Abstract:
A system for mounting at least one solar panel on a roof may include a plurality of panel mounting brackets each including a base to be positioned on the roof having a first opening(s) therein, and a vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends. The distal end may define a fastener channel having a fastener slot opening vertically aligned with the first opening(s) in the base. The central portion may include a cross member(s) defining a second opening(s) therein vertically aligned with the fastener slot opening and the first opening(s) in the base. The system may further include a bracket fastener(s) to be inserted through the fastener slot opening, the second opening(s), and the first opening(s) of a respective panel mounting bracket and coupled to the roof.

Description:
TECHNICAL FIELD 
     The present disclosure generally relates to mounting fixtures, and, more particularly, to mounting fixtures or brackets for panel installations, such as for solar panels, for example, to standing seam metal rooftops. 
     BACKGROUND 
     Solar panels, such as photovoltaic (PV) and solar water heating panels, are frequently used to take advantage of electrical power generation and heating properties of sunlight. To provide space savings and potentially enhanced efficiency, solar panels are in many cases installed on rooftops of buildings (e.g., office buildings, houses, etc.). However, because of winds and storms, the mounting fixtures used for installing solar panels on buildings need to be sufficiently strong and durable to reduce the chances of damage or injury from a panel coming loose during a storm, etc. 
     Various mounting fixtures have been developed for solar panel installation. For example, U.S. Pat. No. 7,963,074 discloses a device for fixing a photovoltaic module on a sloping roof having a roof structure and a roof covering with individual roof covering elements. The device includes a roof-side connecting piece disposable beneath the roof covering and a module-side connecting piece disposable on an edge of the photovoltaic module. A flexible retaining element interconnects the roof-side connecting piece and the module-side connecting piece. The flexible retaining element is loadable by pulling and adapted to be guided through the roof covering without altering a position or shape of the individual roof covering elements. 
     Despite the existence of such mounting fixtures, further enhancements may be desirable in some applications. 
     SUMMARY 
     A system for mounting at least one solar panel on a roof may include a plurality of panel mounting brackets each including a base to be positioned on the roof having at least one first opening therein, and a vertical extension having a proximal end coupled to the base, a distal end, and a central portion extending between the proximal and distal ends. The distal end may define a fastener channel having a fastener slot opening vertically aligned with the at least one first opening in the base. The central portion may include at least one cross member defining at least one second opening therein vertically aligned with the fastener slot opening and the at least one first opening in the base. The system may further include at least one bracket fastener to be inserted through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupled to the roof. Furthermore, a plurality of clamps and corresponding clamp fasteners may be configured to couple the at least one solar panel with the fastener channel of a respective panel mounting bracket so that each clamp fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel. 
     The at least one first opening may comprise a plurality of spaced-apart first openings, the at least one second opening may comprise a plurality of second spaced-apart openings, and the at least one bracket fastener may comprise a plurality of bracket fasteners for each panel mounting bracket. Furthermore, the at least one cross member may comprise a plurality of cross members vertically spaced apart from one another. 
     The at least one first opening may comprise a central opening in the base, and the base may further define a plurality of peripheral openings laterally spaced apart from the central opening. The base may have a non-linear cross section, such as an arcuate cross section, for example. The base may have a bottom surface to be positioned on the roof, and each bracket may further include a pad coupled to the bottom surface. 
     A related panel mounting bracket, such as the one described briefly above, is also provided. A related method is for mounting at least one solar panel on a roof, which may include arranging a plurality of panel mounting brackets, such as the ones described briefly above, on the roof. The method may also include inserting at least one bracket fastener through the fastener slot opening, the at least one second opening, and the at least one first opening of a respective panel mounting bracket and coupling the bracket fastener to the roof, and coupling a plurality of clamps and corresponding clamp fasteners to the at least one solar panel so that each fastener is retained within the respective fastener channel and extends vertically upward through the fastener slot opening to the at least one solar panel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an end view of a panel mounting bracket in according with an exemplary embodiment of the invention including a set screw locking mechanism. 
         FIG. 2  is an end view of a panel mounting bracket in according with an alternative embodiment of the invention including a cam bolt locking mechanism. 
         FIG. 3  is an end view of a panel mounting bracket in according with another alternative embodiment of the invention including a toothed locking cam mechanism. 
         FIGS. 4-6  are end views illustrating the installation of the brackets of  FIGS. 1-3 , respectively, on a metal standing seam rooftop. 
         FIG. 7  is a side view of a solar panel installation with an end-clamp using the bracket of  FIG. 1 . 
         FIG. 8  is a side view of a panel installed with a mid-clamp using the bracket of  FIG. 1 . 
