Abstract:
An attachment system is provided. In another aspect, an elongated member is inserted through support assembly to secure the support assembly to a building roof. Another aspect employs a bracket having a guide pin that engages a pin receptacle on a stand as the bracket is lowered onto the stand. A method of attaching a solar panel to a building is additionally provided.

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, an elongated member is inserted through support assembly to secure the support assembly to a building roof. Another aspect employs a bracket having a guide pin that engages a pin receptacle on a stand as the bracket is lowered onto the stand. A method of attaching a solar panel to a building is additionally provided. 
         [0004]    The present attachment system is advantageous over traditional devices. For example, in one aspect, an elongated member is inserted through a support assembly to secure a solar panel to a building roof without piercing the building roof. In an aspect of the present attachment system, a solar panel is quickly and easily secured to a building roof in a fast manner without requiring an installer to juggle multiple parts. In another aspect, a bracket is preassembled directly to a glass surface of a solar panel and a stand is secured to a building roof via an elongated member, prior to assembly of the bracket to the stand. Moreover, the solar panel is easily disassembled from a portion of a support assembly in an aspect of the present system. In another aspect, a bracket is preassembled to a solar panel and a guide pin on the bracket engages a pin receptacle on a stand to position the solar panel as the solar panel is lowered onto the stand. Another aspect involves a coupler that engages the guide pin when the guide pin is positioned in the pin receptacle to removably couple the bracket to the stand. Another aspect of the present system is advantageous over conventional devices since this aspect uses lightweight and strong plastic materials for various components of the attachment system. Additional advantages 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 a solar panel to a building roof; 
           [0006]      FIG. 2  is a perspective view showing a portion of the first preferred embodiment attachment system; 
           [0007]      FIG. 3  is an exploded perspective view showing a portion of the first preferred embodiment attachment system; 
           [0008]      FIG. 4  is a top view of a portion of the first preferred embodiment attachment system; 
           [0009]      FIG. 5  is a cross-sectional view, taken along line  5 - 5  of  FIG. 4 , showing the first preferred embodiment attachment system; 
           [0010]      FIG. 6  is a cross-sectional view, taken along line  6 - 6  of  FIG. 4 , showing the first preferred embodiment attachment system; 
           [0011]      FIG. 7  is a perspective view showing a bracket assembly as an alternative to a bracket of the first preferred embodiment attachment system; 
           [0012]      FIG. 8  is an exploded perspective view showing the bracket assembly; 
           [0013]      FIG. 9  is a perspective view of a second preferred embodiment attachment system securing the solar panel to the building roof; 
           [0014]      FIG. 10  is a perspective view showing a portion of the second preferred embodiment attachment system securing the solar panel; 
           [0015]      FIG. 11  is an exploded perspective view showing a portion of the second preferred embodiment attachment system; 
           [0016]      FIG. 12  is a top view of a portion of the second preferred embodiment attachment system; 
           [0017]      FIG. 13  is a cross-sectional view, taken along line  13 - 13  of  FIG. 12 , showing the second preferred embodiment attachment system; 
           [0018]      FIG. 14  is a cross-sectional view, taken along line  14 - 14  of  FIG. 12 , showing the second preferred embodiment attachment system; and 
           [0019]      FIG. 15  is an exploded perspective view of a guide pin and a coupler of the second preferred embodiment attachment system. 
       
    
    
     DETAILED DESCRIPTION 
       [0020]    Example embodiments will now be described more fully with reference to the accompanying drawings. 
         [0021]    Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments. 
         [0022]    Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
         [0023]      FIG. 1  illustrates a solar panel system  10  in accordance with the present invention. The solar panel system  10  includes a solar panel  12  and a solar panel attachment system  14  that mounts the solar panel  12  to a building  16 . The building  16  includes a roof  18  having a first section  20  and a second section  22 . The first section  20  of the roof  18  may be covered by a rubber membrane, and the second section  22  may be suitable for inserting fasteners therethrough. The solar panel attachment system  14  includes one or more support assemblies  24  that rest on the roof  18  and support the solar panel  12 . One of the support assemblies  24  may be positioned adjacent to each corner of the solar panel  12 , as shown. 
