4165.

Left roof panel4105is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,38,40, and42. In one aspect, left roof panel4105includes left roof panel end4110. Left roof panel end4110is an example of, or includes aspects of, the corresponding element described with reference toFIG.44. In one aspect, left roof panel end4110includes first bulb shape4115and support shelf4120. Support shelf4120is an example of, or includes aspects of, the corresponding element described with reference toFIGS.32,34, and40.

Right roof panel4125is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,38, and40. In one aspect, right roof panel4125includes right roof panel end4130. In one aspect, right roof panel end4130includes second bulb shape4135. Continuous panel joint4140is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22-24,26-28,31-33,35,36, and38. In one aspect, continuous panel joint4140includes engagement contour4145. Engagement contour4145is an example of, or includes aspects of, the corresponding element described with reference toFIGS.40and44. Left solar panel module4150is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,34,37,38,40, and43. Right solar panel module4160is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20,23,27,28,30,34,37,38, and40. In one aspect, left solar panel module4150and right solar panel module4160each include contoured edges4155. A contoured edge4155is an example of, or includes aspects of, the corresponding element described with reference toFIGS.40and43.

InFIG.41, a detailed view of a panel support location is shown. The solar panel modules may cover a planar surface4165, which in the example shown is a roof surface with corresponding roof panels, but the planar surface4165may be a vertical exterior wall surface or other suitable exterior surface for mounting solar panel modules thereto, and the roof panels may be other panels suitable for covering the specific exterior surface. The right roof panel end4130and the left roof panel end4110may overlap, with the right roof panel end4130snap-locking over the left roof panel end4110. Each panel end may include a central bulb-shape transitioning to a substantially horizontal support shelf4120on either side. The panel ends may be shaped such that when coupled together each shelf of the second panel (e.g., of the right roof panel4125) lies on top of and is supported by the corresponding shelf of the first panel (e.g., of the left roof panel4105) underneath, forming the support shelf4120. In some examples, the sides of the bulb portion of the right roof panel end4130may include the concave engagement contour4145to receive the corresponding solar panel frame end. The bulb portions of the left and right panel ends may be configured such that the right roof panel end4130can be snap-locked over and retained by the left roof panel end4110. In the configuration shown, this results in the bulb portion of the left roof panel end4110having a smooth arc-shape transitioning into vertical sides whereas the top of the bulb portion of the right roof panel end4130has a smaller top arc shape with additional straight vertical sides, and the lower sides of the bulb portion are concave. Generally, any other complementary panel end profiles may be implemented by analogy, provided that the two profiles can be snap-locked as described and also provide the required support shelves and engagement contours4145for retaining the solar panel end therein.

The perimeter frame of the solar panel module (i.e. the portion of a solar panel module that forms the shape of the panel ends) may be, for example, a UV stabilized plastic resistant to, rot, mildew, abrasion, chemicals and weather damage (e.g., such as polycarbonate, PVC, HDPE, UHMW Polyethylene, etc.). In some implementations, for example, the solar panel frame may have a height of approximately ⅝″ to ¾″. In some examples, electronics for the solar panel modules may be pre-installed on the panel. As a result, for the perimeter frame without metallic parts to conduct electricity, an equipment ground (EGC) may not be required and, with modern electronics, a grounding equipment conductor (GEC) may also not be required (e.g., since the devices test for insulation resistance before exporting power).

Accordingly, a system for solar panel installation is described. One or more aspects of the system include a left roof panel4105configured for coupling onto a substantially planar surface4165and including a left roof panel end4110, a left roof panel4105second end opposite to the left roof panel end4110, and a left roof panel4105middle portion connecting the left roof panel end4110and the left roof panel4105second end and a right roof panel4125configured for coupling onto the substantially planar surface4165and including a right roof panel end4130, a right roof panel4125second end, and a right roof panel4125middle portion connecting the right roof panel end4130and the second panel second end, wherein the left roof panel end4110and the right roof panel end4130are configured to couple together to form a continuous panel joint4140projecting outward from the substantially planar surface4165, wherein the panel joint includes a left engagement contour4145on a left side of the continuous panel joint4140and a right engagement contour4145on a right side of the continuous panel joint4140, wherein the left engagement contour4145is configured to interlock with a contoured edge4155of a frame of a left solar panel module4150spanning over at least a portion of the left roof panel4105and the right engagement contour4145is configured to interlock with a contoured edge4155of a frame of a right solar panel module4160spanning over at least a portion of the right roof panel4125.

