Patent ID: 12249949

DETAILED DESCRIPTION

The Detailed Description and Claims may use ordinals such as “first,” “second,” or “third,” to differentiate between similarly named parts. These ordinals do not imply order, preference, or importance. This disclosure uses “optional” to describe features or structures that are optional. Not using the word “optional” does not imply a feature or structure is not optional. In this disclosure, “or” is an “inclusive or,” unless preceded by a qualifier, such as “either,” which signals an “exclusive or.” As used throughout this disclosure, “comprise,” “include,” “including,” “have,” “having,” “contain,” “containing” or “with” are inclusive, or open ended, and do not exclude unrecited elements.

The Detailed Description includes the following sections: “Definitions,” “Overview and Common Features,” “Components,” “Example Assembly Method,” and “Conclusion and Variations.”

Definitions

Return flange: As defined in this disclosure, a return flange is the lower lip of a solar module frame that projects inward underneath the solar module.

Solar module assembly: As defined in this disclosure, a solar module assembly includes a solar module that is pre-assembled with module-roof attachment assemblies necessary for attaching the solar module to a roof or building structure.

Overview and Common Features

As discussed in the Summary, the Inventors recognized that while railless systems generally use less mounting hardware than rail-based systems, the railless mounting assemblies can be structurally complex. They can also be difficult to install, requiring pre-planning and complex adjustment. The Inventors' railless solar module system solves these problems.FIGS.1-3illustrate a solar module system100that represents a simplified version of the Inventors' system. For simplicity,FIGS.1-3illustrate solar module system100with six solar modules, solar module101,102,103,104,105,106, arranged in three rows and two columns. Using the principles discussed in this disclosure, an installer or system architect may scale the solar module system100as large as needed. For example, a residential system with fifty solar modules could include five rows and ten columns.

FIGS.2and3are shown in “x-ray” view with the solar module top surface made transparent to reveal system components and devices. Referring toFIGS.2and3, these components and devices include module-roof attachment assembly108, module-roof attachment assembly109, skirt clamp111, and skirt splice112, which are attached to solar module frame107and module hook clamp110, which is attached to solar module frame117.

To simplify assembly and the structural complexity of components and devices, the solar module system100integrates with solar modules that include a first detent in the outward-facing surface of their frame and a second detent extending from the return flange of their frame. For example, the solar module frame107ofFIGS.1-3includes these detent structures.FIG.4shows a section view of solar module101fromFIG.3, taken along section lines4-4. Referring toFIG.4, the solar module frame107of the solar module101includes a first detent107dextending into the outward-facing surface107aof the solar module frame107. A second detent107eis positioned on an upward-projected portion107cprojected upward from the return flange107b. The second detent107eand upward-projected portion107cform a return flange end. The second detent may extend inward and downward toward the outward-facing surface. The solar module top101a(i.e., cells and substrate) are seated between the frame top107gand the module shelf107f.

Integrating the solar module mounting system with solar module frames as described above, simplifies the structure of mounting components. For example, the mounting components share structure that allows them to snap into the first detent107dand the second detent107ein the solar module frame107without the use of tools as illustrated inFIGS.5,6, and7. The bracket body113and the clamp body114ofFIG.5, bracket body115ofFIG.6, and skirt clamp body116ofFIG.7each include a pair of arms extending upward from a base. Each arm includes a hook that is structured to capture and hold the detents in the solar module frame by spring tension.

For example, inFIG.5, the bracket body113of the module-roof attachment assembly108includes a first bracket body arm113aand a second bracket body arm113bextending upward from a bracket body base113c. The first bracket body arm113aincludes a first hook113dand the second bracket body arm113bincludes a second hook113eeach facing the bracket body base113c. The first hook113dand the second hook113esnap into the first detent107dand the second detent107e, respectively, of solar module frame107.

The clamp body114of the module hook clamp110inFIG.5includes a first clamp arm114aand a second clamp arm114bextending upward from a clamp body base114c. The first clamp arm114aincludes a first hook114dand the second clamp arm includes a second hook114e. The first hook114dand the second hook114esnap into the first detent117dand the second detent117e, respectively, of solar module frame117of solar module103.

Referring toFIG.6, the bracket body115of the module-roof attachment assembly109includes a first bracket body arm115aand a second bracket body arm115bextending upward from a bracket body base115c. The first bracket body arm115aincludes a first hook115dand the second bracket body arm115bincludes a second hook115eeach facing the bracket body base115c. The first hook115dand the second hook115esnap into the first detent107dand the second detent107e, respectively, of the solar module frame107by spring tension.

Referring toFIG.7, the skirt clamp body116of the skirt clamp111includes a first clamp arm116aand a second clamp arm116bextending upward from a skirt body base116c. The first clamp arm116aincludes a first hook116d, and the second clamp arm116bincludes a second hook116e, each facing the skirt body base116c. The first hook116dand the second hook116esnap into the first detent107dand the second detent107e, respectively, of the solar module frame107.

Referring toFIGS.5-7, the return flange of the solar module frame can be optionally seated against a removably positionable spacer. The spacer is positioned so that it seats against the return flange of the solar module, while the first hook and the second hook secure the solar module. For example,FIG.5illustrates spacer118and spacer119,FIG.6illustrates spacer120, andFIG.7illustrates spacer121.

