Abstract:
Disclosed is an apparatus for mounting solar panels and other rooftop objects to a shingle roof or other roof structures. The apparatus includes a panel-mount and a base-plate. The base-plate is securable to the roof structures. The panel-mount can be secured to the base-plate and intermediary flashing plate. The panel-mount includes vertical sidewalls adapted to receive and hold wires, and panel-mount top surface adapted to seat solar panels. In one aspect, the panel-mount top surface includes an alignment projection adapted to align solar panels in one of two orthogonal directions. Grounding pins are arranged in a square pattern and aligned with the corners of the alignment projection in order to assure that the solar panel frame will make contact with at least two of the grounding pins in either of the two possible alignments.

Description:
BACKGROUND 
     The present disclosure relates to an apparatus for mounting solar panels and other roof top equipment to a roof. For the purpose of this disclosure the term solar panel refers to devices that collect energy from the sun, for example, a solar photovoltaic (PV) panel or solar hot water heater panel. 
     Typically, solar panels can be mounted to shingle, metal, or tile roofs using a mounting system that includes rails for supporting one or more solar panels and brackets for holding solar panels to the roof. The mounting systems are often coupled with flashing plates or other water proofing provisions for preventing water from penetrating the roof sheeting. 
     Using rails for mounting solar panels requires the cost of purchasing and transporting the rails as well as the labor cost of installing and cutting the rails on site. In addition, long lengths or rails are susceptible to thermal expansion and contraction. For example, a 100 ft. (30.48 m) length of aluminum rail can expand or contract 1.5 in (0.038 m) over a seasonal variation of 100 F (54.5 C) typical in many regions of the world. This may cause damage to the solar panel-mounting system including buckling of components and detachment of mounting bolts. 
     SUMMARY 
     The present disclosure overcomes the problems described in the Background section associated with rails, by providing a rail-less solar panel-mounting system. The rail-less solar panel-mounting system includes a panel-mount and a base-plate. The panel-mount includes a panel-mount top surface, two vertical sidewalls, and a panel-mount base. The base-plate is secured to the roof by threaded fasteners and can be covered by a cavity formed by a raised portion of a flashing plate. The panel-mount is secured to the base-plate through the flashing-plate. The panel-mount top surface is substantially planar in order to flatly mount one or more solar panels. The solar panels are secured to the panel-mount top surface by either a solar panel end-clamp or mid-clamp in combination with a machine-threaded fastener. 
     The vertical sidewalls include wire-mounting portions. The space between the vertical sidewalls defines a hollow cavity that can route or dress wire. The wire-mounting portions include a cavity formed inward from the outer surface of the vertical sidewalls and an opening on the outer surface of the vertical sidewall. The height of the opening is smaller than the height of the cavity. In one aspect, the profile of the combination of the cavity and the opening form an arcuate in shape or alternatively a portion of a circular or elliptical cross section. In another aspect, the cavity includes rounded projections, and at least two of the rounded projections on opposing surfaces of the cavity. The rounded projections run along the front to back length of the cavity. Each wire-mounting portion can be designed to hold a specific gauge of insulated wire. The height of the cavity is approximately the same width as the wire&#39;s cross-section. The height of the opening is slightly smaller than the wire&#39;s cross-section so as to compress the insulation jacket of the wire as it is passed into the cavity. This arrangement holds the wire securely in the cavity. The optional rounded projections act to compress the insulation once the wire is in the cavity in order to further hold the wire in place. 
     In one aspect, the base-plate includes threaded standoffs, positioned on opposing sides of base-plate. The threaded standoffs project upward from the base-plate. The base-plate includes grooves encircling each of the threaded standoffs. Each groove receives and seats an elastomeric washer. The base-plate includes a pair of apertures orthogonally positioned in relationship to the threaded standoffs. The position maximizes the mounting strength of the base-plate against forces applied to the panel-mount. A recess encircles the base-plate apertures. The base-plate apertures are sized to receive and pass a threaded fastener for securing the base-plate to the roof. The recess is sized to receive and seat the head of the threaded fastener. 
