Patent Abstract:
An attachment system is provided. In another aspect, a latching assembly is mounted to a building roof. Another aspect employs a moveable latch that removeably attaches an auxiliary component, such as a solar panel, to a building in a single motion and/or snap-in installation manner.

Full Description:
BACKGROUND AND SUMMARY 
       [0001]    The present application relates generally to an attachment system and more particularly to a solar panel attachment system for a roof of a building. 
         [0002]    Conventional photovoltaic or solar panels are mounted to roofs of buildings through screw-in clips or the like. Examples of such conventional devices are disclosed in U.S. Patent Publication No. 2011/0088740 entitled “Photovoltaic Panel Clamp” which published to Mittan et al. on Apr. 21, 2011, and U.S. Pat. No. 6,672,018 entitled “Solar Module Mounting Method and Clip” which issued to Shingleton on Jan. 6, 2004, both of which are incorporated by reference herein. Such conventional methods cause the installer to juggle many loose fasteners while simultaneously holding heavy solar panels and/or roof mounting components, often on a tilted metal roof in unpleasant weather conditions. Furthermore, such traditional multi-piece screw or bolt arrangements take considerable time to install while also having inconsistent installation torque values, especially in the common situation where many of these solar panel mounting devices are required for each roof. 
         [0003]    In accordance with the present invention, an attachment system is provided. In another aspect, a latching assembly is mounted to a building roof. Another aspect employs a moveable latch that removeably attaches an auxiliary component, such as a solar panel, to a building in a single motion and/or snap-in installation manner. A method of installing a latch assembly is additionally provided. Furthermore, a method of manufacturing a latch assembly is disclosed. 
         [0004]    The present attachment system is advantagous over traditional devices. For example, in one aspect, a single motion installation is employed to engage an auxiliary roof component, such as a solar panel, for latch engagement without requiring tools. In an aspect of the present attachment system, an auxiliary roof component is quickly and easily secured to a building roof in a fast manner without requiring the installer to juggle multiple parts. In another aspect, a striker or protruding member is preassembled directly to a glass surface of a solar panel and a latch assembly is preassembled to a building roof via an easy to install roof clamp, prior to assembly of the solar panel to the latch assembly. Moreover, the auxiliary roof component can be easily detached from the latch assembly in an aspect of the present system. Another aspect allows for quick connect mounting of the auxiliary roof component to a latch assembly coupled to a tilted frame and/or by use of ballast on a horizontal surface. Another aspect of the present system is advantageous over conventional devices since this aspect uses lightweight and strong composite materials for various components of the attachment system. When installed, the latch assembly and roof clamp can optionally provide an electrical grounding path between the auxiliary roof component and the metal roof, or wires attached thereto. Additional advantageous and features of the present invention will become apparent in the following description and appended claims, taking in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0005]      FIG. 1  is a perspective view showing a first preferred embodiment attachment system securing solar panels to a building roof; 
           [0006]      FIG. 2  is an exploded perspective view showing the first preferred embodiment attachment system; 
           [0007]      FIG. 3  is a cross-sectional view, taken along line  3 - 3  of  FIG. 4 , showing the first preferred embodiment attachment system; 
           [0008]      FIG. 4  is a perspective view showing the first preferred embodiment attachment system; 
           [0009]      FIG. 5  is a partially fragmented perspective view showing the first preferred embodiment attachment system; 
           [0010]      FIG. 6  is a perspective view, generally opposite that of  FIG. 4 , showing the first preferred embodiment attachment system; 
           [0011]      FIG. 7  is a partially fragmented perspective view, like that of  FIG. 5 , showing the first preferred embodiment attachment system; 
           [0012]      FIG. 8  is a cross-sectional view, taken along line  8 - 8  of  FIG. 7 , showing the first preferred embodiment attachment system; 
           [0013]      FIG. 9  is a perspective view showing a second preferred embodiment attachment system; and 
           [0014]      FIG. 10  is a partially exploded perspective view showing a third preferred embodiment attachment system. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]      FIG. 1  illustrates a building  21  having a tilted roof  23 , preferably made from sheet metal sections joined together at folded over, raised standing seams  25 . Auxiliary roof components, preferably multiple solar panel assemblies  27 , are secured to seams  25  by way of multiple attachment systems  29 . Each attachment system  29  includes a roof clamp  31  and a latch assembly  33 . 
         [0016]      FIGS. 2 and 3  depict roof clamp  31  attached to seam  25  of roof  23 . Roof clamp  31  includes a saddle  41 , a roof seam-engaging wedge  43 , and an elongated shaft or securing member  45 . An optional part includes a retaining element  71 . Securing member  45  fits into and aligns saddle  41  with wedge  43  so that upon engaging securing member  45 , camming action of roof seam-engaging wedge  43  along saddle  41  secures roof clamp  31  to roof  23 . Notably the same securing member  45  that secures roof clamp  31  to roof  23  also secures an auxiliary-retaining device, such as latch assembly  33 , to roof  23  along a top surface of saddle  41 . 