Components

FIGS.8-32illustrate in more detail, the various components discussed forFIGS.2and3.FIG.8illustrates the module-roof attachment assembly108withFIGS.9-13illustrating the module attachment bracket122of the module-roof attachment assembly108ofFIG.8.FIG.14illustrates the module-roof attachment assembly109withFIGS.15-19illustrating the module attachment bracket123of the module-roof attachment assembly109.FIGS.20-24illustrate the module hook clamp110.FIGS.25-30illustrate the skirt clamp111withFIGS.25-27also illustrating a portion of the skirt125.FIGS.31and32illustrate the skirt splice112.

Referring toFIG.8, the module-roof attachment assembly108, as illustrated, includes the module attachment bracket122, and a roof attachment bracket126. The module attachment bracket122can be used as a mid-clamp or universal clamp, because it can be positioned between solar modules or on the outside edges (i.e., the leading or trailing edges) of the solar module assembly. A threaded fastener127, which is part of the module attachment bracket122, secures the bracket body113of the module attachment bracket122to the roof attachment bracket126. The fastener body127apasses through a slot-shaped opening126ain a bracket riser126bwhere it engages a threaded aperture113f. The fastener head127brests against the slot-shaped opening126a. The roof attachment bracket126is illustrated as an L-foot. The bracket riser126bextends upward from a bracket base126c. The bracket base126cis structured to attach to a roof surface. For example, the bracket base126cmay include various apertures for attaching deck screws, lag bolts, or other roof fasteners. The bottom surface of the bracket base126cmay include a recess and an elastomeric or butyl gasket positioned in the recess to facilitate water tightness.

Referring toFIG.9-13, the module attachment bracket122includes a bracket body113. Referring toFIGS.9and10, the module attachment bracket122also may include threaded fastener127, threaded fastener128, bonding screw129, bonding screw130, and optionally, the removably positionable spacer, spacer118. Threaded fastener127extends through and engages threaded aperture113fin the riser113gof the bracket body113. Threaded fastener128extends through aperture113hin the first bracket body arm113a, through an aperture118athat ends lengthwise through the spacer118, and threadedly engages the threaded aperture113iin the second bracket body arm113b. Bonding screw129, extends through an aperture113jin the hook arm receiver113kof the bracket body113. Bonding screw130extends through an aperture113min the second bracket body arm113b. Spacer stop113uextends inward from the first bracket body arm113a. Spacer stop113uis positioned so that the bottom surface of the spacer118rests against it. The spacer stop113uprevents rotation of the spacer118while turning threaded fastener128. The spacer118is positioned so that the spacer118seats against the solar module (for example, the return flange of the solar module) while the first hook113dand the second hook113esecures the solar module.

Referring toFIGS.12and13, platform113nextends away from the riser113gon the opposite side of the riser113gas the bracket body base113c. The hook arm receiver113kextends away from the riser113g, with an end portion1130of the hook arm receiver113kextending toward the platform113n. The platform113nofFIGS.12and13is structured to seat the hook arm114nof the clamp body114of the module hook clamp110ofFIGS.23and24. The hook arm receiver113kin combination of the platform113nofFIGS.12and13, are together structured to rotationally receive and capture the open end114kof the hook arm114nofFIGS.23and24. InFIGS.12and13, the hook arm receiver113k, for example, may include an arc-shaped, or concave shaped interior. Alternatively, it may include linear portions with arc-shaped, or concave shaped corners. The hook arm receiver113kmay include end portion1130that extends downward toward the platform113nto help retain the open end114kof the hook arm ofFIGS.23and24. The open end114kcan be a ball hook catch to help facilitate rotation and remain captured in the hook arm receiver113k, once positioned.

Referring toFIG.14, the module-roof attachment assembly109, as illustrated, includes the module attachment bracket123, and a roof attachment bracket136. The module attachment bracket123can be used as an end-clamp because it can be positioned on the outside edges (i.e., the leading or trailing edges) of the solar module assembly. A threaded fastener137, which is part of the module attachment bracket123, secures the bracket body115of the module attachment bracket123to the roof attachment bracket136in the same manner as described for module-roof attachment assembly108ofFIG.8. InFIG.14, the threaded fastener137passes through a slot-shaped opening136ain a bracket riser136bwhere it engages a threaded aperture115fin the riser115g.

Referring toFIG.15-19, the module attachment bracket123includes a bracket body115. Referring toFIGS.15and16, the module attachment bracket123also may include threaded fastener137, threaded fastener138, bonding screw140, and optionally, the spacer120. Threaded fastener137extends through and engages threaded aperture115fin the riser115gof the bracket body115. Threaded fastener138extends through aperture115hin the first bracket body arm115a, through an aperture120athat ends lengthwise through the spacer120, and threadedly engages the threaded aperture115iin the second bracket body arm115b. Bonding screw140extends through an aperture115min the second bracket body arm115b. Spacer stop115uextends inward from the first bracket body arm115a. Spacer stop115uis positioned so that the bottom surface of the spacer118rests against it. The spacer stop115uprevents rotation of the spacer while turning threaded fastener138.

Referring toFIGS.14and16, bracket stop115nextends away from the riser115gon the opposite side of the riser115gas the bracket body base115c, i.e., the bracket stop115nextends away from the bracket body base115c. Referring toFIG.14, the bracket stop115nis structured and positioned to create a stop or reference position for the bracket riser136b.