         [0024]    Cables or wires  26  extend through the support assemblies  24  and secure the support assemblies  24  to the building  16 . The wires  26  may be fixed to the second section  22  of the roof  18  using fasteners  28  such as eye bolts. Alternatively, the wires  26  may be fixed to another portion of the building  16 , such as a wall. Although only one end of the wires  26  is shown, the other end of the wires  26  may be secured to the building  16  in a similar manner. The solar panel  12  is secured to the support assemblies  24  using an adhesive  30 , such as Techbond® polyurethane adhesive (e.g., PUR 2 Max Tabs) obtained from A. Raybond Sarl. 
         [0025]    The first section  20  may be covered by the rubber membrane to seal the first section  20  and thereby prevent the roof  18  from leaking. Conventional attachment systems mount solar panels to a roof of a building by driving a fastener into the roof and thereby piercing the roof. Piercing the first section  20  may cause water to penetrate the rubber membrane and, ultimately, cause leaks in the roof  18 . In contrast, the solar panel attachment system  14  secures the solar panel  12  to the building  16  without piercing the first section  20 , and thereby mounts the solar panel  12  without causing leaks in the roof  18 . 
         [0026]    Referring now to  FIGS. 2 through 6 , each of the support assemblies  24  includes a stand  32  and a bracket  34 . The stand  32  is formed from a permeated plastic, such as AR-Bag® plastic obtained from A. Raymond Group, which includes voids below the surface of the stand  32 . The voids inhibit fracture propagation in the stand  32  and thereby improve the impact resistance of the stand  32 . The bracket  34  is formed (e.g., stamped) from metal. The stand  32  may be overmolded (e.g., molded over the bracket  34 ), as shown. Alternatively, the stand  32  may be injection molded or vacuum formed and/or the bracket  34  may be assembled (e.g., fastened) to the stand  32 . 
         [0027]    As best shown in  FIG. 2 , the stand  32  has a base  36  and an apex  38  opposite from the base  36 . The base  36  is wider than the apex  38  to distribute the load of the solar panel system  10  and thereby prevent leaks in the roof  18  caused by overloading the first section  20  of the roof  18 . The apex  38  may be narrower than the base  36  to reduce material cost. The stand  32  may be a square frustum, as shown, or the stand  32  may have another suitable shape, such as a conical or rectangular frustum. 
         [0028]    The stand  32  has edges  40  that are rounded to avoid piercing the roof  18  as the edges  40  contact the roof  18 . The stand  32  defines a hole  42  that extends through opposite sidewalls  44  of the stand  32 . The wires  26  are inserted through the hole  42  to secure the stand  32  to the roof  18 . The hole  42  includes a guide portion  46  that guides the wires  26  into the hole  42 . The guide portion  46  is tapered or funnel shaped. 
         [0029]    As best shown in  FIG. 3 , the bracket  34  has a yoke shape and includes a rectangular portion  48  and flanges  50  that extend downward from the rectangular portion  48 . The flanges  50  define holes  52  that receive the wire  26 . The wire  26  is routed through the hole  42  in the stand  32  ( FIG. 2 ) and the holes  52  in the bracket  34  ( FIG. 3 ) to secure the support assemblies  24  to the roof  18 . In this regard, the bracket  34  reinforces the connection between the wire  26  and the stand  32 . In addition, the stand  32  may be formed hollow or cored out to reduce material costs, in which case the hole  42  in the stand  32  would be divided into two holes. Thus, the holes  52  in the bracket  34  may help to guide the wire  26  from one of the holes in the stand  32  to the other one of the holes in the stand  32 . 
         [0030]    The rectangular portion  48  includes a generally flat portion  54  and pads  56  that are raised relative to the flat portion  54 . The adhesive  30  is applied to the pads  56  to secure the solar panel  12  to each of the support assemblies  24 . The pads  56  may be raised relative to the flat portion  54  by an amount that ensures the solar panel  12  does not contact the top surface of the stand  32  when the solar panel  12  is resting on the pads  56 . 
         [0031]    Referring now to  FIGS. 7 and 8 , a bracket assembly  58  in accordance with the present invention may be used in place of the bracket  34 . The bracket assembly  58  includes a first bracket  60  and a second bracket  62 . The first bracket  60  has a generally rectangular shape and the second bracket  62  has a yoke shape. The first bracket  60  and the second bracket  62  are formed (e.g., stamped) from metal. 
         [0032]    The first bracket  60  includes a generally flat portion  64 , pads  66  that are raised relative to the flat portion  64 , and a flexible arm  68  extending from the flat portion  64 . The second bracket  62  includes a generally flat portion  70  and flanges  72  extending downward from the flat portion  70 , along with guide rails  74  and a tab  76  extending upward from the flat portion  70 . In addition, the guide rails  74  extend laterally inward from the flat portion  70 , and a slot  78  extends through the flat portion  70 . 