In some aspects, the left roof panel end4110and the right roof panel end4130each include a support shelf4120located below the engagement contour4145and configured to support a lower edge of the corresponding solar module frame when that solar module is spanning over the panel.

In some aspects, the left roof panel end4110includes a first bulb shape4115and the right roof panel end4130includes a second bulb shape4135, wherein the coupling together to form a continuous panel joint4140further comprises the second bulb shape4135snap-locked over the first bulb shape4115.

In some aspects, each contoured edge4155of the frame comprises a convex surface, and wherein each engagement contour4145comprises a concave surface.

In some aspects, each contoured edge4155of the frame comprises a concave surface, and wherein each engagement contour4145comprises a convex surface.

In some aspects, each solar module frame further comprises a foot extending downwards from the contoured edge4155of the solar panel frame.

In some aspects, each engagement contour4145includes a plurality of notches in a surface of the contour, and each contoured edge4155of the solar panel frame includes a plurality of bumps in a surface of the contoured edge4155, wherein the bumps and notches are configured such that at least one bump is received by at least one notch when the engagement contour4145is interlocked with the corresponding contoured edge4155of the solar panel frame and forms an engagement separate from the interlock of the engagement contour4145with the contoured edge4155of the solar module frame.

In some aspects, the substantially planar surface4165is an exterior surface of a structure. In some examples, the left roof panel4105and the right roof panel4125are roofing panels. In some examples, the left roof panel4105and the right roof panel4125are cladding panels.

A method for solar panel installation is also described. One or more aspects of the method include coupling a left roof panel4105to a substantially planar surface4165, the left roof panel4105including a left roof panel end4110, a left roof panel4105second end opposite to the left roof panel end4110, and a left roof panel4105middle portion connecting the left roof panel end4110and the left roof panel4105second end; coupling a right roof panel4125to the substantially planar surface4165, the right roof panel4125including a right roof panel end4130, a right roof panel4125second end, and a right roof panel4125middle portion connecting the right roof panel4125first end and the second panel second end; coupling the left roof panel end4110to the right roof panel end4130to form a continuous panel joint4140projecting outward from the substantially planar surface4165, wherein the panel joint includes a left engagement contour4145on a left side of the continuous panel joint4140and a right engagement contour4145on a right side of the continuous panel joint4140; interlocking a contoured edge4155of a frame of a left solar panel module4150with the left engagement contour4145such that the contoured edge4155is coupled to the left engagement contour4145and the left solar panel module4150is spanning over at least a portion of the left roof panel4105; and interlocking a contoured edge4155of a frame of a right solar panel module4160with the right engagement contour4145such that the contoured edge4155is coupled to the right engagement contour4145and the right solar panel module4160is spanning over at least a portion of the right roof panel4125.

In some aspects, the left roof panel end4110and the right roof panel end4130each include a support shelf4120located below the engagement contour4145and configured to support a lower edge of the corresponding solar module frame.

Some examples of the methods and systems described herein further include supporting the lower edge of the corresponding solar module frame on the support shelf4120in response to interlocking the corresponding contoured edge4155of the frame.

In some aspects, the left roof panel end4110includes a first bulb shape4115and the right roof panel end4130includes a second bulb shape4135, wherein the coupling of the left roof panel end4110to the right roof panel end4130to form a continuous panel joint4140further comprises the second bulb shape4135snap-locked over the first bulb shape4115.

In some aspects, each contoured edge4155of the frame comprises a convex surface, and wherein each engagement contour4145comprises a concave surface.

In some aspects, each contoured edge4155of the frame comprises a concave surface, and wherein each engagement contour4145comprises a convex surface.

In some aspects, each solar module frame further comprises a foot extending downwards from the contoured edge4155of the solar panel frame.

