Abstract:
A wire management system and method for protecting wires originating from roof-mountable photovoltaic panels, including system components made up of base support (s), an elongated tray and an elongated cap or cover piece. The base supports are mountable to the roof, the elongated tray fits within the base supports, and the cap or cover piece overlies the tray and interlocks with the base supports. Wires from the photovoltaic panels are threaded within the base supports, through the tray, and protected by the cover piece.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention relates to a wire management system and system components for protecting wires originating from roof-mounted solar panels such as photovoltaic (“PV”) laminated panels. The invention further relates to a method of installing the wire management system adjacent the roof-mounted PV laminated panels. 
         [0003]    2. Description of the Related Art 
         [0004]    Solar panels, such as PV laminated panels, mounted to roofs are well known in the art. Such panels necessarily include a plurality of wires that are connected to the PV panels and then routed into electrical components, such as storage batteries or converted to alternating current for use in an electrical utility grid. Conventional methods of mounting PV panels may involve drilling of holes into or through the roof of a building. The various wires connected to the PV panels may also be routed through holes or openings within the roof. 
         [0005]    A need has arisen for a wire management system to protect the wires from the environment, such as rain and solar ultraviolet rays, and to keep the roof neat, clean, and free of haphazardly-arranged loose wires, without penetrating the roof. A need has arisen for such system to be easily installed and to ensure a safe roof environment. 
       SUMMARY OF THE INVENTION 
       [0006]    The wire management system of the present invention is a UV-protected system to protect the wires and to keep the roof neat, clean, and free of loose wires without penetrating the roof. The wire management system is preferably a three-piece system consisting of (1) a base support, preferably plural base supports, that are fastened to the roof adjacent each PV junction, (2) an elongated tray, and (3) an elongated cap or cover piece. In the preferred embodiment, the first piece of the system includes a plurality of base supports fastened to the roof adjacent each PV panel or panel pair. The plurality of base supports are fastened so as to be aligned with each other. The base supports include an opening to receive the wires that are connected to the PV panel. 
         [0007]    The second piece of the wire management system is an elongated tray, preferably a single elongated tray that overlies the plurality of base supports and is fitted into each of the base supports and supported and retained thereby. Holes or openings are preferably cut on site adjacent to where the wires are pulled into the base supports. The cut holes or openings receive the wires from the base supports. 
         [0008]    The third piece of the system is the cap or cover piece which covers the tray and locks onto the base support(s) to ensure a stable wire management system. Preferably the cover piece is substantially the same overall length as the tray and sufficiently long enough to overly the plural base supports. The locking of the cover piece to the base supports results in the tray being protected and “sandwiched” between the base supports and cover piece. 
         [0009]    Thus, it is an object of the present invention to provide a wire management system for a roof-mounted PV panel array that protects the wires and keeps the roof neat, clean, and free of loose wires. 
         [0010]    It is further an object of the present invention to provide a wire management system that protects the loose wires originating from the PV panels without penetrating the roof. 
         [0011]    It is further an object of the present invention to provide a wire management system that can be easily and effectively installed on the roof without penetrating the roof or requiring complex attachment components. 
         [0012]    These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a cross-sectional exploded view of the three components of the wire management system, i.e., the base support, the elongated tray, and the elongated cover piece; 
           [0014]      FIG. 2  is a perspective view showing the placement of plural base supports on the roof of a building adjacent the PV panels; 
           [0015]      FIG. 3  shows the plural base supports each with a roof membrane piece heat welded or having an adhesive to attach the base supports to the roof; 
           [0016]      FIG. 4  is a perspective view similar to that of  FIG. 3  and showing the threading of the wires from the PV panel through the holes in the base support; 
           [0017]      FIG. 5  shows the placement of the elongated tray over the plural base supports before holes are drilled therethrough; 
           [0018]      FIG. 6  is a perspective view showing the tray with a hole cut or drilled therethrough prior to placement on the base supports; 
           [0019]      FIG. 7  shows the elongated tray with all holes cut therethrough positioned and supported by a ledge of the base supports with the wires threaded through the drilled holes; and 
           [0020]      FIG. 8  shows the elongated cap or cover piece interlocked with the base supports with the tray sandwiched therebetween. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0021]    In describing preferred embodiments of the invention illustrated in the drawings, specific terminology will be resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
         [0022]    Although only certain embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, in describing the various embodiments, specific terminology will be resorted to for the sake of clarity. It is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. 
         [0023]    As shown in  FIG. 1 , the wire management system  1  of the present invention comprises at least three components, a base support  100 , an elongated tray  200 , and a cap or cover piece  300 . Each of these components is formed of a plastic material, preferably polyvinyl chloride (“PVC”) or acrylonitrile styrene acrylate (“ASA”) each of which are preferably outdoor rated. In addition, each of the plastic components includes an ultraviolet (“UV”) coating to provide protection from the ultraviolet rays. The coating can be a dual extruded Duracap brand UV coating. 
