Patent Publication Number: US-2013239495-A1

Title: Roofing Installation System

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not Applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT 
     Not Applicable. 
     FIELD OF THE INVENTION 
     This invention relates to a roofing system, and more particularly to a roofing installation system integrated with a gutter system. 
     DISCUSSION OF RELATED ART 
     Solar electric systems are the most environmentally friendly way of generating electricity for heating and other residential applications. Varieties of roofing installation systems for supporting solar energy collecting panels are available on the market. The existing roofing installation systems can be mechanically complicated. Most of the systems utilize metallic frames and mechanical fasteners for anchoring the solar panels to an existing roof structure. The existing systems may use a large number of penetrating mechanical fasteners on the roof deck, which can compromise the watertight integrity of the roof. Some conventional mounting systems cannot be installed on sloped roof structures. 
     U.S. Pat. No. 7,806,377 issued to Strizki on Oct. 5, 2010, discloses a modular solar panel mounting system. The mounting system for frameless solar panels is comprised of a plurality of base-mounting members and a plurality of mounting brackets. Each of the mounting brackets includes one or more elongated bars having a center portion, a flat top plane and a flat bottom plane. Each of the elongated bars includes slotted holes formed on either end of the elongated bars. The mounting brackets are fastened to the base mounting members through the slotted holes. The invention is designed to mount solar panels on the ground or on essentially flat rooftops by utilizing ground mounting pans as the base mounting members. However the mounting system is not designed to be installed on slanting roofs where proper drain channels have to be provided to drain out the rain water or water from melting snow. 
     In addition, U.S. Pat. No. 6,877,287 issued to Szacsvay on Apr. 12, 2005, discloses a device with flat, panel shaped components. The flat, panel shaped components may be photovoltaic elements. Adjacent rows of the flat, panel-shaped components are disposed below one another, overlapping in a shingle-like way, to form a covering for a roof or a facade. The flat, panel shaped components are preferably designed as photovoltaic elements. Disposed under the components in each case in the region between adjacently situated vertical rows is a section forming an open channel to receive and drain water running off adjacent components. The section has sawtooth-shaped lateral parts on which the components are borne in their shingle-like configuration. By means of the lateral parts, a clearly defined support for the components is formed. However the invention may not be suitable for supporting slates or photovoltaic elements of larger dimensions. 
     U. S. Pat. Application No. 20100236183 entitled to Cusson on Sep. 23, 2010, describes a support system for solar panels. The support system for solar panels or other panel-like structures are fabricated by maintaining precise parameters. Through use of a collapsible folding, support frame which is preassembled to precise tolerances at a convenient staging site before being collapsed for shipment. Installation on flat roofs is facilitated through the use of a roof interface frame which rotatably supports the panel support frame of the support system and folds along with it at the assembly, staging site. Even though the installation is simple and faster the drainage system of the invention may not be effective to drain away the rain water or snow melt. 
     Therefore, there is a need for a roofing installation system that is adaptable to various environments; can be easily configured to accommodate existing roof installations; can be applied to different types of roofing configurations, both flat and sloped. Also the roofing installation system should be aesthetically pleasing and able to support larger sized solar modules available on the market. Moreover, the roofing installation system should not compromise the watertight integrity of the existing roof. The present disclosure accomplishes all these objectives. 
     SUMMARY OF THE INVENTION 
     The present invention is a roofing installation system for supporting solar electric modules. The roofing installation system comprises a plurality of metal battens mounted horizontally onto a plurality of parallel wooden battens, which are mounted vertically over a slope roof. A plurality of link channel brackets having a plurality of hooks is fastened vertically between a pair of the plurality of metal battens using a latch. A plurality of slate modules is mounted on the plurality of metal battens. The plurality of slate modules are the solar electric modules, which generates direct current electricity when exposed to sunlight. Each slate module is made to slide through the plurality of link channel brackets till a bottom portion of the slate module fits into the plurality of hooks. 
     An adjacent pair of slate modules is placed on the both edges of the each of the plurality of link channel brackets, leaving a central grooved portion. This central grooved portion may act as a drainage channel for the water falling on the slate modules. The plurality of metal battens may have ridges provided on the surface. The ridges may engage with a right angled protruded portion at a top end of each of the plurality of plurality of link channel brackets which holds the plurality of link channel brackets in position. Any of the slate modules can be removed by swinging the plurality of hooks towards the centre of the link channel bracket. A flange, which is protruding from the bottom side of the link channel bracket, may act as a location guide when placing the plurality of link channel brackets. The installation procedure of the roofing installation system should start at the bottom of the slope roof. 