In some aspects, the coupling of the left roof panel end4110to the right roof panel end4130to form a continuous panel joint4140projecting outward from the substantially planar surface4165further comprises folding of an edge of the left roof panel end4110with and edge of the right roof panel end4130to form a continuous seam (e.g., as described in more detail herein, for example, with reference toFIG.38).

In some aspects, each engagement contour4145includes a plurality of notches in a surface of the contour, and each contoured edge4155of the solar panel frame includes a plurality of bumps in a surface of the contoured edge4155.

Some examples of the methods and systems described herein further include receiving at least one bump being received by at least one notch when the engagement contour4145is interlocked with the corresponding contoured edge4155of the solar panel frame, whereby an engagement is formed that is separate from the interlock of the engagement contour4145with the contoured edge4155of the solar module frame.

In some aspects, the substantially planar surface4165is an exterior surface of a structure. In some aspects, the left roof panel4105and the right roof panel4125are roofing panels. In some aspects, the left roof panel4105and the right roof panel4125are cladding panels.

FIG.42shows an example of a sectional view of a roof panel installation system according to aspects of the present disclosure. Roof panel4200is an example of, or includes aspects of, the corresponding element described with reference toFIGS.22,23,27,28,31-34,38,40, and41. In one aspect, roof panel4200includes first end portion4205, middle portion4215, and second end portion4225.

In one aspect, first end portion4205includes first profile4210. In one aspect, middle portion4215includes ribs4220. In one aspect, second end portion4225includes second profile4230.

InFIG.42, a sectional view of a toolless install roof panel4200is shown. Shown is a first end portion4205, a second end portion4225, and a middle portion4215. As shown inFIG.42, the middle portion4215of a toolless roof panel4200may have a corrugated configuration with raised parallel ribs4220, and the ribs4220may act as support shelves for solar panel modules (e.g., to be installed solar panel modules). The corrugation may be any suitable type for the demanded strength and serviceability conditions of a given application. The ribs4220are configured to support the middle portions4215of the solar panel modules.

The panel includes the first end with a first profile4210and a second end with a second profile4230. In the example shown, the first profile4210and the second profile4230may correspond to the profiles described herein (e.g., such as the profiles shown inFIG.41, with the first profile4210corresponding to the first-installed left roof panel4200end, and the second profile4230corresponding to the second-installed right roof panel end that snap-locks over the first profile4210).

In some aspects, the left roof panel4200middle portion4215and the right roof panel middle portion4215each include at least one secondary support member (e.g., ribs4220) configured to support the corresponding solar module spanning over that panel.

Some examples of the methods, apparatuses, and systems described herein further include supporting of the corresponding solar module by the at least one secondary support member in response to interlocking the corresponding contoured edge of the frame.

FIG.43shows an example of a detailed view of a solar panel module edge according to aspects of the present disclosure. Solar panel module4300is an example of, or includes aspects of, the corresponding element described with reference toFIGS.20-23,27,28,30,31,34,37,38,40, and41.

In one aspect, solar panel module4300includes edge frame4305. In one aspect, edge frame4305includes contoured edge4310. Contoured edge4310is an example of, or includes aspects of, the corresponding element described with reference toFIGS.40and41. In one aspect, contoured edge4310includes notches4315.

In the example ofFIG.43, a detail of an edge frame4305of an exemplary solar panel module4300for use in the toolless install system is shown.

The end of the solar panel module4300that is received by the concave indentation in the roof panel (e.g., as described in more detail herein, for example, with reference toFIGS.41and42) may include an edge frame4305with a convex surface generally matching the concave indentation. The convex surface of the edge frame4305may, in some examples, also includes a plurality of narrow vertical notches4315that are closely spaced along the edge (e.g., as shown inFIG.44). Some of the vertical notches4315may receive corresponding bumps on the corresponding roofing panel ends (e.g., as shown inFIG.44). In the example ofFIG.43, the spacing of the notches4315may be smaller than the bump spacing to allow for greater flexibility in matching the notches4315to the bumps. In some cases, other suitable notch shapes or notch configurations may be used by analogy, without departing from the scope of the present disclosure.