     The panel-mount base includes apertures. The panel-mount base apertures are sized to receive a corresponding threaded standoff through a corresponding aperture in raised portion of the flashing plate. Nuts engage the threaded standoff and secure the panel-mount to the base-plate. When the nuts are tightened to the threaded standoff and the elastomeric washer creates a watertight seal under the aperture in the flashing plate. 
     In another aspect, the base-plate, instead of the thread standoff includes a hollow projection, projecting upward from the base-plate. The hollow projection is threaded on its exterior surface. The apertures in flashing plate and the panel-mount base are sized to receive the hollow projection. A hollow cap with interior threading engages the hollow projection and secures the panel-mount and flashing to the base-plate. The aperture of the hollow projection is sized to receive and pass through the body of a threaded fastener and seat the head of the threaded fastener. The threaded fastener secures the base-plate to the roof. 
     In another aspect, the panel-mount top surface is approximately planar so as to receive and seat the bottom surface of the solar panel. The panel-mount top surface includes an alignment projection. The alignment projection is approximately centered on the panel-mount top surface. The top surface of the alignment projection can be square or rectangular shaped. Grounding pins can be arranged so at least one grounding pin is placed in each of four regions bound by lines extending outward from and parallel to adjacent sides of the alignment projection and by the edges of the panel-mount top surface. For example, the grounding pins can be placed in a square pattern and aligned with the corners of the alignment projection. The rectangular shape of the alignment projection allows for two possible orthogonally opposed alignments of the solar panels. The rectangular shape of the alignment projection in combination with the specific arrangement of the grounding pins ensures that the solar panel will make contact with at least two of the grounding pins in either of the two possible alignments. 
     This Summary has introduced a selection of concepts in simplified form that will be later described the Description. The Summary is not intended to identify essential features or limit the scope of the claimed subject matter. 
    
    
     
       DRAWINGS 
         FIG. 1  shows a rail-less solar panel-mounting system. 
         FIG. 2  shows a front view of  FIG. 1 . 
         FIG. 3  shows a detailed view of a portion of  FIG. 2  showing the panel-mount and an end-clamp. 
         FIG. 4  shows a detailed view of a portion of  FIG. 2  showing the panel-mount and a mid-clamp. 
         FIG. 5  shows, in front perspective view, a detailed view of a portion of  FIG. 1 . 
         FIG. 6  shows, a front perspective exploded view of the solar panel-mounting apparatus. 
         FIG. 7  shows, a top plan view of the solar panel-mounting apparatus. 
         FIG. 8  shows a top view of panel-mount in relationship to solar panels mounted in the first of two directions. 
         FIG. 9  shows a top view of the panel-mount in relationship to solar panels mounted in the second of two directions. 
         FIG. 10  shows a top view of the panel-mount showing the grounding pin mounting regions. 
         FIG. 11  shows, a sectional view of  FIG. 7 . 
         FIG. 12  shows, in perspective view, the panel-mount portion of the solar panel-mounting apparatus. 
         FIG. 13  shows a front view of  FIG. 12 . 
         FIG. 14  shows a detailed view of a portion of  FIG. 13 . 
         FIG. 15  shows a portion of the rail-less solar panel-mounting system with an alternative base and fastening system, coupled to an end-clamp. 
         FIG. 16  shows a portion of the rail-less solar panel-mounting system with an alternative base and fastening system, coupled to a mid-clamp. 
         FIG. 17  shows an exploded perspective view of the rail-less solar panel-mounting system of  FIG. 15 . 
         FIG. 18  shows a top view of the rail-less solar panel-mounting system of  FIG. 15 . 
         FIG. 19  shows a sectional view of  FIG. 18 . 
         FIG. 20  shows a perspective view of the rail-less solar panel-mounting system of  FIG. 15  showing electrical wires secured by the built-in wire channels. 
         FIG. 21  shows a top plan view of the rail-less solar panel-mounting system of  FIG. 5  showing electrical wires secured by an alternative wire-mounting clamp. 
         FIG. 22  shows side view of  FIG. 21 . 
         FIG. 23  shows a front perspective view of the alternative wire-mounting clamp of  FIG. 21 . 
     
    
    
     DESCRIPTION 
     The terms “left”, “right”, “front”, “back”, and “side” are relative terms used throughout the disclosure to aid in the understanding of the figures. Unless otherwise indicated, these terms are not used to denote absolute direction, or orientation. They are not meant to imply a particular preference or limitation for a particular orientation or direction. 
