Mounting system for installing an array of solar battery modules of a panel-like configuration on a roof

• US 6,105,317 A
• Filed: 08/12/1998
• Issued: 08/22/2000
• Est. Priority Date: 09/24/1997
• Status: Expired due to Fees

• Current Assignee: Asahi Matsushita Electric Works Ltd. (Panasonic Holdings Corporation)
• Original Assignee: Asahi Matsushita Electric Works Ltd. (Panasonic Holdings Corporation)
• Inventors: Yoshida, Tomohide, Noda, Yosuke, Takeda, Shigeki, Urano, Shinji, Osaka, Kenji, Tanimoto, Norihisa, Tomiuchi, Shinichi, Akai, Takayoshi
• Primary Examiner(s): Kent, Christopher T.
• Assistant Examiner(s): Thissell, Jennifer I.
• Application Number:
  US09/132,825
• Time in Patent Office: 741 Days
• Field of Search: 52/173.3, 52/460, 52/464, 52/467, 52/468, 52/469, 52/506.06, 126/623
• US Class Current: 52/173.3
• CPC Class Codes: E04D 2003/0806 the supporting section of the glazing bar consisting of one single extruded or rolled metal part
• CPC Class Codes: E04D 2003/0856 locked by screws, bolts or pins
• CPC Class Codes: E04D 3/08 with metal glazing bars
• CPC Class Codes: F24S 20/67 in the form of roof constructions in the form of shingles or tiles F24S20/69
• CPC Class Codes: F24S 2020/17 Arrangements of solar thermal modules combined with solar PV modules
• CPC Class Codes: F24S 2025/014 Methods for installing support elements
• CPC Class Codes: F24S 2025/015 Supports with play between elements
• CPC Class Codes: F24S 2025/6002 by using hooks
• CPC Class Codes: F24S 2025/6007 by using form-fitting connection means, e.g. tongue and groove
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: F24S 25/35 by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/37 forming coplanar grids comprising longitudinal and transversal profiles
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 40/44 Draining rainwater or condensation
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 40/44 Means to utilise heat energy, e.g. hybrid systems producing warm water and electricity at the same time directly associated with the PV cell or integrated with the PV cell H01L31/0525
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02B 10/70 Hybrid systems, e.g. uninterruptible or back-up power supplies integrating renewable energies
• CPC Class Codes: Y02E 10/44 Heat exchange systems
• CPC Class Codes: Y02E 10/47 : Mountings or tracking
• CPC Class Codes: Y02E 10/50 : Photovoltaic [PV] energy
• CPC Class Codes: Y02E 10/60 : Thermal-PV hybrids

Abstract

A mounting system that is capable of effectively draining the rainwater off the roof, while enabling easy installation of the solar battery modules. The mounting system is adapted to install on the roof an array of the solar battery modules each of a panel-like configuration with a rectangular frame. The system includes a plurality of vertical rails which are secured to the roof and extend along a roof sloping direction towards eaves from a ridge of the roof for holding the solar battery modules between a laterally spaced pair of the vertical rails in a spaced relation from a roof sheathing. Each of the vertical rails is formed on opposite sides thereof respectively with stepped shoulders which extend the full length of the vertical rail for supporting thereon the frame of the laterally adjoining solar battery modules. The vertical rail is further formed on opposite sides thereof with respective trough sections which extend the full length of the vertical rail and are disposed below and outwardly of the corresponding stepped shoulders for receiving the rainwater sneaking along the frame. Thus, the rainwater is effectively prohibited from reaching the roof sheathing and advancing through the roof into interior of the house.

Claims

1. A mounting system claimed in combination with suitable to install an array of solar battery modules, each of the solar battery modules providing a plurality of solar cells arranged within a rectangular frame to form a panel-like configuration on a roof, the roof having roof sheathing extending from a ridge of the roof, said system including:

a plurality of vertical rails secured to the roof and slopingly extend along the roof from the ridge of the roof toward the eaves, a laterally adjacent pair of said vertical rails hold the solar battery modules in a spaced relation from the roof sheathing;

each of said vertical rails having a rectangular base secured to the roof sheathing, a pair of stepped shoulders which extend away from the rectangular base toward the solar battery modules along an entire length of said vertical rail to support thereon the rectangular frames of adjoining solar battery modules;

a pair of trough sections which extend away from the rectangular base toward the solar battery modules along the entire length of said vertical rail, the trough sections being disposed outwardly of the stepped shoulders relative to a longitudinal axis of the vertical rails to receive rainwater that passes through joints formed by the rectangular frames within the vertical rails; and

a plurality of horizontal rails extending in a direction perpendicular to a sloping direction of the roof, each horizontal rail engaging an intermediate portion of the rectangular frame between lateral ends of each vertically adjoining solar battery module, said horizontal rails secured at a bottom to the roof and having hooks that engage the frames of the adjoining solar battery modules located on opposite sides of each horizontal rail.