FIG.44shows an example of a detailed view of a roof panel end portion according to aspects of the present disclosure. Roof panel end4400is an example of, or includes aspects of, the corresponding element described with reference toFIG.41. In one aspect, roof panel end4400includes engagement contour4405. Engagement contour4405is an example of, or includes aspects of, the corresponding element described with reference toFIGS.40and41. In one aspect, engagement contour4405includes bumps4410.

A perspective detail illustration of an end portion of a roof panel (e.g., a second end portion of a roof panel) is shown inFIG.44. As described herein, a concave engagement contour4405may include regularly-spaced, and generally circular, bumps4410. The bumps4410may be received by corresponding notches in a convex edge frame surface of a solar panel module. The engagement of the bumps4410with the notches may prevent the solar panel module edge from sliding laterally along the concave engagement contour4405(e.g., due to thermal expansion or other horizontal forces).

In some aspects, the examples described with reference toFIGS.40-44may utilize solar panel modules that are precisely dimensioned, with interlocking frames and indexing features to assure solar panel module to solar panel module row alignment horizontally across the solar panel module/solar array. Such embodiments may use a press-in, snap-fit design (to which, in some examples, an adhesive may be added for security without detriment to performance) with module level electronics pre-installed (e.g., such that the system is essentially a tool-less, snap in, “plug-and-play” system that can be delivered at low cost and installed, uninstalled and expanded or reduced by the consumer in most cases once a roofing system is in place).

The toolless embodiments ofFIGS.40-44may reduce manufacturing costs and shipping volume, while also eliminating electrical grounding requirements for the module frame and offering tool-free installation. Moreover, the innovative aspects ofFIGS.40-44are not limited to execution in metals, but also may be adapted to any material having suitable physical properties (e.g., such as fiberglass and various plastics including plexiglass and vinyl). Having the solar panel module electronics preinstalled, tool-less install and no racking required may reduce onsite labor, especially labor on the roof, which increases the safety of solar panel installation jobs.

FIG.45shows an example of a solar panel cleaning system4500according to aspects of the present disclosure. Solar panel cleaning system4500is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46-49. In one aspect, solar panel cleaning system4500includes cleaning apparatus4505, cover4510, fluid tank4515, weathercap rail4520, and solar panel row4525.

Cleaning apparatus4505is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46-48. Cover4510is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and48. Fluid tank4515is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46-48. Weathercap rail4520is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46-49. Solar panel row4525is an example of, or includes aspects of, the corresponding element described with reference toFIG.49.

FIG.46shows an example of a solar panel cleaning system4600according to aspects of the present disclosure. Solar panel cleaning system4600is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45, and47-49. In one aspect, solar panel cleaning system4600includes cleaning apparatus4605, cover4610, rod4615, fluid tank4620, gripper base4625, gripper element4630, actuator plate4635, wheel4640, first gripper assembly4645, second gripper assembly4650, and weathercap rail4655.

Cleaning apparatus4605is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45,47, and48. Cover4610is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45and48. Rod4615is an example of, or includes aspects of, the corresponding element described with reference toFIG.47. Fluid tank4620is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45,47, and48. Gripper base4625is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and48. Gripper element4630is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and48. Wheel4640is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and48. First gripper assembly4645is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and49. Second gripper assembly4650is an example of, or includes aspects of, the corresponding element described with reference toFIG.49. Weathercap rail4655is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45, and47-49.

FIG.47shows an example of a solar panel cleaning system4700according to aspects of the present disclosure.

Cleaning apparatus4705is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45,46, and48. Fluid tank4710is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45,46, and48. Rod4720is an example of, or includes aspects of, the corresponding element described with reference toFIG.46. Rail4725is an example of, or includes aspects of, the corresponding element described with reference toFIG.48. First gripper assembly4730is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and49. Gripper base4735is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and48. Actuator4740is an example of, or includes aspects of, the corresponding element described with reference toFIG.48. Gripper element4745is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and48. Weathercap rail4750is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45,46,48, and49. Wheel4755is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and48. Third gripper assembly4760is an example of, or includes aspects of, the corresponding element described with reference toFIGS.48and49.