         [0024]    As shown in  FIGS. 2-8 , the wire management system  1  is arranged to be positioned and secured to a roof  3  adjacent the solar panels or PV laminated panels  5 . As shown in  FIG. 2 , a pair of PV laminated panels are spaced apart just slightly greater than the width of the planar base  101  of the base supports  100 . As shown in  FIGS. 2-8 , the base supports  100  are formed in relatively short sections with each base support  100  positionable adjacent a PV laminated panel or panel pair and aligned with adjacent base supports. By contrast, the elongated tray  200  and cover piece  300  are preferably single piece components where each single component fits within the plurality of base supports  100  in a manner to be described. Of course, there could be circumstances where a single elongated base support is utilized. And the tray  200  and/or cover piece  300  could be formed of separate shorter segments that may abut each other or indeed may be slightly spaced apart in the lengthwise direction. 
         [0025]    The base support  100  is the first piece of the wire management system  1  to be installed, supports the entire system, and allows water to flow under the tray  200  and cover piece or cap  300  when the latter two elements are coupled to the base support  100 . Each base support  100  receives wires  7  that are potted to the PV panels  5 . The base support  100  includes a planar base  101  that is mountable upon the roof  3  and is integrally connected with a pair of vertical side panels  103  extending substantially perpendicularly and upwardly therefrom. Each side panel  103  includes an internally facing side panel face  105  and an externally facing side panel face  107 . Each side panel  103  has an opening  109  to receive the wires  7  from the PV panel  5 . The internally facing side panel faces  107  include a ledge  111 , preferably substantially L-shaped with the short leg  113  of the ledge  111  extending in an upward direction from the longer leg  115 . The ledge  111  extends the entire length of the base support  100  and lies above the holes or openings  109  in the side panels  103 . The openings  109  receive the wires  7 . 
         [0026]    At the upper or free end  117  of each vertical side panel  103  is an interlocking edge member  119  that extends outwardly from the externally facing side panel face  105 . The interlocking edge member  119  is angled downwardly to form a lip  121  for receiving a corresponding lip  303  from the cover piece  300  as will be described. Obviously, other forms of interlock are possible and are within the scope of the present invention. Further, the interlocking edge  119  need not be precisely at the free end  117  of the vertical side panel  103 , but may be displaced downwardly therefrom. 
         [0027]    Extending outwardly and angularly downwardly from each of the externally facing side panel faces  105  is a wing member  121  having a length substantially equal to the length of the planar base  101  and extends downwardly to a location substantially aligned with the planar base  101 . Preferably, each wing member  121  includes a perpendicular or vertical edge as shown  123 . However, it should be understood that the wing  121  can be formed without any edge, but extends completely angularly downwardly so as to rest upon the PV panels  5 . Each wing member  121  is intended to overly and protect the wire junction that extends from the PV panel  5 . Based upon the thickness of the PV panel, there may be a slight tension or upward reactive force from the wing member  121  on the panel  5  which thus provides a secure and tight mating between the base support  100  and the panel  5 . 
         [0028]    As shown in  FIG. 3 , after the plural base supports  100  are arranged adjacent the PV laminated panels  5  in an aligned direction so as to receive the tray  200  and cover piece  30 , each base support  100  is secured to the roof by adhering strips of roof membrane  11  to affix the base support  100  to the roof  3 . The roof membrane  11  preferably is heat welded to the membrane of the roof or, alternatively, may include an adhesive or glue to secure itself to the base support  100  and roof  3 . It should be realized that other effective means of securing the base support  100  to the roof  3  may be utilized. 
         [0029]    As stated earlier, it is desirable to include no holes in the roof  3  and, thus, a heat welding of roofing membrane to roofing membrane is preferred. A strip of roofing membrane  11  may be laid across planar base  101  and then heat welded to the roofing membrane below. Another alternative is a taping or gluing arrangement. However, there may be circumstances where the base support is secured to the roof in a manner that would require a hole, such as a screw hole or nail hole. Obviously, if the base support  100  is secured by heat welding, taping or gluing, the area upon which the base supports will be adhered may require cleaning with a cleaning solvent so as to maintain a secured connection. 
         [0030]    An elongated tray  200  fits between the upright base support side panels  130  and is supported by the ledges  111  extending inwardly from the side panels. The elongated tray  200  is sized so as to overly the plural base supports. It has been found that a tray having a 20 foot length may be effectively utilized with plural base supports numbering between 10 and 20, preferably  15 , depending upon the number of photovoltaic devices protected. Each photovoltaic panel or panel pair should have a single base support adjacent thereto. Generally the spacing between adjacent base supports is greater than the length of the base supports. As previously discussed, there may be circumstances where the length of the tray  200  and cover piece  300  are each shorter and may be installed in components, rather than one long piece for each element. 
         [0031]    Turning to the configuration of the tray  200 , the tray includes a planar tray base  201  having upright tray side panels  203  extending vertically from the tray base  201  and having a pair of vertical support legs  205  extending downwardly from the tray base  201 . The support legs are supportable by the ledges  111  of the base supports  100  to maintain the tray  200  supportable by the base supports  100  between the base support side panels  103  and above the base support holes or openings  109 . 
