RADISCHAT, Uwe (Amtsstrasse 8, Berlin, 12555, DE)
ZSCHOCH, Stefan (Möllendorffstr. 80, Berlin, 10367, DE)
WENZLAFF, Jan (Mainzer Strasse 26, Berlin, 10247, DE)
KÜBSCH, Michael (Pestalozzistr. 31, Bernau bei Berlin, 16321, DE)
WILDE, Kevin (Seehausener Str. 6, Berlin, 13057, DE)
RADISCHAT, Uwe (Amtsstrasse 8, Berlin, 12555, DE)
ZSCHOCH, Stefan (Möllendorffstr. 80, Berlin, 10367, DE)
WENZLAFF, Jan (Mainzer Strasse 26, Berlin, 10247, DE)
KÜBSCH, Michael (Pestalozzistr. 31, Bernau bei Berlin, 16321, DE)
| Claims: 1 . Mounting system (100) for mounting an array of solar panels (S), comprising: a plurality of elongate mounting members (20) adapted to be arranged and secured spaced apart and substantially parallel to one another, wherein each of the mounting members (20) is adapted to receive and support an edge region (E) of a solar panel (S) such that each solar panel (S) extends between two of the spaced apart and substantially parallel mounting members (20); and a plurality of fastening devices (30) for securely fastening the solar panels (S) to the mounting members (20), wherein each fastening device (30) comprises: a clip (31 ) for clipped or snap-fit attachment to a respective one of the mounting members (20), and a clamping member (41 ) provided on or carried by the clip (31 ) for engagement with an edge region (E) of the solar panel (S), wherein the clamping member (41 ) is configured to be biased or pressed with respect to the clip (31 ) to clamp and securely hold the solar panel (S) in position on the respective mounting member (20). 2. Mounting system (100) according to claim 1 , wherein each of the fastening devices (30) includes an operating member (44) which is adapted to bias, e.g. to press or draw, the clamping member (41 ) towards the clip (31 ) thereby to impart a clamping force to the solar panel (S). 3. Mounting system (100) according to claim 2, wherein the operating member (44) connects the clamping member (41 ) with the clip (31 ) and is adapted to apply the said bias or pressure to the clamping member (41 ) incrementally, wherein the operating member (44) preferably comprises screw means for a threaded connection between the clamping member (41 ) and the clip (31 ). 4. Mounting system (100) according to any of the preceding claims, wherein each mounting member (20) has laterally opposite, longitudinally extending panel seating areas (21 ) for receiving and fixing the edge region (E) of an associated solar panel (S), and means for attaching one or more said clip (31 ) of the fastening devices (30) between the opposite panel seating areas (21 ), wherein a body of the clip (30) is configured to at least partially define a limit or boundary to the panel receiving areas (21 ) on the mounting member (20) and to form a spacer between the panel receiving areas (21 ). 5. Mounting system (100) according to claim 4, wherein the means for attaching the clip (31 ) comprises a longitudinally extending channel (26) that opens to an upper side of the mounting member (20), and at least one engagement element (28, 29) provided in or on the channel (26) configured to engage and/or interlock with the clip (31 ) in a slot-in clipped or snap-in attachment; wherein at least one engagement element (28, 29) preferably comprise inwardly projecting profile elements, such as flanges or shoulders, which may have a bead- or barb-like cross-sectional profile. 6. Mounting system (100) according to any of the preceding claims, wherein the clip (31 ) includes at least one catch member (35, 36) configured to engage and/or interlock with at least one engagement element (28, 29) of the respective mounting member (20) in the attached state to prevent the clip (31 ) separating from the mounting member (20) when the clamping member (41 ) is biased or pressed with respect to the clip (31 ). 7. Mounting system (100) according to claim 6, wherein the at least one catch member (35, 36) comprises a projection, preferably in the form of a hook or barb, for engaging and/or interlocking with at least one profile element (28, 29) of the respective mounting member (20), the at least one profile element (28, 29) preferably being in the form of a complementary flange or shoulder. 8. Mounting system (100) according to claim 6 or claim 7, wherein the clip (31 ) includes a pair of limbs (32) and each limb (32) includes at least one catch member (35, 36), wherein at least one limb (32) is resiliently deformable with respect to the other for effecting the clipped or snap-fit attachment to the mounting member (20). 9. Mounting system (100) according to any of the preceding claims, wherein the clip (31 ) is configured to receive and engage with the operating member (44), preferably in a recess or aperture (39) having thread means (40) for threaded interaction with the operating member (44). 10. Mounting system (100) according to claim 9, wherein the clip (31 ) receives and engages the operating member (44) in a connection member (33) which extends between and/or interconnects the limbs (32) of the clip (31 ), the limbs (32) in turn extending from the connection member. 1 1 . Mounting system (100) according to any of the preceding claims, further comprising a lateral support member (50) configured to fit in a panel seating area (21 ) on the mounting member (20) in place of the edge region (E) of a solar panel (S), and configured to support the clamping member (41 ) of the fastening device (30) at an outer lateral periphery of the solar panel array. 12. Mounting system (100) according to claim 1 1 , wherein the lateral support member (50) is elongate and extends parallel to the mounting member (20) upon which it is fitted; and/or wherein the lateral support member (50) has at least one abutment element (55) against which the clamping member (41 ) directly bears; wherein the abutment elements (55) are height adjustable to match a position of the clamping member and/or may be adjustably positioned and fixed along the length of the mounting member (20). 1 3. Mounting system (100) according to any of the preceding claims, further including at least one elongate capping member (60, 60') adapted to be secured along an edge region of a solar panel (S) in the array extending transverse to the mounting members (20), wherein the at least one capping member (60, 60') is adapted to guide rainwater over an upper surface of the solar panel array and to prevent ingress or penetration of rainwater at the adjoining edge regions of the solar panels (S). 14. Mounting system (100) according to claim 13, wherein the capping member (60, 60') includes a cover plate (61 ) for bearing and sealing against an upper side of a solar panel (S), and wherein bracket means are provided to clamp the capping member (60, 60') along the edge region of the solar panel (S); wherein the bracket means preferably includes a bracket member (70), such as an angle bracket, and a fixing member (72), such as a bolt, for engaging both the capping member (60, 60') and a frame (F) of the solar panel (S) along the edge region thereof and clamping the two together. 