     The present invention provides a roofing installation system for supporting solar electric modules over a slope roof. The roofing installation system includes a plurality of metal battens which is attached to a plurality of parallel wooden battens to form a frame. Such a roofing installation system utilizes sunlight for generating electricity effectively without compromising with the watertight integrity of the roof structure. Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a roofing installation system in accordance with a preferred embodiment of the present invention; 
         FIG. 2  is a perspective view of a metal batten of the roofing installation system; 
         FIG. 3  is a perspective view of a link channel bracket with a plurality of hooks of the roofing installation system; 
         FIG. 4  is an operational flow chart of the method for installing the roofing installation system in accordance with the preferred embodiment of the present invention; 
         FIG. 5  is a perspective view of a roofing installation system in accordance with an alternative embodiment of the present invention; 
         FIG. 6  illustrates a top view of the roofing installation system in accordance with an alternative embodiment of the present invention; and 
         FIG. 7  is a perspective view of a metal gutter of the roofing installation system in accordance with an alternative embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  is a perspective view of a roofing installation system  10  for supporting solar electric modules. The roofing installation system  10  comprises a plurality of metal battens  12  placed parallel to each other. The plurality of metal battens  12  are mounted horizontally onto a plurality of parallel wooden battens  14 , which are mounted vertically over a slope roof. A plurality of link channel brackets  16  having a plurality of hooks  18  is fastened vertically between a pair of the plurality of metal battens  12  using a latch (not shown). A plurality of slate modules  20  is mounted on the plurality of metal battens  12 . The plurality of slate modules  20  are the solar electric modules, which generates direct current electricity when exposed to sunlight. Each of the plurality of slate modules  20  is made to slide through the plurality of link channel brackets  16  so that a bottom portion of the slate module  20  fits into the plurality of hooks  18 . 
     The plurality of link channel brackets  16  are the main support for the slate modules  20 . Each of the plurality of link channel brackets  16  supports the sides of two adjacent slate modules  20 . The plurality of ink channel brackets  16  provides support all along the slate modules  20 . A firm support to the slate modules  20  makes the roof walkable. An adjacent pair of the slate modules  20  is placed on the two edges of the plurality of link channel brackets  16 , leaving a central grooved portion. This central grooved portion may act as a drainage channel for the water falling on the slate modules  20 . The wooden brackets  14  provided on the roof may act as a means of support to the metal battens  12  and to the whole slate module  20  structure. The wooden battens  14  provide electrical insulation to the slate modules  20  from the underlying roof structure. They may be laminated with a regular junction box (not shown). These are electrically connected to form a string. These slate modules  20  generate direct current and the output of the string is connected to an inverter (not shown). The inverter (not shown) converts the generated direct current to alternating current, which can be directly utilized for consumer applications or a user can feed the electricity to a utility grid. 
       FIG. 2  is a perspective view of the metal batten  12  which may be attached to the wooden battens  14  for supporting the slate modules  20 . The metal batten  12  is provided with a plurality of ridges  22 . The metal battens  12  are placed horizontally over the plurality of wooden battens  14 . The wooden battens  14  provide insulation and support to the horizontal metal battens  12  arranged over the wooden battens  14 . The metal battens  12  may have ridges or folding  22  provided on the surface. The ridges  22  may engage with a right angled protruded portion (not shown) at a top end of the plurality of link channel brackets  16 . These ridges  22  on the metal batten  12  holds the plurality of link channel brackets  16  and prevent the plurality of link channel brackets  16  from sliding down. 
       FIG. 3  is a perspective view of the plurality of link channel brackets  16  with the plurality of hooks  18  attached to the plurality of link channel brackets  16 . The plurality of link channel brackets  16  is provided with a central drain channel  24 . Water falling on the adjacent slate modules  20  are drained through the drain channel  24  provided on the plurality of link channel brackets  16 . The plurality of hooks  18  are attached to the bottom end  28  of each of the plurality of link channel brackets  16 . The plurality of hooks  18  may be made of stainless steel. The plurality of hooks  18  hold each of the slate modules  20  supported on the plurality of link channel brackets  16 , and prevent the slate modules  20  from sliding down. The plurality of hooks  18  extends approximately ¼″ from the bottom end  28  of the plurality of link channel brackets  16 . In case of maintenance, any of the slate modules  20  can be removed without disturbing the position and alignment of adjacent slate modules  20 . An operator can swing the hook  18  towards the centre of the plurality of link channel brackets  16 , to release the fixed slate module  20 . Moving the hook  18  towards the centre of the plurality of link channel brackets  16  will not disengage the hook  18  from the plurality of link channel brackets  16 . A flange  26 , which is protruding from the bottom side of the plurality of link channel brackets  16 , is provided. The flange  26  may act as a location guide when placing the plurality of link channel brackets  16 . In order to place the slate module  20 , it is slided onto the plurality of link channel brackets  16  and the bottom of the module onto the plurality of hooks  18  of the plurality of link channel brackets  16 . The metal batten  12  has a right angle that enable the plurality of link channel brackets  16  to secure very firmly between the metal battens  12 . The installation procedure should start at the bottom of the slope roof. A top hook blocks the top slate module  20  and a top ridge cover the top edge of the slope roof. 
