Abstract:
A system is provided for mounting at least one solar panel on a roof having standing seams protruding outwardly therefrom. The system may include a plurality of panel mounting brackets each comprising first and second flanges laterally spaced apart to define a seam channel therebetween, with the seam channel for receiving a given standing seam therein when the first and second flanges are positioned on the roof straddling the given standing seam. Each panel mounting bracket may also include a vertical extension portion carried by the first and second flanges. The system may further include a plurality of clamps each configured to couple the vertical extension portion of a respective panel mounting bracket with the at least one solar panel.

Description:
TECHNICAL FIELD 
     The present disclosure generally relates to mounting fixtures, and, more particularly, to mounting fixtures or brackets for panel installations, such as for solar panels, for example, to standing seam rooftops. 
     BACKGROUND 
     Solar panels, such as photovoltaic (PV) and solar water heating panels, are frequently used to take advantage of electrical power generation and heating properties of sunlight. To provide space savings and potentially enhanced efficiency, solar panels are in many cases installed on rooftops of buildings (e.g., office buildings, houses, etc.). However, because of winds and storms, the mounting fixtures used for installing solar panels on buildings need to be sufficiently strong and durable to reduce the chances of damage or injury from a panel coming loose during a storm, etc. 
     Various mounting fixtures have been developed for solar panel installation. For example, U.S. Pat. No. 7,963,074 discloses a device for fixing a photovoltaic module on a sloping roof having a roof structure and a roof covering with individual roof covering elements. The device includes a roof-side connecting piece disposable beneath the roof covering and a module-side connecting piece disposable on an edge of the photovoltaic module. A flexible retaining element interconnects the roof-side connecting piece and the module-side connecting piece. The flexible retaining element is loadable by pulling and adapted to be guided through the roof covering without altering a position or shape of the individual roof covering elements. 
     Despite the existence of such mounting fixtures, further enhancements may be desirable in some applications. 
     SUMMARY 
     A system is provided for mounting at least one solar panel on a roof having standing seams protruding outwardly therefrom. The system may include a plurality of panel mounting brackets each comprising first and second flanges laterally spaced apart to define a seam channel therebetween, with the seam channel for receiving a given standing seam therein when the first and second flanges are positioned on the roof straddling the given standing seam. Each panel mounting bracket may also include a vertical extension portion carried by the first and second flanges. The system may further include a plurality of clamps each configured to couple the vertical extension portion of a respective panel mounting bracket with the at least one solar panel. 
     More particularly, the seam channel may extend vertically into the vertical extension portion. Moreover, at least one adjustable locking mechanism may be carried by the vertical extension portion for contacting the given standing seam within the seam channel. For example, the at least one adjustable locking mechanism may comprise at least one set screw. In accordance with another example, at least one locking mechanism may be carried by the first flange for contacting the given standing seam within the seam channel (e.g., a locking cam(s)). 
     In some configurations, the at least one solar panel may comprises a pair of solar panels, and at least one of the clamps may be configured to couple the pair of solar panels to a same vertical extension portion. Each vertical extension portion may define a fastener channel therein, and the system may further include a respective fastener to be received within each fastener channel to couple each vertical extension portion with a respective clamp. The vertical extension portion may have one or more hollow channels therein. In addition, the vertical extension portion may be coupled to upper surfaces of the first and second flanges, and the system may further include a respective pad coupled to bottom surfaces of each of the first and second flanges opposite the upper surfaces. 
     A related panel mounting bracket, such as the one described briefly above, as well as a related method for mounting at least one solar panel on a roof having standing seams protruding outwardly therefrom, are also provided. The method may include positioning a plurality of panel mounting brackets on the roof overlapping the standing seams, with each panel mounting bracket including first and second flanges laterally spaced apart to define a seam channel therebetween. The seam channel may be for receiving a given standing seam therein when the first and second flanges are positioned on the roof straddling the given standing seam. Each panel mounting bracket may also include a vertical extension portion carried by the first and second flanges. The method may further include coupling the vertical extension portion of each panel mounting bracket with the at least one solar panel using a respective clamp. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an end view of a panel mounting bracket in according with an exemplary embodiment of the invention including a set screw locking mechanism. 
         FIG. 2  is an end view of a panel mounting bracket in according with an alternative embodiment of the invention including a cam bolt locking mechanism. 
         FIG. 3  is an end view of a panel mounting bracket in according with another alternative embodiment of the invention including a toothed locking cam mechanism. 
         FIGS. 4-6  are end views illustrating the installation of the brackets of  FIGS. 1-3 , respectively, on a metal standing seam rooftop. 
         FIG. 7  is a side view of a solar panel installation with an end-clamp using the bracket of  FIG. 1 . 