         FIG. 9  is a top view illustrating solar panel installation using the bracket of  FIG. 1 . 
         FIGS. 10-12  are bottom, side, and top views, respectively, of the mounting bracket of  FIG. 2 . 
         FIGS. 13-15  are end, bottom, and cutaway end views, respectively, of the mounting bracket of  FIG. 3 . 
         FIGS. 16-17  are side and top views, respectively, of another exemplary embodiment of a panel mounting bracket. 
         FIGS. 18-20  are top, side, and perspective views, respectively, of another exemplary embodiment of a panel mounting bracket which includes holes for providing rafter connections. 
         FIGS. 21 and 22  are side views of further exemplary bracket embodiments including various base profiles. 
     
    
    
     DETAILED DESCRIPTION 
     The present description is made with reference to the accompanying drawings, in which exemplary embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in different embodiments. 
     Referring initially to  FIGS. 1-8 , mounting brackets  30 ,  30 ′, and  30 ″ (which are individually also referred to as a “foot” herein) for installing panels or modules  31 , such as solar modules, is first described. By way of background, solar modules or panels are typically mounted to standing seam metal roofs  32 ,  32 ′  32 ″ with clamps that tighten against the seam  33 ,  33 ′  33 ″ alone but do not simultaneously rest on the flat portion of the metal roof. The mounting brackets  30 ,  30 ′, and  30 ″ illustrated in  FIGS. 1 through 3  advantageously set firmly against the flat portion of a seemed roof  32 ,  32 ′,  33 ″ so as to remain perpendicular to the roof without rotating or twisting or allowing the solar modules  31 , when installed, to shift as with typical clamps that are only attached to the standing seam  33 ,  33 ′,  33 ″ of the metal roof. The mounting brackets  30 ,  30 ′, and  30 ″ have a generally rectangular central vertical extension portion or rail  34 ,  34 ′,  34 ″ with a hollow central area or channel  35 ,  35 ′,  35 ″ therethrough defined by a plurality of cross members  36 ,  36 ′,  36 ″. An upper slot or groove  37 ,  37 ′,  37 ″ for attaching a clamp fastener, such as a bolt  38  (e.g., a hex head bolt) and/or nuts  39 , is provided on the top of the mounting brackets  30 ,  30 ′, and  30 ″. It should be noted that the exemplary dimensions provided in  FIGS. 1-3  are for illustrational purposes, and that other dimensions and brackets sizes may be used in different embodiments. The hollow channels  35 ,  35 ′,  35 ″ in the vertical upper rail portion  34 ,  34 ′,  34 ″ extend laterally therethrough, and may be used for routing electrical wiring, for example, if desired. 
     Flanges or extensions  40 ,  40 ′,  40 ″ at the bottom of the mounting brackets  30 ,  30 ′, and  30 ″, which define a base of the mounting brackets, extend outwardly away from the central portion  34 ,  34 ′,  34 ″ so as to sit flat on the rooftop or roof deck  32 ,  32 ′  32 ″ upon installation. Serrations or other surface features (not shown) may optionally be included on the top and/or bottom of the central portion  34 ,  34 ′,  34 ″ (and flanges  40 ,  40 ′,  40 ″), if desired. The serrations may advantageously provide for improved electrical grounding with the frame of the module  31 , as well as increased grip or friction, for example. A pad  41 ,  41 ′,  41 ″ of rubber or other insulating material may optionally be included on the bottom of the flanges  40 ,  40 ′,  40 ″ to protect the standing seam metal roof  32 ,  32 ′,  32 ″ from being damaged by the flanges. 
     In the illustrated example, the mounting brackets or feet  30 ,  30 ′, and  30 ″ clamp and hold the solar modules  31 ,  31 ′,  31 ″ via bolts  38  which screw downward through end and mid clamps  42 ,  43  into nuts located in the top rails, as seen in  FIGS. 7 and 8 , for example. For the bracket  30 , set screws  45 ′ carried by the vertical extension  34  secure the bracket to the standing seam  33  (see  FIGS. 1 and 4 ). For the bracket  30 ′ a locking cam  46 ′, which is actuated via a cam bolt  47 ′ is used to secure the bracket to the standing seam  33 ′ (see  FIGS. 2 and 5 ). Moreover, for the bracket  33 ″ a toothed locking cam  48 ″, which is actuated by a cam handle  49 ″, is used to secure the bracket to the standing seam  33 ″ (see  FIGS. 3 and 6 ). 