         [0032]    The tray  200  is intended to be supplied to the installer with the planar tray base  201  being free of holes or openings. As will be described, the holes/openings  207  are formed on site adjacent the location where each of the wires or wire sets  7  enter the base supports  100 . Because the base supports  100  may not be precisely evenly spaced in the longitudinal direction, it cannot be determined in advance where the holes  207  in the tray  200  should be located. On the other hand, there may be circumstances where a single elongated base support is utilized in which case the openings within the tray may be pre-drilled. Both of these possibilities are within the scope of the present invention. 
         [0033]    The openings  207  to be cut in the bottom  201  of the tray  200  are substantially aligned with the openings  109  of the base supports  100  so that the wires  7  from the PV panels  5 , after being threaded through the openings  109  of the base supports  100 , may be threaded upwardly and outwardly within the tray  200 . 
         [0034]    The elongated cap or cover piece  300  for covering the tray  200  and interlocking with the base supports  100  will now be described. The elongated cover piece  300  is preferably of the same length as the tray  200  and is formed in a single section (or plural sections fit adjacent to each other) to provide a complete cover for the base supports  100  and tray  200 . The cover piece  300  includes a top portion  305  generally planar, although other shapes are certainly within the scope of the present invention. For example, the top portion  305  could be cylindrical, i.e., semi-circular in cross-section. Extending downwardly from the top portion  305  are a pair of vertical side walls  307 . Each of the vertical side walls  307  has a free edge  309  that defines an interlocking lip for interlocking with the interlocking edge member  119  of the plural base supports  100 . This secures the cover piece  300  to the plural base supports  100  with the tray  200  supported therebetween. The cap or cover piece  300  is the final piece of the wire management system that ties the system together and protects the wires from the elements. It is the tray  200  that carries all of the wires and connectors for the PV system protected by the cover piece  300 . The space between the bottom  201  of the tray  200  and the plural base supports  100  provides a conduit for water to flow under the tray  200  and cap  300 . 
         [0035]    Installation of the system will now be described. As shown in  FIG. 2 , the PV laminate panels  5  are installed on the roof  3  aligned with adjacent panels and spaced apart a distance sufficient to enable the base supports  100  to be fitted therebetween. By way of example, if the base support  100  is approximately three inches wide, it is suggested that the PV panels be spaced apart approximately four and one-half inches. After the PV laminate panels  5  are installed on the roof in a generally aligned position, each of the plural base supports  100  is placed on the roof  3  at a location where the holes  109  will be adjacent, or as close as possible, to where the wires  7 , potted to the panels  5 , are located. Generally, the base supports  100  will be spaced an equal distance from each other, but this is not required. The positioning of the base supports  100  depends upon the positioning of the laminate panels  5  and must be adjacent to the panels  5  such that the wires  7  from the panels can be threaded through the openings  109  of the base supports  100 . As earlier stated, the roof  3  is first generally cleaned with a solvent so that the base supports  100  can be heat welded, taped or glued to the roof by the roof membrane  11  in a secure manner. This is shown in  FIG. 3  where strips of roof membrane  11  are heat welded to secure the base supports to the roof. 
         [0036]    After the base supports  100  are secured to the roof ( FIG. 3 ), the wires  7  from the PV panels are threaded through the openings  109  of the base supports as shown in  FIG. 4 . Then, as shown in  FIG. 5 , the elongated tray  200  is generally positioned to overly the base supports and the wire locations are marked on the bottom  201  of the tray  200  so that a hole  207 , such as a one inch hole, is drilled or cut out in the tray bottom  201  to allow the group of wires  7  to pass therethrough. See  FIG. 6 . (Only one hole  207  is depicted, but the location of the other holes, as marked by the installer on site, is shown and will be the location of the other holes.) 
         [0037]    After the holes  207  in the tray are cut out at the appropriate location, the tray  200  is positioned to be supported by the base supports  100  and the wires  7  that had been threaded internally within the base supports are threaded upwardly through the holes  207  of the planar base  201 . The wires  7  that are shown in  FIG. 7  as loosely supported by the tray  200  are ultimately connected to further components of the electrical system that receive the power generated by the PV panels. 
         [0038]    The next step in the method is the securing of the cover piece or cap  300  to overly the tray  200  and protect the wires  7 , as well as to secure the cover piece  300  to the base supports  100  to provide a firm interlock. This is shown in  FIG. 8 . The width between the vertical side walls  307  of the cover piece  300  is substantially the same width as the width between the side panels  103  of the base supports  100  so that, as the cover piece  300  is pressed downwardly from above, after the tray  200  is supported by the base supports  100 , the walls  307  of the cover piece  300  and side panel walls  103  of the base supports  100  will flex sufficiently to provide a snap interlock connection therebetween. 
         [0039]    The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and, accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.