FIG.48shows an example of a solar panel cleaning system4800according to aspects of the present disclosure. Solar panel cleaning system4800is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-47, and49. In one aspect, solar panel cleaning system4800includes cleaning apparatus4805, fluid tank4810, rail4815, cover4820, third gripper assembly4825, and weathercap rail4855.

Cleaning apparatus4805is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-47. Fluid tank4810is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-47. Rail4815is an example of, or includes aspects of, the corresponding element described with reference toFIG.47. over 4820 is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45and46. Third gripper assembly4825is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and49. In one aspect, third gripper assembly4825includes gripper base4830, actuator4835, pin4840, gripper element4845, and wheel4850. Gripper base4830is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and47. Actuator4835is an example of, or includes aspects of, the corresponding element described with reference toFIG.47. Gripper element4845is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and47. Wheel4850is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and47. Weathercap rail4855is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-47, and49.

FIGS.45-48illustrate one or more aspects of described solar panel cleaning systems4800(e.g., where solar panel modules are omitted for clarity). In some examples, solar panel cleaning systems4800may removably and movably couple to a plurality of parallel weathercaps of a solar panel mounting system. Each weathercap (e.g., each weathercap rail4855) may include an upper rail4815profile that is configured for allowing the cleaning system to move along the rail4815(e.g., longitudinally). Each weathercap also may provide for removable detaching of the cleaning system from the rail4815. The cleaning system/rail4815interaction is described in more detail below.

In some aspects, the cleaning system may be illustrated and described as spanning over two solar panel module widths when in the cleaning position. Generally, the system may be expanded to span over more than two modules by analogy, without departing from the scope of the present disclosure. A cleaning system in the example ofFIGS.45-48may be coupled to the outer weathercaps when in the cleaning position, and the cleaning system may span over the middle weathercap without coupling to it when in the cleaning position. The middle weathercap may be utilized as a temporary support when the cleaning system moves transversely to position over the next set of solar panel modules to be cleaned. In the present example, the two modes of locomotion of the cleaning system (longitudinal and transverse) may be distinct (e.g., may not overlap).

The chassis comprises the plurality of gripper assemblies, the rods, and the rails4815. The example ofFIGS.45-48may include four gripper assemblies, two coupled to each of the outer weathercaps when in the cleaning position. Each gripper assembly may be supported by, and may be movably coupled to, the weathercap (e.g., where each gripper assembly may extend upwards from the weathercap). Each pair of gripper assemblies aligned across the panel widths (e.g., a first gripper assembly and a second gripper assembly as shown inFIG.46) is connected by a horizonal rail4815and a horizontal rod that is substantially parallel to the rod. Each gripper assembly may be slidably coupled to the corresponding rod and rail4815for transverse motion of the gripper assembly with respect to the rod and rail4815.

The cover4820is coupled to and supported by the chassis via the rails4815(e.g., as shown inFIG.47). The cover4820comprises a general box shape that encloses the chassis on the sides and on the top, but is open on the bottom, whereby the cleaning apparatus4805mounted to the chassis located inside the cover4820provides cleaning to the solar panel modules below via the bottom opening. A fluid tank4810configured to hold fluid for cleaning and fluidly coupled to the cleaning apparatus4805may be coupled to the cover4820in the present example. The fluid tank4810and the cleaning apparatus4805are shown in schematic form for illustrative purposes. However, many types of suitable cleaning apparatus4805mechanisms may be implemented by analogy, without departing from the scope of the present disclosure. In some examples, the fluid tank4810may be incorporated into the cleaning apparatus4805.

Example gripper assemblies are shown in more detail inFIGS.47and48. Each gripper assembly may include an upper gripper base4830, a lower plurality of gripper elements4845, and an actuator4835connecting the gripper base4830and the plurality of gripper elements4845. At least one gripper element4845may be pivotally coupled to a lower end of the actuator4835(e.g., as shown inFIG.48). The pivotal coupling shown inFIG.48is a pin4840connection, but any connection suitable for pivoting the gripper element4845away from the weathercap rail4855profile may be implemented.