FIGS.18and19also illustrate, in perspective view the relationship between the first bracket body arm115a, the second bracket body arm115b, the bracket body base115c, the first hook115d, the second hook115e, and the spacer120. The spacer120is removably positionable between the first bracket body arm115aand the second bracket body arm115b. The spacer120is positioned so that the spacer120seats against the solar module (for example, the return flange of the solar module) while the first hook115dand the second hook115esecures the solar module.

The module hook bracket ofFIGS.20-24allows installers to quickly add rows of solar module assemblies. New solar module assemblies with leading-edge mounted instances of module hook clamp110(FIGS.20-24) can secure to trailing-edge instances of module attachment bracket122(FIG.12) of a previous row of solar module assemblies. Referring toFIGS.20-24, the module hook clamp110includes a hook arm114nwith an open end114k. The hook arm114nis pivotable against the platform113nofFIG.12. The open end114kengages the hook arm receiver113kofFIG.12. As illustrated, inFIGS.20-24, the shape of the open end can be a ball hook catch to help facilitate pivoting. Referring toFIG.21, to help facilitate pivoting, the hook arm114nmay be a generally curved-shaped seating surface. The generally curved-shaped seating surface may be downward-facing generally convex shape to help facilitate pivoting. Referring toFIGS.21,23, and24, the hook arm114nextends away from below the clamp body base114c. The clamp body114may also include a riser114gextending between and spacing apart the clamp body base114cand the hook arm114n.

Referring toFIGS.20and21, the module hook clamp110may also include threaded fastener148, bonding screw150, and optionally, the spacer119. Threaded fastener148extends through aperture114hin the first clamp arm114a, through an aperture119athat ends lengthwise through the spacer119, and engages the threaded aperture114iin the second clamp arm114b. Bonding screw150extends through an aperture114min the second clamp arm114b. Spacer stop114uextends inward from the first clamp arm114a. Spacer stop114uis positioned so that the bottom surface of the spacer119rests against it. The spacer stop114uprevents rotation of the spacer119while turning threaded fastener148.

FIGS.23and24also illustrate, in perspective view, the relationship between the first clamp arm114a, the second clamp arm114b, the clamp body base114c, the first hook114d, the second hook114e, and the spacer119. As previously described, the spacer119is removably positionable between the first clamp arm114aand the second clamp arm114b, the spacer119is positioned so that the spacer119seats against the solar module (for example, the return flange of the solar module) while the first hook114dand the second hook114esecures the solar module.

ReferringFIG.1, the solar module system100may include trim to create an architectural or aesthetic appearance. InFIG.1, this trim is in the form of a skirt125the surrounds the perimeter of the solar module system. Referring toFIG.2, instances of skirt clamp111secure the skirt ofFIG.1to the solar modules. Instances of the skirt splice112secure the ends of adjacent skirt sections to each other.FIGS.25-30illustrate the skirt clamp111in various views.FIGS.31and32illustrate the skirt splice112.

FIGS.25-27illustrate how the skirt clamp111secures the skirt125, with these figures showing a portion of the skirt125. InFIGS.25and26, the skirt clamp111includes a skirt clamp body116with an upper arm116p. The upper arm116pincludes an upper groove116qextending the length of the upper arm116p. The skirt clamp body116includes a lower arm116rwith a lower groove116s. The lower groove116sextends the length of the lower arm116r. The skirt125includes an outer face125athat faces outward away from skirt clamp111. The skirt125also includes an inner face125bthat faces inward toward the skirt clamp111. The inner face125bincludes an upper tongue125qand a lower tongue125s. Portions of the upper tongue125qand the lower tongue125sproject downward. The upper tongue125qand lower tongue125sare positioned and structured to slide into the upper groove116qand lower groove116s, respectively. Referring toFIG.25-27, threaded fastener157secures a portion of upper tongue125qto the upper arm116p. Referring toFIGS.25and26, this also holds the lower tongue125sin the lower groove116s.

Referring toFIG.28, the threaded fastener157threadedly engages aperture116tin the upper arm116p. Threaded fastener158extends through aperture116hin the first clamp arm116a, through an aperture121athat extends lengthwise through the spacer121, and threadedly engages the threaded aperture116iin the second clamp arm116b. Bonding screw160extends through an aperture116min the second clamp arm116b. Spacer stop116uextends inward from the first clamp arm116a. Spacer stop116uis positioned so that the bottom surface of the spacer121rests against it. The spacer stop116uprevents rotation of the spacer121while turning threaded fastener158.

FIGS.29and30also illustrate, in perspective view the relationship between the first clamp arm116a, the second clamp arm116b, the skirt body base116c, the first hook116d, the second hook116e, and the spacer121.FIGS.29and30also illustrate the relationship between the upper arm116p, the lower arm116r, and the skirt body base116c. The spacer121is removably positionable between the first clamp arm116aand the second clamp arm116b, the spacer121is positioned so that the spacer121seats against the solar module as previously discussed for other similar spacers. The upper arm116pand the lower arm116rare spaced apart by the first clamp arm116aand the riser116g. The riser116gextends downward from the skirt body base116cand the first clamp arm116aextends upward from the skirt body base116c.