     The following description is made with reference to figures, where like numerals refer to like elements throughout the several views,  FIG. 1  shows a solar panel-mounting system  10  that does not require rails.  FIG. 2  shows a front view of  FIG. 1 .  FIG. 3  shows a detailed view of a portion of  FIG. 2  showing a panel-mount  11  and an end-clamp  12 .  FIG. 4  shows a detailed view of a portion of  FIG. 2  showing the panel-mount  11  and a mid-clamp  13 .  FIG. 5  shows, in front perspective view, a detailed view of a portion of  FIG. 1 . 
     Referring to  FIGS. 1-5 , solar panel-mounting system  10  includes the panel-mount  11 , one or more solar panels  14 , and a flashing plate  15 . In  FIGS. 1-3 , and  5 , the solar panels  14  can be secured to the panel-mounts  11  by the end-clamp  12  or in  FIGS. 1-2 , and  4  by mid-clamps  13 . In  FIGS. 2-5 , the panel-mount  11  is secured to the flashing plate  15  by a threaded standoff  16  or stud and a nut  17 . 
     In  FIG. 6 , which is an exploded view of the solar panel-mounting system  10 , the threaded standoff  16 , is integral to a base-plate  18 . The threaded standoff can be integrally attached, for example, swedged into the base-plate  18 , or alternatively can be integrally formed into the base-plate  18 . The nuts  17  secure the panel-mount  11  to the threaded standoffs  16  through apertures  19  in the flashing plate  15  and panel-mount base  20 . The aperture  19  in the panel-mount base  20  is shown as a slotted aperture however, this can also be a round aperture. 
     One of the challenges in flashing plate based solar panel-mounting systems is to prevent water damage to the roof caused by leaks in the mounting structure. Often waterproofing comes at the cost of simplicity of design. The solar panel-mounting system  10  disclosed solves the problem of waterproofing but still maintains simplicity of design. The base-plate  18  includes grooves  21  encircling each of the threaded standoffs  16 . Each groove  21  receives and seats an elastomeric washer  22 . When the nut  17  is tightened to the threaded standoff  16  the elastomeric washer  22  creates a watertight seal under the aperture  19  in the flashing plate  15 . The base-plate  18  is secured to the roof by threaded fasteners  23 . The threaded fasteners  23  shown in  FIG. 6  are lag bolts as this can secure the base to a truss rafter in a shingle roof. Alternatively, the threaded fasteners  23  can be wood screws or other types of threaded fasteners, as appropriate, depending on the roof type. The base-plate  18 , as illustrated, includes an aperture  19  for receiving and passing through the threaded fastener  23  and a recess  24  encircling the aperture  19 ; the recess  24  is sized to receive and seat the head of the threaded fastener  23 . The pair of threaded fasteners  23  is shown positioned on opposing sides of the base-plate  18 . The pair of threaded standoffs  16  is shown in a position on the base-plate  18  that is orthogonally opposed to the threaded fasteners  23 . The position maximizes the mounting strength of the base-plate  18  against forces applied to the panel-mount  11 . In addition, since the base-plate is protected from water infiltration by the elastomeric washers  22  surrounding the threaded standoffs  16 , it is not necessary to water seal the threaded fasteners  23 . 
     The panel-mount top surface  25  shown in  FIG. 6  is approximately planar so as to receive and seat the bottom surface of the solar panels  14  of  FIGS. 2-5 . In  FIGS. 6-7 , the panel-mount top surface  25  includes an alignment projection  26 . The alignment projection  26  is shown centered on the panel-mount top surface  25 . The top surface of the alignment projection  26  is shown as square shaped. Grounding pins  27  are shown arranged in a square pattern and aligned with the corners of the alignment projection  26 . This square shape of the alignment projection  26  allows for two possible orthogonally opposed alignments of the solar panels  14 . The square shape of the alignment projection  26  in combination with the specific arrangement of the grounding pins  27  ensures that the solar panel  14  will make contact with at least two of the grounding pins  27  in either of the two possible alignments.  FIG. 6  also shows the end-clamp  12  and a machine-thread fastener  28 . The machine thread fastener secures the end-clamp  12  to the panel-mount top surface  25  by engaging a threaded aperture  29  centered in the top surface of the alignment projection  26 . 