     A first row of panels  30  ( FIG. 9 ) may then be attached on the roof  32 ,  32 ′,  32 ″ by clamping to the existing standing seams  33 ,  33 ′,  33 ″ on standing seam metal roofs  32 ,  32 ′,  32 ″ as shown in  FIGS. 4-6  for the mounting brackets  30 ,  30 ′, and  30 ″, respectively. Again, an end-clamp  42  may be used as demonstrated in  FIG. 7 . A next row of modules  31  may then be attached with additional mounting brackets  30 ,  30 ′, or  30 ″ on the bottom of the second row modules with a mid-clamp  43 , as shown in  FIG. 8 . It should be noted that different mounting brackets  30 ,  30 ′, and  30 ″ may be used during an installation, that this, not all of the same type of mounting bracket need by used in a given installation, but rather they may be intermixed. 
     The above steps may be repeated for each row of modules  31  to be installed, until the last row of modules is in place. The last module  31  of each row may be attached to the mounting brackets  30 ,  30 ′, and  30 ″ using end-clamps  42  as discussed above. 
     It should be noted that the mounting brackets  30 ,  30 ′, and  30 ″ need not be hollow in all embodiments, and that different shapes beside a rectangular shape may also be used in some embodiments. Example materials for the foot  30 ,  30 ′,  30 ″ may include aluminum, which may be extruded into the desired shape, although other suitable materials may also be used in different embodiments. For example, composite materials (e.g., fiber-reinforced polymer, etc.) may be used in some applications, which may also provide an added benefit with respect to electrical grounding, for example. The various locking mechanisms may be made of metal components, such as stainless steel, aluminum, etc. 
     It should also be noted that the above-described mounting feet or brackets  30 ,  30 ′,  30 ″ may be used with a variety of standing seam profiles. 
     Referring additionally to  FIGS. 16-17 , in addition to being used for standing seam metal roofs as described above, the same part can be used with or without a chamfer in the base to mount solar panels  31  to flush mount roofs  132  by attaching them to the decking with decking screws (not shown) through mounting holes  150  on each side of the vertical upper rail  134  of the mount. As before, the vertical extension or rail  134  defines hollow channels  135  therein and an upper slot  137 , and the base includes flanges  140 . As a result, the bracket  130  may be more versatile than typical brackets, as it may be used for both standing seam metal roofs (when a chamfer is used) and flush mount roof applications. More particularly, the bracket  130  may be used for composition shingle mount roofs, flat roofs, and sheet metal roofs with screws or other suitable mounting hardware (e.g., bolts, etc.) designed for such decking, for example. 
     Another example embodiment of a bracket  230  without the standing seam chamfer is shown in  FIG. 18 . The bracket  230  has central holes or openings  251  drilled or formed in the center of the vertical upper rail portion for centering them over roof rafters for mounting with longer wood screws  252 . While it may typically be easier to install a bracket  230  using only decking screws through holes  250  in the flanges  240  to either side of the vertical upper rail portion  234 , some local building codes may require that solar fixtures be secured to trusses or rafters, as opposed to roof decking  232  alone, and the rafter screw holes may be used in such jurisdictions. Decking screws (not shown) may still be installed through peripheral mounting holes  250  in each flange  240  to provide added strength and stability, if desired. Accordingly, in different embodiments, holes  251 ,  250  for respective rafter screws  252  or decking screws, or both, may be provided on the bracket  230 , with or without a chamfer for a standing seam. Moreover, different numbers of rafter screw holes  251  and decking screw holes  250  may be used in different embodiments. As with the above-described embodiments, the vertical extension  234  also illustratively includes an upper slot  237 . 
     It should be noted that other base shapes besides those shown in the illustrated examples noted above may also be used. For example, instead of a generally rectangular/square shape, the base may take other shapes such as a circle, oval, polygon, etc. 
     Furthermore, the base may have different non-linear profiles in different embodiments. Referring now to  FIG. 21 , in accordance with another example embodiment of the bracket  330 , the flanges  340  of the base define a curved or arcuate shape (i.e., when viewed from the side or cross-section) that may be helpful for installations on corrugated roofs, barrel tile roofs, etc. Another similar example of the bracket  430  is shown in  FIG. 22 , in which the base has downward pointing wings or flanges  440  which may also be helpful for such three-dimensional (3D) roof types. Other similar 3D profiles for the base may also be used that are appropriate for a given roof type, as will be appreciated by those skilled in the art. As with the above-described embodiments, the brackets  330  and  340  have respective vertical extensions  334 ,  434 , each of which has a respective upper slot  337 ,  437 , and each vertical extension has respective cross-support members  336 ,  436  defining hollow channels  335 ,  435  within the vertical extension. 
     Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within the scope of the appended claims.