FIGS.31and32illustrate front and rear perspective view of the skirt splice112. The skirt splice112may be structurally similar to the skirt clamp111ofFIGS.25-30with the following differences. The skirt splice112may be longer to allow attachment of two adjacent skirt sections. In addition to threaded fastener157, the skirt splice112includes threaded fastener167, each threaded fastener securing the end of an adjacent skirt section. Because of the additional length, the skirt splice112may optionally include an additional spacer, spacer161, with an associated fastener, threaded fastener168. Threaded fastener168and spacer161maintain the same relation with the skirt splice body171as described for threaded fastener157, and spacer121ofFIGS.29and30.

Example Assembly Method

FIGS.33-56illustrate an example of an assembly method.FIG.33illustrates a flowchart that provides an overview of a typical assembly method. In step200, the installer pre-attaches, at the job site, module-roof attachment assemblies and module hook clamps to solar modules to create solar module assemblies ready to install on the roof. Referring toFIG.34, in step200a, the installer pre-attaches universal-clamp type module-roof attachment assemblies (for example,FIG.8) or end-clamp type module-roof attachment assemblies (for example,FIG.14) to the leading edge and pre-attaches universal-type module-roof attachment assemblies to the trailing edge, creating first-row type solar module assemblies. In step200bofFIG.34, the installer pre-attaches module hook clamps on the leading edge and universal-type module-roof attachment assemblies on the trailing edge of solar modules, creating interior-row type solar module assemblies. In step200cofFIG.34, the installer pre-attaches module hook clamps to the leading edge and end-clamp type module-roof attachment assemblies or universal clamp type module-roof attachment assemblies to the trailing edge of solar modules, creating last-row type solar module assemblies.

An installer may pre-attach module-roof attachment assemblies and module hook clamps to the solar modules on the ground, a work surface, against building surfaces, such as a wall, or the job-site roof. For example, an installer may pre-install the module-roof attachment assemblies and module hook clamps to their respective solar modules with the solar module placed face down on the work surface or ground. The installer might lean the solar module against the side of the building and install the module-roof attachment assemblies and module hook clamps. In either case, the installer would then carry or lift, by hand, or by mechanical assistance, the resultant solar module assemblies to the roof. The installer might opt to pre-attach some or all of the module-roof attachment assemblies and module hook clamps to their respective solar modules on the roof. In this example, the installer would typically place the solar module face down on the roof during assembly.

FIGS.35-37illustrate an example, of step200afromFIG.34.FIG.35illustrates the attachment process in perspective view, andFIGS.36and37illustrate the attachment process in side view with portions of the solar module cutaway for clarity. Referring toFIG.35, the solar module101is placed face down on a work surface172, such as a driveway, carport, workbench, or the surface of a roof. Instances of module-roof attachment assembly108attach to the solar module frame107at the trailing edge of solar module101. Instances of module-roof attachment assembly109attach to the solar module frame107at the leading edge of solar module101. Note that additional instances of module-roof attachment assembly108can be substituted for each instance of module-roof attachment assembly109. The completed assembly results in solar module assembly173.

Referring toFIG.36, the installer aligns the first bracket body arm113aand second bracket body arm113bof the module-roof attachment assembly108over trailing-edge side of the return flange107b. The installer then pushes the first bracket body arm113aand second bracket body arm113bover the outward-facing surface107aand the return flange end, respectively, of the solar module frame107. The return flange end, as illustrated, includes the upward-projected portion107c. The first bracket body arm113asplays outward while both bracket body arms are pushed over the solar module frame107.

Referring toFIG.37, with the first hook113dand second hook113eengaged within the first detent107dand second detent107erespectively, the first bracket body arm113asprings back toward its resting position and the module-roof attachment assembly108is held to the solar module frame107by spring tension. The return flange107brests against the spacer118. The installer may then tighten threaded fastener128to create additional clamping force on the first detent107dand second detent107e. The installer also may tighten bonding screw130to create an electrical bond between the bracket body113and the solar module frame107.

Referring toFIG.36, the installer aligns the first bracket body arm115aand second bracket body arm115bof the module-roof attachment assembly109over the leading-edge side of the return flange107b. The installer pushes the first bracket body arm115aand second bracket body arm115bover the outward-facing surface107aand the return flange end, respectively of the solar module frame107. The return flange end, as illustrated, includes the upward-projected portion107c. The first bracket body arm115asplays outward while both bracket body arms are pushed over the solar module frame107. Referring toFIG.37, with the first hook115dand second hook115eengaged within the first detent107dand second detent107erespectively, the first bracket body arm115asprings back toward its resting position, and the module-roof attachment assembly109is held to the solar module frame107by spring tension. The return flange107brests against the spacer120. The installer may then tighten threaded fastener138to create additional clamping force on the first detent107dand second detent107e. The installer also may tighten bonding screw140to create an electrical bond between the bracket body115and the solar module frame107.

FIGS.38-40illustrate an example, of steps200band200cfromFIG.34.FIG.38illustrates the attachment process in perspective view, andFIGS.39and40illustrate the attachment process in side view with portions of the solar module cutaway for clarity. Referring toFIG.38, the solar module103is placed face down on a work surface172, such as a driveway, carport, workbench, or the surface of a roof. Instances of module-roof attachment assembly108attach to the solar module frame117at the trailing edge of solar module101. Instances of module hook clamp110attach to the solar module frame117at the leading edge of solar module103. The completed assembly results in solar module assembly174.