         [0017]    Saddle  41  further includes a saddle bore  51 , two side walls  53 , and a camming surface  55  located on each side wall  53 . Saddle  41  has an inverted U-shape or a bifurcated yoke body. Furthermore, the saddle top surface serves as the region through which securing member  45  is advanced or retracted so that the roof seam is engaged. 
         [0018]    Saddle  41  defines a slot  61  which serves in part to engage seam  25  of roof  23  and also to serve as camming surface  55 . Slot  61  includes a substantially vertical access area and is adjacent camming surface  55  to facilitate trapping or clamping the roof seam in the roof clamp. 
         [0019]    Roof seam-engaging wedge  43  includes a wedge bore which allows securing member  45  to pass through wedge  43  and into saddle  41 . This operates to secure roof clamp  31  on the roof seam and to also secure latch assembly  33  using the single securing member  45  and a nut fastener  63  secured to an upper end thereof. Wedge  43  includes at least one angled surface  65  that mates with camming surface  55  so that when securing member  45  is pulled by tightening nut  63 , wedge angled surface  65  moves along camming surface  55  of saddle  41 . A polygonal head of securing member  45  is prevented from rotation by a matching recess in a bottom of wedge  43 . 
         [0020]    Retaining element  71  is disposed between an interior of saddle  41  and a top surface of wedge  43 . Protrusions on the inside of saddle  41  mate with retaining element  71 . This is either by a snap fit or interference fit to prevent retaining element  71  from becoming dislodged from saddle  41  prior to wedge  43  engaging the roof seam. In another construction, the retaining element can be replaced by a leaf spring secured to the saddle and/or wedge. 
         [0021]    Saddle  41 , roof seam-engaging wedge  43 , securing member  45 , and optionally retaining element  71 , are pre-assembled prior to placing roof clamp  31  in the proximity of roof seam. “Pre-assembled” for the clamp refers to the components being aligned such that securing member  45  keeps them attached together. This can be achieved either on the ground at the work site, at a remote site, or at the factory at which roof clamp  32  is manufactured. When wedge  43  is retracted to trap seam  25  between an inner foot of the wedge and the inner slot edge of saddle  41 , a portion of securing member  45  extends beyond the top surface of saddle  43  such that proximal threaded end of member  45  also provides an attachment point for latch assembly  33 . 
         [0022]    Referring now to  FIGS. 2-7 , latch assembly  33  includes a stamped metal bracket  101 , a spring steel insert  103  and a pair of latches  105  and  107 . Bracket  101  has a generally U-end view shape defined by a generally flat bottom or base wall  111  and a pair of spaced apart and upstanding side walls  113 . Multiple slots  117  are provided in each side wall  113  which are openly accessible adjacent a top edge  119  thereof. An aperture  121  is provided in bottom wall  111  of bracket  101  to receive the threaded end of securing member  45  for nut attachment thereto. 
         [0023]    Insert  103  is a stamped metal part including an outer ring  123  and a pair of tabs  125  diagonally projecting and biasing upwardly away from bottom wall  111  of bracket  101 . A generally horizontal turned flange  125  inwardly projects from each diagonal section of tab  123  within which is an internally slotted receptacle  127 . A central hole is also provided in insert  103  to receive member  45  therethrough. 
         [0024]    Latches  105  and  107  are in mirrored symmetry to each other and have a generally hook-like shape defined by a somewhat radially extending engagement surface  141 . A pivot pin  143  projects laterally from each side wall  145  of latches  105  and  107 . The ends of each pin  143  have peripheral grooves therein for a compression fit into the side wall or for receiving circlips external to the side walls, such that pin is rotatably journaled within side walls  113  of bracket  101  to allow pin  143  to rotate with each associated latch. Alternately, the pivot pin can be stationarily affixed to bracket such that each latch rotates about the pin. 
         [0025]    Furthermore, a central rib  147  extends from an internal ledge of each latch  105  and  107 , which is spaced apart from and between outer walls  145  in a generally parallel configuration. Alternately, each latch may be a single solid piece such that the peripheral surface continuously extends between walls  145  thereby subsuming central rib  147 . A peripheral camming surface  151  is provided on walls  145  and  147  such that each tab  123  acts as a cam follower by riding against and controlling motion of camming surface  151  for at least central wall  147 , and optionally outer walls  145 , of each latch. This camming action serves to urge each latch to either its unlatched position (as shown for latch  107 ) or its latched position (as shown for latch  105 ). The latches are preferably made by compressing sintered powder metal, but may alternately be cast metal which is thereafter machined. 
         [0026]    A striker arm  201  protrudes from each auxiliary roof component, preferably solar panel  27 , for engagement by latch assembly  33 . More specifically, each striker  201  includes a generally cylindrical rod  203  bordered by laterally enlarged and generally circular abutment stops  205  and  207 . A curved neck  209  ends with a generally flat pad  211  which is adhesively bonded directly to a bottom surface  213  of the glass solar panel with a suitable adhesive, such as that obtained from A. Raybond Sarl as Techbond™ brand polyurethane adhesive. Thus, an expensive and heavy peripheral frame is not required to mount the solar panels  27  to the building roof  23 . The strikers  201  are preferably made by compressing sintered powder metal in the present system, but may alternately be cast metal or extruded and then cold head compression formed for the pads. 