         FIG. 8  is a side view of a pair of panels installed with a mid-clamp using the bracket of  FIG. 1 . 
         FIG. 9  is a top view illustrating an example solar panel installation using the bracket of  FIG. 1 . 
         FIGS. 10-12  are bottom, side, and top views, respectively, of the mounting bracket of  FIG. 2 . 
         FIGS. 13-15  are perspective end, bottom, and cutaway end views, respectively, of the mounting bracket of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION 
     The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in different embodiments. 
     Referring initially to  FIGS. 1-6 , panel mounting brackets  30 ,  30 ′, and  30 ″ (which are each individually also referred to as a “foot” herein) for installing panels or modules, such as solar modules (e.g., photovoltaic or water heating modules), are first described. By way of background, solar modules or panels, particularly photovoltaic panels, are typically mounted to standing seam roofs  31 ,  31 ′,  31 ″ (e.g., standing seam metal roofs) with clamps that tighten against the seam  32 ,  32 ′,  32 ″ alone, but do not simultaneously rest on the flat portion of the metal roof. 
     The mounting brackets  30 ,  30 ′, and  30 ″ illustrated in  FIGS. 1 through 6  advantageously have first and second extensions or flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ which are set firmly against the flat portion of the seemed roof  31 ,  31 ′,  31 ″, so that a vertical extension portion  35 ,  35 ′,  35 ″ of the mounting brackets remains perpendicular to the roof without rotating or twisting or allowing the solar modules, when installed, to shift as with typical clamps that are only attached to the standing seam of the metal roof, as with the above-noted conventional clamps. The vertical extension portions  35 ,  35 ′,  35 ″ of the mounting brackets  30 ,  30 ′,  30 ″ are generally rectangular in the illustrated embodiments, and are centered between the first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ and extend upwardly therefrom. As such, the overall appearance of the mounting brackets  30 ,  30 ′,  30 ″ (from an end view) resembles an inverted “T”, but other shapes or profiles may also be used in different embodiments. 
     The first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ extend laterally outward away from the seam  32 ,  32 ′,  32 ″ to provide a foot or base to set on the flat portions of the roofs  31 ,  31 ′,  31 ″ when a gap or seam channel  36 ,  36 ′,  36 ″ between the first and second flanges is positioned over a respective seam. In this way, the mounting brackets  30 ,  30 ′,  30 ″ straddle the respective standing seam  32 ,  32 ′,  32 ″. In the illustrated example, the seam channels  36 ,  36 ′,  36 ″ extend vertically up into the vertical extension portions  35 ,  35 ′,  35 ″, but in some embodiments relatively thick first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ may be used so that the seam channels do not extend into the vertical extension members, if desired. 
     The mounting brackets  30 ,  30 ′,  30 ″ may further include one or more adjustable locking mechanisms to help secure the mounting bracket to a given standing seam  32 ,  32 ′,  32 ″. In the example shown in  FIGS. 1 ,  4 , and  7 - 8 , a pair of set screws  50  is carried by the vertical extension portion  35 , which may be screwed inwardly to contact the standing seam  32  and thereby provide an adjustable amount of tension for holding the mounting bracket  30  securely in place. While the set screws are only shown on one side of the vertical extension portion  35 , it should be noted that one or more screws  50  may also be used on the opposing side of the vertical extension portion as well (i.e., set screws may be used on both sides), if desired in some embodiments. Also, other number of screws  50  may also be used (e.g., a single screw or more than two screws). 
     In the example embodiments illustrated in  FIGS. 2-3 ,  5 - 6 , and  10 - 15 , the adjustable locking mechanism is a locking cam mechanism housed within one (or both) of the first and second flanges  33 ′,  34 ′;  33 ″,  34 ″. In the example of  FIGS. 2 ,  5 , and  10 - 12 , the locking cam mechanism illustratively includes a locking cam  51 ′ and a cam bolt  52 ′ for adjusting the locking cam. Similarly, in  FIGS. 3 ,  6 , and  13 - 15 , a toothed locking cam  51 ″ and cam handle  52 ″ are used. It should be noted that both locking cams and set screws (or other suitable locking mechanisms) may be used in some embodiments in combination. Moreover, in other embodiments, a locking mechanism may not be required, for example, if the seam channel  36 ,  36 ′,  36 ″ is sized to fit snug, or interlock, with the respective standing seam  32 ,  32 ′,  32 ″. 