Referring toFIGS.39and40, with the solar module103positioned on a work surface172, the installer installs an instance of the module-roof attachment assembly108to the trailing edge of the solar module frame117as described for solar module101inFIGS.36and37for step200a.

Referring toFIG.39, the installer aligns the first clamp arm114aand second clamp arm114bof the module hook clamp110over the leading-edge side of the return flange117b. The installer pushes the first clamp arm114aand second clamp arm114bover the outward-facing surface117aand the return flange end, respectively of the solar module frame117. The return flange end, as illustrated, includes the upward-projected portion117c. The first clamp arm114asplays outward while both clamp arms are pushed over the solar module frame117. Referring toFIG.40, with first hook114dand second hook114eengaged within the first detent117dand second detent117erespectively, the first clamp arm114asprings back toward its resting position. The module hook clamp110is held to the solar module frame117by spring tension. The return flange117brests against the spacer119. The installer may then tighten threaded fastener148to create additional clamping force on the first detent117dand second detent117e. The installer also may tighten bonding screw150to create an electrical bond between the clamp body114and the solar module frame117.

Referring toFIG.33, in step201, the installer places and secures the first of the first-row type solar module assemblies to the roof, creating a leading-edge row. Referring toFIG.41, the installer may use a reference line175, such as a chalk line, to place the first row of solar module assemblies. The installer than may simply place the solar module assembly173, “feet down” on the roof176, with roof attachment bracket126on the leading edge of the solar module assembly173aligned with the reference line175. Referring toFIG.42, the installer secures the solar module assembly173to the roof176by securing instances of the roof attachment bracket126using instances of threaded fastener177. The threaded fastener177is typically a deck screw, a lag bolt, or other threaded fastener. Any threaded fastener may be used that is suitable for securing roof attachment brackets to a roof and can withstand being pulled out of the roof by wind uplift according to local, regional, or national building codes.

Referring toFIGS.43and44, the solar module assembly173and other solar module assemblies of the present disclosure can be deck-mounted or rafter-mounted. In a deck-mounted installation, the installer can place the roof mounting assemblies anywhere on the roof deck. This has the advantage of simplicity of installation. In a rafter-mounted installation, the roof attachment brackets are aligned over roof rafters or the top cord of roof trusses. Rafter-mounted installations requires alignment with roof rafters, making the installation more complex than deck-mounted installations. However, some installations and jurisdictions require rafter-mounted systems.

FIG.43illustrates an example of deck mounting the solar module assembly173. The roof attachment bracket126of the module-roof attachment assembly109, can be positioned anywhere on the roof deck178. Instances of threaded fastener177extend through the roof attachment bracket126and attach the solar module101to the roof deck178. Note that roof attachment bracket126is designed for both deck mounting and rafter mounting, and is the subject of the Applicant's U.S. Pat. No. 11,750,143, issued on Sep. 5, 2023 and hereby incorporated by reference.

FIG.44illustrates an example of rafter mounting the solar module assembly173. The roof attachment bracket126of the module-roof attachment assembly109is positioned over a rafter179. Instances of threaded fastener177extend through the roof attachment bracket126, through the roof deck178and into the rafter179, and attach the solar module101to the roof deck178.FIG.45shows instances of roof attachment bracket126of the module-roof attachment assembly108on the trailing edge of the solar module system100.FIG.45also shows instances of roof attachment bracket126of the module-roof attachment assembly109on the leading edge of solar module system100aligned along corresponding instances of rafter179. The instances of rafter179are shown in dashed lines indicating that they are hidden from view under the surface of the roof176. Note that other instances of the module-roof attachment assembly108secured to the trailing edge of the interior solar module are also aligned with the instances of the rafter179. These are not shown inFIG.45for simplicity.

Referring toFIG.33, in step202, the installer places and secures additional first-row type solar module assemblies in the leading-edge row of the solar module system, creating an installed row.FIG.46illustrates, in top view, a first and second instance of solar module assembly173, with instances of roof attachment bracket126on the leading edge of the solar module assemblies, aligned along the reference line175. Additional instances of solar module assembly173in the leading-edge row may be placed in the same way and secured to the roof176as described forFIG.42. The installer may place the additional instances of solar module assembly173on the roof176as they see fit. For example, the installer may place the solar module assembly173straight down on the roof176. Alternately, as shown inFIG.47, they may first place the leading edge-mounted instances of the roof attachment bracket126on the roof176along the reference line175, and pivot the solar module assembly173in place.FIG.48illustrates, in rear perspective view, the resultant assembly of two instances of solar module assembly173, with the module-roof attachment assembly108secured to the roof.

Referring toFIG.33, in step203, the installer secures the interior-row type solar module assemblies to an immediately adjacent row of solar module assemblies, by engaging module hook clamps attached to the leading edge of the immediately adjacent row of solar module assemblies, to universal-type module-roof attachment assembly attached to the trailing edge of the interior-row type solar module assemblies, creating an interior-row.FIG.49illustrates, in side view, solar module assembly174being attached to the solar module assembly173that was secured to the roof176inFIG.42. The module hook clamp110pivoted within the bracket body113of the module-roof attachment assembly108.FIG.50shows this in rear perspective view, where instances of solar module assembly173in the first row are secured to the roof. The first instance of the solar module assembly174is being pivoted in place.FIG.50shows the module hook clamp110and module-roof attachment assembly108, between the first row of solar module assembly173, and solar module assembly174, in dashed lines to indicate that they are hidden from view.