A horizontal wheel4850is coupled to a lower end of each gripper element4845such that the wheel4850rotates about a generally vertical axis. An angled profile of the wheel4850may match with, and engage with, the rail4815profile of the weathercap (e.g., as shown inFIG.48). The profile of the wheels4850/weathercap rail4855is such that the gripper element4845is supported on the weathercap rail4855while still able to move along the rail4815when the wheels4850are rotated by at least one motor. In the embodiment shown, each gripper assembly includes three gripper-wheel4850assemblies. The wheels4850mechanically engage the weathercap rail4855profile such that the cleaning system can generate adequate downforce for mechanical cleaning action (e.g. utilizing rotating brush(es) and squeegee) to effectively clean the surface of the solar panel module.

Each gripper assembly may include a motor coupled to the gripper base4830and the rod. The motor is configured to move the gripper assembly along the rod (transversely). The motor is coupled to one or more batteries for providing power to the motor. The actuator4835is configured to move the gripper/wheel4850assemblies between the lower position shown inFIGS.46-48and an upper position such that the gripper-wheel4850assembly clears the weathercap rails4855so that the gripper assembly can be moved from one rail4815to another parallel rail4815.

While the wheels4850are shown engaging with the weathercap rail4855profile, it should be understood that other engagement profiles shown and described herein may be utilized as rail4815profiles for attachment and movement of the cleaning system. For example, the second profile of the toolless panel system described herein may be modified to accommodate a cleaning system attachment.

FIG.49shows an example of a solar panel cleaning system4900according to aspects of the present disclosure.

FIG.49shows an example solar panel cleaning diagram illustrating one or more aspects of solar panel cleaning systems4900and techniques described herein. For instance,FIG.49illustrates aspects of transverse solar panel cleaning movement utilizing solar panel cleaning system4900examples described with reference toFIGS.45-48. Solar panel cleaning system4900is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-48. In one aspect, solar panel cleaning system4900includes weathercap rail4905, solar panel row4935, first gripper assembly4940, second gripper assembly4945, third gripper assembly4950, and fourth gripper assembly4955.

Weathercap rail4905is an example of, or includes aspects of, the corresponding element described with reference toFIGS.45-48. In one aspect, weathercap rail4905includes first weathercap rail4910, second weathercap rail4915, third weathercap rail4920, fourth weathercap rail4925, and fifth weathercap rail4930. Solar panel row4935is an example of, or includes aspects of, the corresponding element described with reference toFIG.45. First gripper assembly4940is an example of, or includes aspects of, the corresponding element described with reference toFIGS.46and47. Second gripper assembly4945is an example of, or includes aspects of, the corresponding element described with reference toFIG.46. Third gripper assembly4950is an example of, or includes aspects of, the corresponding element described with reference toFIGS.47and48.

In some aspects,FIG.49shows a method for moving the solar panel cleaning system4900from a first cleaning position (e.g., where the solar panel cleaning system4900spans a first set of solar panel rows4935), to a second cleaning position (e.g., where the solar panel spans an adjacent set of solar panel rows4935).

In the initial state (e.g., in the first cleaning position), the solar panel cleaning system4900is in a position for cleaning the first set of two adjacent solar panel rows4935. First gripper assembly4940and second gripper assembly4945are coupled to first weathercap rail4910. Third gripper assembly4950and fourth gripper assembly4955are coupled to third weathercap rail4920.

Initially, the cleaning apparatus may be in a first position. In step49A, second gripper assembly4945is uncoupled from first weathercap rail4910, moved to the right, and coupled to second weathercap rail4915.

In step49B, first gripper assembly4940is uncoupled from first weathercap rail4910, moved to the right, and coupled to second weathercap rail4915.

In step49C, the cover/carriage assembly is moved from the initial position of spanning over second weathercap rail4915to the position of spanning over third weathercap rail4920(e.g., generally positioned between second weathercap rail4915and fourth weathercap rail4925).

In step49D, fourth gripper assembly4955is uncoupled from third weathercap rail4920, moved to the right, and coupled to fourth weathercap rail4925.

In step49E, second gripper assembly4945is uncoupled from second weathercap rail4915, moved to the right, and coupled to third weathercap rail4920. Also, third gripper assembly4950is uncoupled from third weathercap rail4920, moved to the right, and coupled to fourth weathercap rail4925.