       FIGS. 8-9 , shows, in top view, the solar panels  14  in each of the two possible alignments in relationship to the panel-mount top surface  25 . The grounding pins  27  and a portion of the panel-mount top surface  25  are hidden under the solar panel and are represented by broken lines. The alignment projection  26  shown is rectangular in shape. The alignment projection  26  and panel-mount top surface  25  are sized so that the solar panel metal frame  30  is supported by the panel-mount top surface. 
     In  FIGS. 8-9 , the grounding pins  27  are shown forming an approximately square pattern and aligned with the vertices of the alignment projection  26 . In general, in order for at least two of the grounding pins  27  to electrically contact with each of the solar panel metal frames  30 , in either of the two possible alignments allowed by the alignment projection  26 , at least one of the grounding pin  27  must be placed in each of four grounding pin placement regions  31  on the panel-mount top surface  25  as shown for the panel-mount  11  in  FIG. 10 . Each of the grounding pin placement regions  31  is defined as a region bound by lines extending outward from and parallel to adjacent sides of the alignment projection  26 , and by the edges of the panel-mount top surface  25 . This is illustrated in  FIG. 10  by cross-hatching. 
       FIG. 11  shows, a sectional view of  FIG. 7 . One of the threaded fasteners  23  is visible in the view and shown securing the base-plate  18  to the wood sheeting  32  and the truss joist  33  of the roof structure. A raised portion  34  of the flashing plate  15  creates a cavity for mounting the base-plate  18  and also serves to deflect water. 
       FIG. 12  shows, in perspective view, the panel-mount  11 .  FIG. 13  shows a front view of panel-mount  11 .  FIGS. 12-13  show the grounding pins  27  and alignment projection  26  in relation to the panel-mount top surface  25 . One of the problems with solar panel-mounting systems is how to dress and route the electrical wires. In order to address this problem, the panel-mount  11  includes wire-mounting portions  35  on the vertical sidewalls  36  of panel-mount  11 . The wire-mounting portions  35  are shaped to receive and hold electrical wires. The wire-mounting portions  35  are shown having a partial circular profile where the groove opening is narrower than the diameter of the circular cross-section. This allows wires that are approximately the diameter of the circular profile, and that have a flexible insulation jacket, to be pressed in the opening and stay captive.  FIG. 13  shows a hollow cavity  37  that is defined by the space between the vertical sidewalls  36 , below the panel-mount top surface  25 , and above the panel-mount base  20 . Wires that are secured to the wire-mounting portions  35  can be bent and routed through the opening or excess wire can be dressed or bundled in the opening. 
       FIG. 14  shows a detailed view  38  of a wire-mounting portion  35  of  FIG. 13 . The wire-mounting portion  35  is shown with rounded projections  39 , each along the length of the wire-mounting portion  35 . The rounded projections  39  are so called because they include a smooth or rounded upper surface that does not pierce the insulation of the wiring. The rounded projections  39  compress the flexible insulation jacket of the wiring. This helps to further hold the wiring in place. While a circular profile is shown, other arcuate profiles can be used as long as either the groove opening is smaller than the cavity or if the groove opening is not smaller than the cavity than the cavity wall includes rounded projections  39  on opposing cavity walls portions. 
       FIG. 15  shows a portion of the solar panel-mounting system  10  that includes an alternative base and fastening system showing the solar panel  14  coupled to the end-clamp  12 .  FIG. 16  shows a portion of the solar panel-mounting system  10  with an alternative base and fastening system, showing the solar panels  14  coupled to the mid-clamp  13 .  FIG. 17  shows an exploded perspective view of the solar panel-mounting system  10  of  FIG. 15 .  FIG. 18  shows a top view of the solar panel-mounting system  10  of  FIG. 15  including the panel-mount top surface  25 , panel-mount base  20 , the alignment projection  26 , and the position of the grounding pins  27  in relation to the alignment projection  26 , as previously described.  FIG. 18  also shows hollow caps  40 .  FIG. 19  shows a sectional view of  FIG. 18 . In  FIGS. 15-16 , the hollow cap  40  helps to secure the panel-mount  11  the raised portion  34  of the flashing plate  15 . In  FIGS. 17 and 19 , the hollow cap  40  engages a hollow projection  41  extending upward from the surface of the base-plate  18 . The interior of the hollow cap  40  and the exterior of the hollow projection  41  have complementary threading allowing the hollow cap  40  and the hollow projection  41  to be removably secured. 