FIG.51shows an enlarged view of the bracket body113of the module-roof attachment assembly108, and the module hook clamp110fromFIG.49, showing how these components interface during assembly. Referring toFIG.51, the open end114kof the hook arm114n, illustrated as a ball hook catch, pivots within the hook arm receiver113kof the bracket body113. At the same time, the hook arm114n, which is a generally curve-shaped seating surface, pivots along platform113n. The top surface of the platform113nmay be angled downward toward the riser113g, i.e., at an obtuse angle with respect to the portion of the riser113gpositioned below the platform113n. The sloping of the platform113nhelps to facilitate pivoting and securing of the open end114kwithin the hook arm receiver113k.

Referring toFIG.33, in step204, the installer secures the interior-row type solar module assemblies by securing the universal-type module-roof attachment assemblies to the roof. InFIGS.52and53, the installer secures the roof attachment bracket126of module-roof attachment assembly108. The module-roof attachment assembly108is attached to the trailing edge of solar module assembly174. The roof attachment bracket126is attached to the roof176using instances of threaded fastener177. Details on how to attach threaded fastener177is described inFIG.42-44.

FIG.54shows an enlarged view of bracket body113of module-roof attachment assembly108, and module hook clamp110, showing how these components interface after assembly. Referring toFIG.54, the open end114k, illustrated as a ball hook catch, of the hook arm114n, pivots within the hook arm receiver113kof the bracket body113. The end portion of the hook arm receiver113kextending downward toward the platform113n, helps to retain the open end114kwithin the hook arm receiver113k. At the same time, the hook arm114npivots along platform113n. The hook arm114nmay be a generally curve-shaped seating surface, and is illustrated as having a downward-facing generally convex shape. The sloping of the platform113n, as previously discussed, helps to prevent movement of the solar module assembly174while it is being secured. The installer may electrically bond module-roof attachment assembly108, solar module assembly173, module hook clamp110, and solar module assembly174, by tightening the bonding screw129against the open end114kof the hook arm114n. Referring toFIG.55, the remaining instances of solar module assembly174in the second row can be installed in the same way.

Referring toFIG.33, in step205, the installer secures the last row of solar module assemblies by engaging module hook clamps attached to the last-row to module-roof attachment assemblies attached to the immediately adjacent row of solar module assemblies. In step206, the installer secures the last row of solar module assemblies by securing the trailing-edge mounted module-roof attachment assemblies to the roof.FIG.56illustrates, in side view, solar module system100with three rows, the first row, or leading-edge row with instances of solar module assembly173, the second row with instances of solar module assembly174, and the third row, with additional instances of solar module assembly174. The module hook clamp110of the third row is secured to the module-roof attachment assembly108of the second row, in the same way as described inFIGS.49-55for the second row. Note that the last row in the solar module assembly can include end-clamp type module-roof attachment assemblies, such as module-roof attachment assembly109, in place of the universal-clamp type module-roof assemblies, module-roof attachment assembly108.

Conclusion and Variations

The Summary, Detailed Description, and figures described devices, systems, and methods for attaching solar module assemblies to roofs. This disclosure provides examples of devices, components, and configurations to help the reader understand the described general principles. The following are examples of variations and combinations of different components, structures, and features that still adhere to the general principles.

Module-roof attachment assembly108and module-roof attachment assembly109are illustrated with roof attachment bracket126inFIGS.8and14, respectively. Roof attachment bracket126is illustrated as an L-foot adapter. One advantage of the illustrated L-foot adapter is its ability to be used in both rafter mount and deck mount installations. For deck mount installations, an installer could substitute an L-foot, an L-bracket, or other roof attachment bracket specifically structured for deck mounting. For rafter mount installations, an installer could substitute an L-foot, an L-bracket, or other roof attachments specifically structured for rafter mounting. For metal roof applications, an installer could substitute an L-foot, L-bracket, or other roof attachment brackets specifically structured for metal roofs. For example, an installer could choose the mounting device of FIG. 5 of the Applicant's U.S. Pat. No. 11,848,638 in place of roof attachment bracket126, for metal roof applications. As another example, an installer could also use the roof mount bracket illustrated in U.S. Pat. No. D983,018 in place of roof attachment bracket126for metal roof application.

The roof attachment bracket126ofFIGS.8and14is illustrated with a slot-shaped opening126a. The slot-shaped opening helps to facilitate sliding the roof attachment bracket126on and off the bracket body113(FIG.8) and bracket body115(FIG.14). An installer might opt to use a roof attachment bracket with a riser that includes a closed slot-shaped aperture in place of the slot-shaped opening. Alternatively, an installer might choose a roof attachment bracket with a riser that includes a circular aperture or series of vertically aligned circular apertures.