         [0033]    The stand  32  may be molded over the second bracket  62 , the first bracket  60  may be preassembled to the solar panel  12  using the adhesive  30 , and the first bracket  60  may be coupled to the second bracket  62  using a tongue-and-groove connection. In this regard, the first bracket  60  may be slid in a direction X until the first bracket  60  abuts the tab  76  on the second bracket  62 . In turn, the guide rails  74  extend over the flat portion  64  of the first bracket  60  to secure the solar panel  12  to the building  16 . In addition, the flexible arm  68  on the first bracket  60  snaps into the slot  78  in the second bracket  62  to prevent the first bracket  60  from sliding in a direction that is opposite from the direction X. The solar panel  12  may be removed by pushing up on the flexible arm  68  and sliding the first bracket  60  in the direction that is opposite from the direction X. 
         [0034]    Alternatively, the solar panel  12  may be secured to the building  16  using a snap-fit connection. The snap-fit connection enables preassembling a portion of the support assemblies  24  to the solar panel  12  and lowering the preassembled components onto the remainder of the support assemblies  24  to secure the solar panel  12  to the building  16 . For example, the guide rails  74  may be flexible so that, as the first bracket  60  is lowered between the guide rails  74 , the guide rails  74  flex laterally outward and then snap back over the first bracket  60 . The solar panel  12  may then be removed by spreading apart the guide rails  74  and lifting up the solar panel  12 . 
         [0035]    In another example, the first bracket  60  may include a first latch that extends downward from the flat portion  64  of the first bracket  60  and the stand  32  may include a second latch that extends upward from the stand  32 . 
         [0036]    The ends of the latches may include hook features that engage one another as the first latch is slid over the second latch. In addition, the first latch may extend laterally inward from the flat portion  64  to ensure that the first latch slides past and engages the second latch as the solar panel  12  is lowered onto the stand  32 . Thus, using either the tongue-and-groove connection or the snap-fit connection, the solar panel  12  may be disassembled for maintenance purposes. 
         [0037]      FIG. 9  illustrates a solar panel system  80  in accordance with the present invention mounted to the building  16 . The solar panel system  80  includes the solar panel  12  and a solar panel attachment system  82  that mounts the solar panel  12  to the building  16 . The solar panel attachment system  82  includes one or more support assemblies  84  that rest on the roof  18  of the building  16  and support the solar panel  12 . One of the support assemblies  84  may be positioned adjacent to each corner of the solar panel  12 , as shown. 
         [0038]    Tubes or pipes  86  are routed through the support assemblies  84  to secure the support assemblies  84  to the building  16 . The pipes  86  may be fixed to the second section  22  of the roof  18  using fasteners  88  such as eye bolts. Alternatively, the support assemblies  84  may be fixed to another portion of the building  16 , such as a wall. Although only one end of the pipes  86  is shown, the other end of the pipes  86  may be secured to the building  16  in a similar manner. Thus, the solar panel attachment system  82  secures the solar panel  12  to the building  16  without piercing the first section  20 , and thereby mounts the solar panel  12  without causing leaks in the roof  18 . The solar panel  12  is secured to the support assemblies  84  using an adhesive  90 , such as Techbond® polyurethane adhesive (e.g., PUR 2 Max Tabs) obtained from A. Raybond Sarl. 
         [0039]    Weights  92  are slid onto the pipes  86  on opposite sides of the support assemblies  84  to prevent the support assemblies  84  from lifting off the roof  18  due to, for example, high winds. The weights  92  may be cylinders formed from cement or recycled rubber. The pipes  86  and the weights  92  may be standard sizes that are already available in, for example, local markets throughout the United States, and therefore do need to be specially made. To aid in positioning the support assemblies  84  on the pipes  86 , holes (not shown) may be formed in the pipes  86  and the support assemblies  84  may include a snap fit mechanism (not shown) that snaps into the holes when the support assemblies  84  reach a certain position. 