     Referring to  FIG. 4 , an operational flow chart of the method for installing the roofing installation system  10  in accordance with the preferred embodiment of the present invention is illustrated. The method initiates by mounting a plurality of metal battens horizontally onto a plurality of wooden battens that is mounted vertically across a roof as indicated at block  30 . A plurality of link channel brackets having a hook between a pair of the plurality of metal battens is securely fastened using a latch as shown in block  32 . A plurality of gutters having a rubber extruded rubber horse shoe/U ring on both bended sides is mounted vertically onto the plurality of metal battens as indicated at block  34 . The plurality of slate modules is slided through the rubber extruded rubber horse shoe/U ring so that a bottom portion of the slate module fits onto the hook as shown in block  36 . Then the plurality of slate modules is electrically connected in series to form a string as shown in block  38 . Finally as shown in block  40 , an inverter is connected to each string for converting the DC electricity from the plurality of slate modules to AC electricity. 
       FIG. 5  is a perspective view of a roofing installation system  50  for supporting solar panel modules  52  in accordance with an alternate embodiment of the present invention. The roofing installation system  50  comprises a plurality of solar electric modules  52 , a plurality of horizontal wooden battens  54  supported over a plurality of vertical wooden battens  56 . A plurality of metal gutters  58  is attached to the plurality of horizontal wooden battens  54 . A plurality of hooks  60  are attached to the plurality of horizontal wooden battens  54 . The alternate embodiment of the invention roofing installation system  50  is particularly useful for supporting solar electric modules  52  of larger dimensions. 
       FIG. 6  shows a top view of the roofing installation system  50  in accordance with the alternative embodiment of the present invention. The plurality of horizontal wooden battens  54  and the plurality of metal gutters  58  are positioned depending upon the dimensions of the solar electric modules  52 . The plurality of hooks  60  of the roofing installation system  50  may be a metallic rod made of cast stainless steel. One end of each of the plurality of hooks  60  is provided with a plurality of holes for attaching the plurality of hooks  60  to the horizontal wooden battens  54  utilizing any fastening means preferably screwing or nailing the plurality of hooks  60  to the horizontal wooden battens  54 . The plurality of hooks  60  have a U shaped portion at a bottom end for holding the solar electric modules  52  and thereby preventing it from sliding down. The plurality of metal gutters  58  are provided on both sides of the solar electric module  52  for support. The metal gutters  58  also acts as a drainage channel for draining off the water falling on the roof. The installation of the horizontal wooden battens  54  and the metal gutters  58  will not compromise with the water tight integrity of the roof. In order to keep the roof perfectly water proof, roofing felt of approximately  301 b is installed before installing the whole roofing installation system  50 . 
       FIG. 7  is a perspective view of the metal gutter  58  with a U shaped rubber covering  66 . The metal gutter  58  comprises a central vertically projected metallic portion  62  and a pair of U shaped sides  64 . The sides of the metal gutter  58  are bended to form a horseshoe/U shaped rubber covering  66 . Both the U shaped sides  64  of the metal gutter  58  are extruded with rubber. Each of these metal gutters  58  are mounted vertically on the plurality of battens  54 . Each of the solar electric modules  52  is slided through the rubber extruded U shaped sides  64 . The bottom portion of the solar electric module  52  fits onto the plurality of hooks  60 . The two U shaped sides  64  with the central vertically projected metallic portion  62  forms a drainage channel for draining off the water on the roof either due to rain or melting snow. Since the solar electric modules  52  are placed on the rubber extruded U shaped sides  64 , little amount of water will be leaked to the underlying roof structure. So the water tight integrity of the roof is not disturbed. 
     While a particular form of the invention has been illustrated and described, it will be apparent that various modifications can be made without departing from the spirit and scope of the invention. For example, the roofing installation system  10  may incorporate different types of non rusting materials for use as battens. The roofing installation system  10  may incorporate a prefabricated frame that can be set easily to support most of the existing, standard sized solar electric modules. Accordingly, it is not intended that the invention be limited, except as by the appended claims.