     Referring to  FIG. 17 , the aperture  19  in the hollow projection is wide enough to pass the body of the threaded fastener  23  but narrow enough to leave a shoulder for seating the head of the threaded fastener  23 . The apertures  19  in both the raised portion  34  of the flashing plate  15  and the panel-mount base  20  of the panel-mount  11  are wide enough to pass the hollow projections  41  but narrower than the exterior of the hollow cap  40 . The base-plate  18  includes grooves  21  encircling each of the hollow projections  41 . Each groove  21  receives and seats an elastomeric washer  22 . When the hollow cap  40  is tightened to the hollow projection  41 , the elastomeric washer  22  creates a watertight seal under the aperture  19  in the flashing plate  15 . In  FIG. 19 , the threaded fastener  23  engages the wood sheeting  32  and the truss joist  33  to secure the base-plate  18  to the roof. 
       FIG. 20  shows a perspective view of the solar panel-mounting system  10  of  FIG. 15  showing electrical wiring  42  secured by the built-in wire channels in one of the vertical sidewalls  36  of the panel-mount  11 . While  FIG. 20  shows the panel-mount  11  in combination with the hollow caps  40 , the wires are engaged in an equivalent manner in the panel-mount  11  of  FIGS. 2-8 . 
       FIG. 21  shows a top plan view of the solar panel-mounting system  10 , and  FIG. 22  a side view of  FIG. 21 , showing electrical wiring  42  secured by an alternative wire-mounting clamp in the form of a wire-mounting bracket  43 . The wire-mounting bracket  43  is secured to the panel-mount base  20  by the threaded standoff  16  and the nut  17 . The nut  17  shown is a shoulder nut. However a regular nut and washer in combination can be used. Similarly, the wire-mounting bracket can be secured to the panel-mount base  20  by the hollow cap  40  and the hollow projection  41  of  FIGS. 17 and 19 . 
       FIG. 23  shows a perspective view of the wire-mounting bracket  43 . The wire-mounting bracket  43  includes an aperture  19  in wire-mounting bracket base portion  44 . Depending on the application, the aperture can be sized to receive the hollow projection  41  of  FIG. 17  or alternatively, the aperture can be large enough receive the threaded standoff of  FIG. 21  but small enough so that the wire-mounting bracket base portion  44  can seat the nut  17  of  FIG. 21 . In  FIG. 23 , the wire-mounting bracket  43  includes wire-holding portion  45  projecting upwardly and approximately perpendicular to that the wire-mounting bracket base portion  44 . The wire-holding portion  45  includes an upper wire-holding portion  46  with two arcuate sidewalls and a lower wire-holding portion  47  with substantially parallel sides. The lower wire-holding portion  47  includes rounded projections  39  extending along the front to back plane, i.e. longitudinally, along the lower wire-holding portion  47 . This arrangement allows smaller wires to be stacked in the lower wire-holding portion  47  and held securely by the rounded projections  39  while holding a larger wire in the upper wire-holding portion  46 . 
     An apparatus and method for mounting solar panels on roofs has been described. It is not the intent of this disclosure to limit the claimed invention to the examples, variations, and exemplary embodiments described in the specification. Those skilled in the art will recognize that variations will occur when embodying the claimed invention in specific implementations and environments. For example, it is possible to implement certain features described in separate embodiments in combination within a single embodiment. Similarly, it is possible to implement certain features described in single embodiments either separately or in combination in multiple embodiments. It is the intent of the inventor that these variations fall within the scope of the claimed invention. While the examples, exemplary embodiments, and variations are helpful to those skilled in the art in understanding the claimed invention, it should be understood that, the scope of the claimed invention is defined solely by the following claims and their equivalents.