The roof attachment bracket can have additional variations. For example, the roof attachment bracket could have a rectangular base or a rectangular riser. The roof bracket could be a T-foot, a pedestal, a pedestal with a flange portion for attaching threaded fasteners to the building surface, and a slotted pedestal to allow for height adjustment. Other equivalent structures could be substituted as long as they are capable of being secured to the roof or building structure with sufficient holding force to withstand normal environmental conditions for solar module systems, and are capable of being used in accordance with the disclosed assembly methods.

The module hook clamp110illustrated throughout this disclosure includes a seating platform with a generally curve-shaped seating surface. This generally curve-shaped seating surface inFIG.51, for example, is the hook arm114nwhich is a generally convex-shaped seating surface with respect to the platform113n. The generally curve-shaped seating surface can be a continuous smooth curve, formed from piece-wise linear segments, formed from piece-wise curved segments, or formed from piece-wise curved segments and piece-wise linear segments. As an example, the hook arm114ncould form a generally curve-shaped seating surface that has a downward-facing generally convex shape where a portion of the seating surface is flat. This portion of the seating platform can be positioned to help resist movement once the open end114kis engaged with the hook arm receiver113k.

Referring toFIG.21, one purpose of the riser114gin the module hook clamp110is to position the height of the solar module so its top surface is co-planar with the adjacent solar module. An example of this is illustrated inFIG.5, where the top of solar module101is co-planar with solar module103. Referring toFIG.23, it may be possible to eliminate the riser114gof the module hook clamp110and still align top surfaces of the solar modules in the same plane by changing the position of the spacer119, the first hook114d, and the second hook114e, to compensate for the elimination of the riser114g, and keep the solar module top surfaces co-planar. It may also be possible to eliminate the riser if co-planar alignment is unnecessary.

The threaded fasteners illustrated throughout this disclosure are suggestive of what could be used. For example, the threaded fastener127and threaded fastener128ofFIG.9, the threaded fastener137and threaded fastener138, ofFIG.15, threaded fastener148ofFIG.20, threaded fastener157and threaded fastener158ofFIG.28, and threaded fastener167and threaded fastener168ofFIG.31, are illustrated as hex head machine screws. This screw head style allows the installer to use a power tool such as an electric drill or impact driver. The Inventors envision that other types of screws could be used. For example, an installer could use socket head cap screws, pan-head screws, button-head screws, or round head screws. These can include hexagonal sockets, Phillips head sockets, slotted sockets, hi-torque sockets, square sockets, Robertson head sockets, or Torx head sockets. They can also include various custom or off-the-shelf security head screws. Any screw or bolt can be used that can perform the function specified in the specification, and provide enough holding strength to perform to typical environmental conditions expected for a solar module system installation.

The threaded fastener177illustrated inFIGS.5,6, and other figures throughout this disclosure typically are hex head decking screws. This screw head style is compatible with common power or hand tools. The installer could choose threaded roof fasteners with other head styles that suits either power tools or hand tools. For rafter installations, an installer may substitute a lag bolt or lag screw for added strength. An installer can substitute screws or bolts that can perform the specified function, provide a watertight seal, and provide enough holding strength to meet environmental and regulatory conditions expected for their installation.

Threaded apertures, such as threaded aperture113fand threaded aperture113iofFIG.9, threaded aperture115fand threaded aperture115iofFIG.15, threaded aperture114iofFIG.20, and threaded aperture116iofFIG.28, can be directly threaded into their respective bracket body arms and clamp arms. They may be indirectly threaded, for example, by using a threaded insert.

FIGS.9,20,15, and28illustrate the spacer118, spacer119, spacer120,121, respectively, as a substantially rectangular prism, or cuboid, with filleted edges. The spacer could be other shapes. For example, it could include convex or concave sides with planar or partially planar top or bottom surfaces. These spacers could be narrower or wider to contact less or more surface area of the solar module return flange. The spacer top surface and bottom surface are illustrated as planar, but could be other shapes to accommodate other solar module frame styles. For example, the spacer could include a keyway extending lengthwise along its top surface to interface with a frame slot in the bottom of a return flange of a solar module frame. An example of a frame slot in the return flange of the solar module frame is shown inFIG.15of the Applicant's U.S. Pat. No. 11,757,400. The spacer is illustrated with fillets, i.e., rounded or radiused edges. This is optional. The edges can be non-radiused. The spacer can have substantially planar sides. The sides can be any shape that allow the spacer to perform the function described in this disclosure. The spacers shown throughout this disclosure are typically made of a rigid material such as aluminum, steel, brass, or hard thermoplastic. This allows the spacer to act as a rigid stop to prevent over tightening. It is possible to form the spacer from a partially compressible material, if that material allows the spacer to perform the equivalent function. Spacer118, spacer119, spacer120,121, ofFIGS.9,20,15, and28, respectively, can be adapted to any of the modifications described in this paragraph. The various features are not necessarily mutually exclusive. For example, planar sides may be combined with a non-planar top. Non-planar sides can be combined with a planar top and so on.

The apertures within the spacers, for example, aperture118aof spacer118ofFIG.9is typically unthreaded. This may allow the threaded fastener to rotate within the spacer without turning the spacer. The spacer may alternatively be threaded and the spacer stop would prevent rotation.