In step49F, first gripper assembly4940is uncoupled from second weathercap rail4915, moved to the right, and coupled to third weathercap rail4920.

In step49G, the cover/carriage assembly is moved from the position of spanning over third weathercap rail4920to the position of spanning over fourth weathercap rail4925(i.e. generally positioned between weathercaps3and5).

In step49H, fourth gripper assembly4955is uncoupled from fourth weathercap rail4925, moved to the right, and coupled to fifth weathercap rail4930.

In step49I, third gripper assembly4950is uncoupled from fourth weathercap rail4925, moved to the right, and coupled to fifth weathercap rail4930. The final second cleaning position is shown in step49J, with the solar panel cleaning system4900in the second cleaning position for cleaning the second set of two adjacent solar panel rows4935(e.g., a cleaning apparatus may move from a first position to a second position via steps49A through49J, as described in more detail herein). First gripper assembly4940and second gripper assembly4945are coupled to third weathercap rail4920. Third gripper assembly4950and fourth gripper assembly4955are coupled to fifth weathercap rail4930.

Methods and systems for cleaning solar panels of a solar panel system installed on an exterior surface are described. One or more aspects of the method include attaching a solar panel cleaning system4900to the solar panel system, wherein the solar panel cleaning system4900comprises a cleaning apparatus, wherein the solar panel system includes a plurality of parallel weathercap rails4905, wherein the parallel rails alternate with rows of solar panels, wherein the attaching is a movable attachment whereby the solar panel cleaning system4900is configured for movement along the direction of the rails; moving of the solar panel cleaning system4900along the direction of the rails, whereby the cleaning apparatus is moved over the solar panels in one row; and activating the cleaning apparatus, whereby the solar panels in the one row are cleaned.

In some cases, initially, the solar panel cleaning system is installed above two rows of solar panel modules. For instance, the solar panel cleaning system shown inFIGS.45-48may be installed over a first set of two adjacent solar panel rows4935.

At operation5005, the solar panel cleaning system4900is self-propelled in the longitudinal direction. In the embodiment shown, the self-propelling is effected by a motor coupled to the plurality of wheels engaged with a weathercap rail4905(e.g., the rail profile of the weathercap). In some aspects, all wheels may be configured for moveable coupling along the rails, however, not all wheels may be powered (e.g., some wheels may be powered, while others may movably guide the solar panel cleaning system along the weathercap rails).

At operation5010(e.g., during the period while the cleaning system is moving from a first location to a second location, although not necessarily while the cleaning system is in motion), the cleaning apparatus may be activated to clean the solar panel module. In some examples, the activation at operation5010may be a manual activation (e.g., via user interaction), an automatic activation (e.g., based on a timer or other sensors for triggering activation), etc.

At operation5015, the solar panel cleaning system may stop at a second location.

At operation5020, the solar panel cleaning system is self-propelled transversely such that the solar panel cleaning system is positioned over a different set of solar panel rows. For instance, after the longitudinal moving period (e.g., after one or more solar panel rows4935are cleaned), self-propelled moving of the solar panel cleaning portion (e.g., transversely) may position the solar panel cleaning system over a different set of solar panel rows for cleaning. In some examples, the transverse movement may be effected by at least one motor for coupling/uncoupling of the gripper assemblies, moving of the gripper assemblies laterally, and moving of the cover/carriage laterally.

In some cases, the operations5005through5020may refer to, or may be performed by, a solar panel cleaning system (e.g., a cleaning apparatus) as described with reference toFIGS.45-49.

Referring again toFIGS.45-50, during cleaning operations, the cover may function to reduce (e.g., contain) the splatter and spray coming from the operation of the cleaning apparatus. In some examples, the cleaning operation includes coordinated operation of a rotating brush or brushes and squeegee of the cleaning system, the fluid tank, and at least one spray nozzle of the cleaning apparatus. The rotating brushes may be actuated mechanically by either the engagement of the wheels turning against the rail profile or by a separate electric motor and could be optionally supplied by a hose for rinse water.