         [0027]    Each striker  201  is preassembled to the associated solar panel  27  either at the solar panel manufacturing plant or on the ground at the job site. Moreover, roof clamp  31  is preassembled onto the roof seam  25  and thereafter, latch assembly  33  is assembled to roof clamp  31  using a single securing member  45  in a top-only access manner. Subsequently, the solar panel assembly, including the preassembled striker  201 , is manually lowered by the installer through the associated slots  117  of bracket  101 . This single linear motion causes rod  203  of striker  201  to manually rotate latch  107  about pin  143  from its unlatched position to its latched position. In the latched position, a pawl  221  (see  FIGS. 3 and 8 ) protrudes into receptacle slot  127  of spring tab  123 , thereby providing a locking function to secure the latch in its latching position. Hence, rod  203  of striker  201  is trapped between latch engaging surface  141  and edges of the bracket side walls defining slots  117 . This is done in a quick connect or snap-in manner without requiring tools or threaded fastener engagement. 
         [0028]    When it is desired to service or remove solar panels  27 , the user can install an elongated tool, such as a flat bladed screw driver, within a gap  223  (see  FIG. 6 ) between solar panels  27 . The screw driver is then pushed against an extending end of tab  125  between latches  105  and  107 . This tab depression unlocks pawl  221  which allows the user to then manually pull up on the solar panel which, in turn, causes counter rotation of the associated latch toward its unlatched position. 
         [0029]      FIG. 9  illustrates another configuration of the latch assembly  301 . The bracket  101 , insert  103  (not shown), latches  105  and  107 , and strikers  201  are the same as the prior embodiment. However, an elongated rail  303  is employed instead of a roof clamp. The bracket and latches are secured within an upper section of rail  303  and upwardly accessible access slots are additionally provided in side walls of rail  303  to match those in bracket  101 . Rail  303  has a generally H-end view shape with a bottom flange  305  laterally extending therefrom. A polarity of holes  307  are located in flange  305  such that screws  309 , rivets or other fasteners can be inserted therein for attachment to a structural rack or frame  311 . Frame  311  is provided with an offset angled configuration relative to a flat or tilted building roof, building side wall, or even on the ground. 
         [0030]    Referring now to  FIG. 10 , another embodiment attachment system  351  includes a latch assembly  33  like that of the first embodiment discussed hereinabove. An elongated rail  353 , however, secures bracket  101  therein and includes a laterally extending lower flange  355 . Heavy weighted ballast members  357 , such as cement blocks, are positioned on flange  355  to hold attachment system  351  onto a flat roof surface  359  without the need for other fasteners or clamps. Additionally, a solar panel or other auxiliary roof component  361 , such as a snow guard, pipe, wire conduit, ladder, or the like, can be adhered or otherwise attached onto strikers  201 . 
         [0031]    It is alternately envisioned that rails  303  and  353 , or even bracket  101 , are made from a composite material including one or more sheets of long strand (e.g., longer than one inch) fiberglass or carbon fiber, either of a woven or random fiber orientation, in polymeric resin such as epoxy. In one version, a pultrusion process is employed to make this composite material prior to its molding, extruding or shaping into the desired configurations. The edges and slots are cut from the sheets before or after curing, and before or after molding. This process and material advantageously provides a lightweight and very durable component for the attachment system. In another alternate configuration, rails  303  and  353  have a single upstanding wall in the upper segment upon which bracket  101  is clamped between a downwardly open slot edge of the bracket and a camming wedge similar to wedge  43 ; this would eliminate the need to cut the slots in the pultruded rails. 
         [0032]    While various aspects of the present attachment system have been disclosed, it should be appreciated that modifications can be made. For example, the present accessory mounting brackets can be secured to conventional roof clamps such as those disclosed in the following U.S. Pat. Nos. 7,758,011 entitled “Adjustable Mounting Assembly for Standing Seam Panels” which issued to Haddock on Jul. 20, 2010; 7,386,922 entitled “Snow-Guard Clamping Unit” which issued to Taylor et al. on Jun. 17, 2008; and 5,715,640 entitled “Mounting Device for Controlling Uplift of a Metal Roof” which issued to Haddock on Feb. 10, 1998; except many of the present advantages will not be realized. These patents are incorporated by reference herein. Moreover, more or less latches can be attached to a single bracket. It is also envisioned that the attachment system is attachable to an exterior side of a building, although various advantages may not be achieved. Furthermore, the latches can have differing camming and/or striker engaging surfaces, such as internally elongated slots, however, various advantages may not be obtained. The striker can also have different shapes, such as a U-shape, although certain advantages may not be observed. In an alternate embodiment, bracket  101  is integrated into saddle  41  as a single piece. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the present invention.

Technology Classification (CPC): 7