The solar module frame illustrated throughout this disclosure is one example of a solar module frame suitable for attachment to the bracket body113, clamp body114, bracket body115, and skirt clamp body116ofFIGS.8,20,14, and28, respectively. Other examples of solar module frames suitable for use with the components in this disclosure include the frames ofFIGS.11,15, and19of the Applicant's U.S. Pat. No. 11,757,400. The Inventors conceive that the system will integrate with other solar modules with frames that include a first detent in the outward-facing surface of their frame and a second detent extending from the return flange, or inward facing flange or lip of the solar module frame.

The solar module frames and module-roof attachment assemblies, module hook clamp, skirt clamp, and skirt splice, and other components in this disclosure are typically aluminum extrusions. Extruded aluminum is durable, electrically conductive, and can have enough strength for typical solar module systems. The Inventors conceive of extruding the solar module frames and module-roof attachment assemblies, module hook clamp, skirt clamp, and skirt splice, and other components from other electrically conductive materials or non-electrically conductive materials. They also conceive of using other manufacturing processes such as molding, 3D printing, or casting. Suitable materials could include steel or electrically conductive plastics, non-electrically conductive thermal plastic, or thermoset polyurethane.

FIGS.33-56illustrate an example of an assembly method where the solar module system was assembled row by row. The system is not limited to this assembly method. It can also be installed column by column following the same assembly principles. For example, an installer could preassemble the module hook clamps and module-roof attachment assemblies following step200a, step200b, and step200cofFIG.34. The installer can then follow steps201-206inFIG.33, column by column rather than row by row. For example, the installer could optionally draw a reference line on the roof or building surface, and place the first instance of solar module assembly173as discussed forFIGS.41and42. Before installing additional instances of solar module assembly173in the first row, the installer could finish installing all solar module assemblies in the first column. For example, they could install solar module assembly174as discussed forFIGS.49,51,52, and54. They would then repeat the procedure of installing additional instances of solar module assembly174in the same column until the column is completed. They would then repeat the installation procedure for the next column, starting with the next instance of solar module assembly173in the first row, followed by each instance of solar module assembly174until the column is completed.

The assembly procedure ofFIGS.33-56, illustrates module-roof attachment assembly109on the leading edge of the first row, for example inFIGS.42and45. An installer may choose to use module-roof attachment assembly108in place of module-roof attachment assembly109on the leading-edge of the first row in the solar module system100. Similarly, an installer may choose to use module-roof attachment assembly109on the trailing edge of the last row of the solar module system100. The installer may also choose to use module-roof attachment assembly109on both the leading edge of the first row and on the trailing edge of the last row. The installer may opt to eliminate module-roof attachment assembly109completely and instead replace it with module-roof attachment assembly108on both the leading-edge and trailing-edge of the solar module system. All of these examples are within the scope of the disclosed solar module system and method. The method ofFIGS.33-56illustrate an assembly with three rows. It is within the scope of this disclosure to create an assembly with two rows by following steps200-204for two rows. Alternatively, the installer could follow steps200-202, skip steps203and204, and proceed with steps205and206.

Referring toFIGS.5,6, and7, the solar module system is electrically bonded through bonding screws, threaded fasteners, and serrations. InFIG.5, bonding screw130electrically bonds to the solar module frame107by piercing through paint or the oxide layer of the solar module frame107, and electrically bonding the solar module frame107to the bracket body113. Threaded fastener127electrically bonds roof attachment bracket126to bracket body113, as does serrations113vin the surface of bracket body113which mesh against serrations126vin the surface of roof attachment bracket126.

Similarly, bonding screw150electrically bonds to solar module frame117by piercing through paint or oxide layer of the solar module frame117, and electrically bonds the solar module frame117to the clamp body114. Bonding screw129bonds clamp body114to bracket body113, and therefore, bonds the solar module frame107to the solar module frame117, by piercing the oxide layer of clamp body114, and bracket body113.

InFIG.6, bonding screw140electrically bonds to solar module frame107by piercing through paint or the oxide layer of the solar module frame107, and electrically bonds the solar module frame107to the bracket body115. Threaded fastener137electrically bonds roof attachment bracket126to bracket body115, as does serrations115v, in the surface of bracket body115which mesh against serrations126v, in the surface of roof attachment bracket126.

Referring toFIG.7, bonding screw160electrically bonds to solar module frame107by piercing through paint or the oxide layer of the solar module frame107, and electrically bonds the solar module frame107to the skirt clamp body116. The threaded fastener157electrically bonds the skirt clamp body116to the skirt (not shown) by piercing through the oxide layer.

The bonding screws described above typically are threaded fasteners with sharpened tips that allows them to pierce the oxide or paint layers. These threaded fasteners are shown as pan-head self-tapping screws with Philips sockets. However, they can be any threaded fastener capable of creating electrical bonding between two electrically-conductive materials. For example, the threaded fasteners can be self-tapping screws, sheet metal screws, or self-drilling screws. Any head style can be used that allows the threaded fastener to tighten sufficiently to create an electrical bond. For example, the threaded fastener can be hex head, socket head, or pan-head. The socket can be Philips, Torx, hexagonal (i.e., Allen head), square, or Robertson.

Throughout this disclosure, unless otherwise indicated, reference to a roof type can equally apply to other building structures.

The variations described, the general principles taught, and undescribed variations, devices, and systems that encompass the general principles described in this disclosure, are within the claim's scope.