Efficient and effective cleaning of solar panel modules may include a wet process and mechanical action (e.g., such as a brush, a rotating brush, etc.). By providing a continuous rail (e.g., weathercap rails4905) between solar panel rows4935, the weathercap rail4905design may be configured to accommodate solar panel cleaning apparatuses specifically designed for that purpose (e.g., such as the solar panel cleaning systems4900described herein). In some cases, the weathercap rail4905design can be modified for various types of cleaning system, such as friction-fit, roller-actuated brushes (e.g., for manual operation of rotary brushes hooked up to a garden-type hose for use on small residential arrays), robotic cleaners (e.g., with electric motors position sensors and sophisticated automation for commercial installations), etc.

In some aspects, such an ability to self-clean may be useful for solar carports where the top of the carport may be viewed from an adjacent building or the ground. For instance, solar arrays collect dust and often appear dirty after a short time. Conventionally, cleaning operations are difficult, dangerous, manual affairs which include the use of long handled pool brushes and squeegees and power washers with workers operating from up-and-over type aerial lifts. During the operation, cleaning water flows right through the system onto the cars below or on to the pavement creating a mess and causing extensive disruption to the parking activity. Alternatively, in some cases, a subsequent weather event (e.g., rain) may adversely carry water, dirt, debris, etc. that has accumulated on solar panel systems soiling onto vehicles underneath a carport solar system (e.g., in cases where the solar system is not efficiently cleaned). Additionally, such rain events may not fully clean the solar panels which leads to production losses due to the stuck-on soiling. Pollen, bird droppings, dust, etc. can create aesthetic nuisances as well as lost electrical production.

With the solar panel cleaning systems4900described herein, cleaning can happen anytime and often, rain or shine, keeping the solar generator in top appearance without impacting parking access or quality, and gray water can be diverted to catchments for appropriate watering applications or other reuse, resulting from cleaning water recycling and rainwater capture.

In some embodiments, the solar panel cleaning system4900may be installed on non-roof applications described herein (e.g., vertical solar panel installation system embodiments). For such applications (e.g., panel cleaning systems on a curtainwall), the solar panel cleaning system4900may be modified to include a cogged/geared/textured engagement at the drive rollers and a rail connection may be implemented.

At operation5105, the system attaches a solar panel cleaning system to the solar panel system, where the solar panel cleaning system includes a cleaning apparatus, where the solar panel system includes a set of parallel weathercap rails, where the parallel rails alternate with rows of solar panels, where the attaching is a movable attachment whereby the solar panel cleaning system is configured for movement along the direction of the rails. In some cases, the operations of this step refer to, or may be performed by, a solar panel cleaning system as described with reference toFIGS.45-49. In some cases, the operations of this step refer to, or may be performed by, a cleaning apparatus as described with reference toFIGS.45-48.

At operation5110, the system moves of the solar panel cleaning system along the direction of the rails, whereby the cleaning apparatus is moved over the solar panels in one row. In some cases, the operations of this step refer to, or may be performed by, a solar panel cleaning system as described with reference toFIGS.45-49. In some cases, the operations of this step refer to, or may be performed by, a cleaning apparatus as described with reference toFIGS.45-48.

At operation5115, the system activates the cleaning apparatus, whereby the solar panels in the one row are cleaned. In some cases, the operations of this step refer to, or may be performed by, a solar panel cleaning system as described with reference toFIGS.45-49. In some cases, the operations of this step refer to, or may be performed by, a cleaning apparatus as described with reference toFIGS.45-48.

Modules may also be implemented in software for execution by various types of processors. An identified module of executable code may, for instance, comprise one or more physical or logical blocks of computer instructions that may, for instance, be organized as an object, procedure, or function. Nevertheless, the executables of an identified module need not be physically located together, but may comprise disparate instructions stored in different locations which, when joined logically together, comprise the module and achieve the stated purpose for the module.

Indeed, a module of executable code could be a single instruction, or many instructions, and may even be distributed over several different code segments, among different programs, and across several memory devices.

Similarly, operational data may be identified and illustrated herein within modules, and may be embodied in any suitable form and organized within any suitable type of data structure. The operational data may be collected as a single data set, or may be distributed over different locations including over different storage devices, and may exist, at least partially, merely as electronic signals on a system or network.