2. The mounting system as set forth in claim 1, wherein each of said vertical rails has a top opening defined between a pair of opposed fins upstanding from inward edges of said stepped shoulders, said system further comprising:

a top cover fitted over said top opening of said vertical rails and the frames of adjoining solar battery modules;

an anchor plate disposed inside each of said vertical rails, opposite lateral ends of said anchor plate respectively abut behind said stepped shoulders; and

a bolt connecting said top cover of said vertical rail and said anchor plate through said top opening so that the top cover presses the frame of each solar battery module against corresponding stepped shoulders and said bolt pulls the anchor plate toward the top cover, thereby securing the solar battery module to said vertical rail.

3. The mounting system as set forth in claim 2, further including an end top cover that covers said vertical rail bordering an outer column of the solar battery modules in said array, said end top cover including a flange on one lateral side that extends over the frame of the solar battery module sitting on said stepped shoulder of said vertical rail and an extension flange on the other lateral side that extends beyond a corresponding stepped shoulder of said vertical rail to at least one shingle disposed laterally adjacent to the column of the solar battery modules, said extension flange having a shoe that engages the corresponding stepped shoulder.

4. The mounting system as set forth in claim 1, wherein at least one of said horizontal rails has a second top opening defined between a pair of opposed ledges, each ledge provided with said hook, said system further including a second top cover which extends a full width between a pair of adjacent vertical rails and is fitted over the frames of the adjoining solar modules, said second top cover having a pair of opposed legs extending to said ledges at a periphery of said second top opening and being connected to said at least one horizontal rail by a second anchor plate and a bolt, said second anchor plate being disposed inside of said at least one horizontal rail with opposite ends of said second anchor plate abutting respectively behind said ledges, and said bolt extending through said second opening to connect said second top cover to said second anchor plate so that the second top cover presses the frame of said solar battery modules against the corresponding ledge as the second anchor plate is pulled towards the second top cover by said bolt, thereby securing the solar battery module to said horizontal rail.

5. The mounting system as set forth in claim 1, further including an eaves attachment extending along the eaves of the roof, said eaves attachment having a unitary structure including a top flange and a bottom flange connected by a web, said top flange and bottom flange located on one side of said web being cooperative to form therebetween a catch recess that receives therein said frame of the solar battery module sitting on the horizontal rail, said bottom flange located on the other side of said web extending to define an apron which covers the eaves of the roof.

6. The mounting system as set forth in claim 1, further including a ventilation module having planar dimensions and a rectangular frame similar to the solar battery module, said ventilation module being disposed on a side of the eaves between an adjacent pair of said vertical rails to feed outside air into an internal space between the roof sheathing and the solar battery modules located nearer to the ridge of the roof than said ventilation module, said ventilation module comprising an upper plate with a plurality of inlets to introduce the outside air and a lower plate shaped to flow thus introducing outside air towards said internal space.

7. The mounting system as set forth in claim 1, further including dummy modules having a horizontal width the same as said solar battery module, said dummy module being made of material to adjust a length along a sloping direction of the roof and connected between said vertical rails at a location immediately adjacent to the ridge of the roof.

8. The mounting system a set forth in claim 1, wherein said rectangular frame includes a pair of opposed vertical channel members integrally connected to said vertical rails, vertical channel members having an identical cross section, a fringe section and a drain section formed immediately below said fringe section, said fringe section formed with an inwardly open recess to receive therein a periphery of a substrate carrying the solar cells, said fringe section comprising an upper fringe and a lower fringe defining therebetween said recess, said lower fringe defining an upper part of said drain section and being bent downwardly at an inward end of said lower fringe to form an inclined edge there at, said drain section being formed with a slit in a bottom of said drain section to drip rainwater proceeding along said lower fringe and said inclined edge off said drain section towards said trough section of said vertical rail, each of a horizontal channel member and said vertical channel members further including at least one screw hole extending along a length of said frame to receive a screw securing the vertical and horizontal channel members to make a miter joint therebetween.

9. The mounting system as set forth in claim 1, further including at least one solar collector module to accumulate solar energy and heat air flowing through a space between the at least one solar collector module and the roof sheathing, the at least one solar collector module having a planar configuration same as said solar battery module so as to be held between the pair of said vertical rails in a spaced relation from said roof sheathing, and baffle means provided on a bottom of said at least one solar collector module to reduce a speed of said air flow through said space from the eaves towards the ridge of the roof.

10. The mounting system as set forth in claim 9, wherein said at least one solar collector module comprises a glass plate, a corrugated metal sheet disposed below said glass plate, supporting strips secured to said metal sheet, and a frame having a configuration that is the same as said solar battery module, said supporting strips extending along said at least one solar collector module and are secured at distal ends to said frame together with corresponding ends of said glass plate.