     Generally speaking, the vertical height of the seam channels  36 ,  36 ′,  36 ″ may generally correspond with a height of the standing seams  32 ,  32 ′,  32 ″ on the given roof  31 ,  31 ′,  31 ″ where the installation is being performed, as will be appreciated by those skilled in the art. By way of example, this may typically be around one inch tall or less, although taller seam channels  36 ,  36 ′,  36 ″ may be used to accommodate taller seams  32 ,  32 ′,  32 ″ in different embodiments. In one example implementation, the bracket  30 ,  30 ′,  30 ″ may have an overall vertical height of about 3 inches, a width of about 3.375 inches, and the vertical extension portion  35 ,  35 ′,  35 ″ may have a width of about 0.875 inches, although these dimensions are merely exemplary and other dimensions and brackets sizes may be used in different embodiments. 
     In the illustrated examples, the vertical extension portions  35 ,  35 ′,  35 ″ have a respective central portions with a hollow central area or channel  37 ,  37 ′,  37 ″ therethrough defined by upper and lower cross-support members  38 ,  38 ′,  38 ″, and  39 ,  39 ′,  39 ″ for example. The central channel  37 ,  37 ′,  37 ″ may be used for routing electrical wires, etc., in some embodiments, if desired, although it should be noted that the central channel may be omitted in some embodiments (i.e., it need not be hollow), or that more than one such channel may be used, if desired. 
     The vertical extension portions  35 ,  35 ′,  35 ″ have an upper slot or groove  40 ,  40 ′,  40 ″ for attaching a fastener such as a bolt (e.g., a hex head bolt)  41  and/or nuts (as seen in  FIGS. 7-8 ) is provided on the tops thereof. As noted above, the first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ at the bottom of the mounting brackets  30 ,  30 ′, and  30 ″ extend outwardly away from the vertical extension portions  35 ,  35 ′,  35 ″ so as to sit flat on the rooftop  31 ,  31 ′,  31 ″ or roof deck upon installation. Serrations or other surface features may optionally be included on the tops and/or bottom surfaces of the first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″, and/or on tops of the vertical extension portions  35 ,  35 ′,  35 ″, if desired. The serrations may advantageously provide for improved electrical grounding with the frame of the module, as well as increased grip or friction, for example. Pads  42 ,  42 ′,  42 ″ of rubber or other insulating material may optionally be included on the bottoms of the first and second flanges  33 ,  34 ;  33 ′,  34 ′;  33 ″,  34 ″ to protect the standing seam metal roof from being damaged by the flanges, if desired. 
     In the example illustrated in  FIGS. 7-9 , the mounting brackets  30  are coupled with solar modules  45  via the bolts  41 , which screw downward through respective end and mid clamps  43 ,  44  into nuts (not shown) located in the top rails or fastener channels  40 , as seen in  FIGS. 7 and 8 , for example. A first row of panels  45  may then be attached on the roof  31  by clamping to the existing standing seams  32  on standing seam metal roofs (as shown in  FIGS. 4-6 ) for the mounting brackets  30 . Again, an end-clamp  43  may be used as demonstrated in  FIG. 7 . A next row of modules may then be attached with additional mounting brackets  30  on the bottom of the second row modules with a mid-clamp  44 , as shown in  FIG. 8 . It should be noted that different mounting brackets  30 ,  30 ′, and  30 ″ may be used during an installation, that this, not all of the same type of mounting bracket need by used in a given installation, but rather they may be intermixed. In the illustrated example, the end clamp  43  generally resembles stair steps, and the mid clamp  44  generally resembles a “U” shape with outwardly extending flanges or arms, as shown, but other suitable clamp types and shapes may be used in different embodiments. 
     The above steps may be repeated for each row of modules  45  to be installed, until the last row of modules is in place. The last module  45  of each row may be attached to the mounting brackets  30  using end-clamps  43 , as discussed above, or attached directly to the panels with a nut and bolt into the pre-existing manufacturer&#39;s mounting holes. 
     It should be noted that different shapes of the vertical extension portions  35 ,  35 ′,  35 ″ beside a rectangular shape may also be used in some embodiments. By way of example, the mounting brackets  30 ,  30 ′, and  30 ″ may be formed out of a metal, such as by extruding aluminum into a beam having the illustrated cross section, and cutting the beam up into desired lengths (e.g., 3-6 inches, although other lengths may be used in different embodiments). However, other suitable materials may also be used in different embodiments (e.g., plastic, etc.). Moreover, the mounting brackets  30 ,  30 ′,  30 ″ need not be formed as an integral unit or unitary body (e.g., by extrusion), as the various components thereof may be separately formed and connected together in some embodiments. The various locking mechanisms described above may also be made of metal components, such as stainless steel, aluminum, etc. It should also be noted that the above-described mounting brackets  30 ,  30 ′,  30 ″ may be used with a variety of standing seam profiles. 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.