         [0040]    Conventional attachment systems place weights, such as cylinder blocks, on the edges of support assemblies so that part of the weights are resting on the support assemblies and part of the weights are resting on the roof  18 . Placing weights on the support assemblies  84  in this manner may obstruct water flow on the roof  18 , causing water (or ice) to puddle at or near the support assemblies  84  and possibly causing leaks in the roof  18 . In contrast, the solar panel attachment system  82  maintains the weights  92  above the roof  18  so that the weights  92  do not obstruct water flow on the roof  18 , and therefore the weights  92  do not cause leaks in the roof  18 . 
         [0041]    Referring now to  FIGS. 10 through 15 , each of the support assemblies  84  includes a stand  94 , a bracket  96 , and a coupler  98  ( FIG. 15 ), such as a u-shaped clip, that secures the bracket  96  to the stand  94 . The stand  94  may be formed from a plastic such as nylon via injection molding or vacuum forming. The bracket  96  may be formed from metal via injection molding or stamping. The stand  94  may be hollow, as shown, to reduce material costs. Holes  100  may be formed in the stand  94 , as shown, to prevent the stand  94  from obstructing water flow on the roof  18 . 
         [0042]    As best shown in  FIG. 10 , the stand  94  has a base  102  and an apex  104  opposite from the base  102 . The base  102  is wider than the apex  104  to distribute the load of the solar panel system  80  and thereby prevent leaks in the roof  18  caused by overloading the first section  20  of the roof  18 . The apex  104  may be narrower than the base  102  to reduce material cost. The stand  94  may be a conical frustum, as shown, or the stand  94  may have another suitable shape, such as a square or rectangular frustum. 
         [0043]    The stand  94  has edges  106  that are rounded to avoid piercing the roof  18  as the edges  106  contact the roof  18 . The stand  94  defines holes  108  that extend horizontally through the stand  94 . The pipes  86  are inserted through the holes  108  to secure the support assemblies  84  to the roof  18 . The stand  94  also defines a hole  110  that provides access to insert the coupler  98  into the hollow interior of the stand  94 . The stand  94  includes vertical ribs  112  disposed around the perimeter of the stand  94  that strengthen the stand  94 , and ramped protrusions  114  that support the pipes  86 . The protrusions  114  have surfaces  116  that are rounded to conform to the outer surfaces of the pipes  86  ( FIG. 11 ). 
         [0044]    As best shown in  FIG. 11 , the bracket  96  includes a pad  118  and a guide pin  120  that extends downward from the pad  118 . The guide pin  120  includes a shank  122  and a head  124 . The pad  118  may be rectangular, the shank  122  of the guide pin  120  may be conical, and the head  124  of the guide pin  120  may be spherical, as shown. 
         [0045]    As best shown in  FIGS. 12 through 15 , the stand  94  includes a pin receptacle  126  that receives the guide pin  120 . The pin receptacle  126  includes a first portion  128 , a second portion  130 , and a shoulder  132  between the first portion  128  and the second portion  130 . The first portion  128  is tapered radially inward, or funnel shaped, to guide the head  124  of the guide pin  120  into the second portion  130 . The second portion  130  has a circular cylinder shape. A hole  134  extends horizontally through the second portion  130  ( FIG. 10 ). 
         [0046]    The solar panel  12  is frameless. Thus, the bracket  96  may be preassembled to the solar panel  12  by applying the adhesive  90  to the top surface of the pad  118  and pressing the top surface of the pad  118  against the bottom or underside surface of the solar panel  12 . In turn, the solar panel  12  may be lowered onto the stand  94  until the bottom surface of the pad  118  rests on the top surface of the stand  94  and the guide pin  120  is in the pin receptacle  126 . The coupler  98  may then be inserted around the guide pin  120  between the head  124  of the guide pin  120  and the shoulder  132  of the pin receptacle  126  to secure that bracket  96  to the stand  94 . The solar panel  12  may be disassembled for maintenance purposes by removing the coupler  98  from the guide pin  120  and lifting up on the solar panel  12 . 
         [0047]    Each of the support assemblies  84  may be modified to support two adjacent solar panels and thereby reduce the number of support assemblies  84  required to support the solar panels. In this regard, each of the support assemblies  84  may include two of the brackets  96 , two of the couplers  98 , and two of the pin receptacles  128 . One of the brackets  96  may be preassembled to each of the two adjacent solar panels, and the solar panels may be individually lowered onto the support assemblies  84 . The couplers  98  may then be inserted around the guide pins  120  on the brackets  96  to secure the brackets  96  to the stand  94 . 
         [0048]    The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. 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. The same may also be varied in many ways. 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 disclosure.