15. Mounting system (100) according to claim 1 3 or claim 14, wherein the capping member (60, 60') further includes a retaining slot (68) formed at an upper side thereof for receiving an edge (N) of flashing sheet material. 16. Fastening device (30) for securely fastening a solar panel (S) to a mounting rail (20) in a solar panel mounting system (100), comprising: a clip component (31 ) configured for clipped or snap-fit attachment to the mounting rail (20), and a clamping member (41 ) provided on or carried by the clip component (31 ) for engagement with an edge region (E) of the solar panel (S), wherein the clamping member (41 ) is adapted to be biased or pressed or drawn relative to the clip component (31 ) to clamp and securely hold the solar panel (S) in position on the mounting rail (20). 1 7. Fastening device (30) according to claim 16, including an operating member (44) that is adapted to bias or press the clamping member (41 ) relative to the clip component (31 ) thereby to impart a clamping force to the solar panel (S). Fastening device (30) according to claim 1 7, wherein the operating member (44) interconnects the clamping member (41 ) and the clip (31 ) and is adapted to apply bias or pressure to the clamping member (41 ) incrementally, wherein the operating member (44) preferably comprises screw means for a threaded connection between the clamping member (41 ) and the clip component (31 ). Fastening device (30) according to any of claims 16 to 18, wherein the clip component (31 ) includes a catch member (35, 36) configured to engage and/ or interlock with a profile element (28 29) of the respective mounting rail (20) in the attached state and to hold the clip component (31 ) on the mounting rail (20) when the clamping member (35) is biased or pressed relative to the clip. Fastening device (30) according to claim 19, wherein the catch member (35, 36) comprises a projection, preferably a hook or barb profile, for engaging or interlocking with the profile element (28) of the mounting rail (20); and/or wherein the clip component (31 ) includes at least one limb (32), the limb (32) including the catch member (36) and being resiliency deformable to effect the snap-fit attachment with the respective mounting rail (20). Fastening device (30) according to any of claims 1 7 to 20, wherein the clip component (31 ) includes a connection member (33) which is configured to receive and be engaged by the operating member (44), preferably via a recess or aperture (39) having thread means (40) for a threaded interaction with the operating member (44). Fastening device (30) according to claim 21 , wherein the connection member (33) extends between and/or interconnects two limbs (32) of the clip (31 ), the connection member (33) preferably having a plate-like form, the limbs (32) preferably depending from the connection member (33). |
The present invention relates to a mounting system for mounting solar panels, as well as to a fastening device, a mounting rail, and a capping rail designed for use in such a mounting system. Furthermore, the invention also contemplates a new frame structure for solar panels, with the frame members incorporating features from the capping rail of the new mounting system. The mounting system of the invention and, of course, the associated fastening device and the mounting rail and capping rail are particularly suitable for use in mounting solar panels on a pitched or sloping roof or similar structure, and it will convenient to describe the invention in this exemplary context. It should be appreciated, however, that the mounting system of the invention is not limited to use on rooftops or sloping surfaces, but may also be employed where solar panels are to be mounted on any of a variety of supporting structures.
Background of the Invention As a result of the increasing trend towards the adoption of renewable energy sources, the installation of photovoltaic (PV) solar panel arrays is gaining in popularity, not only for industrial and institutional applications, but also in domestic and rural environments. Whether in an industrial, institutional, domestic or rural environment, the solar panels are often mounted on the rooftops of buildings - most typically in the area where the solar energy is required. Roof structures are particularly convenient for this purpose as they present a large surface area directed towards the sun, which is both out of the way and often largely out of view from the normal visual perspective, thereby rendering the installations relatively unobtrusive. Horizontal or flat rooftop surfaces are naturally convenient for workers assembling and installing an array of solar panels as they provide an even and stable working environment. Many roof structures, however, are not horizontal but rather are pitched or angled, and thereby present significant challenges for the workers installing the solar panel array.
When installing solar panel arrays on a rooftop, particularly on a pitched or angled rooftop, it is often desirable and necessary to remove a portion of the original roof cladding, such as tiles or sheet material, in that area of the roof at which the solar panels are to be arranged. This is often necessary to gain access to the structural framework of the roof (i.e. the roof beams such as rafters, battens, purlins and/or stringers), upon which the array of solar panels is ultimately to be supported and secured. Removal of the original cladding material in this area also enables the solar panel array to be set into the roof, thereby giving the array a significantly lower profile and making it less conspicuous than if it were simply mounted on top of the original roof cladding. When a solar panel array is integrated into the roof structure such that it replaces the original cladding, however, it is naturally critical to ensure that the integrity of the weather-proofing is retained in the rooftop after installation of the array.
The solar panels are typically provided as photovoltaic (PV) modules, each of which usually comprises a laminated glass panel incorporating a multitude of photovoltaic cells. The glass panel is often surrounded by a metal frame, which not only protects the edges of the glass, but also provides a robust structure for use in mounting the panels. While some manufacturers also produce cheaper solar panels that dispense with the metal frame around the panel edges, the highest quality modules having the highest solar efficiency remain framed panels. Individual framed PV solar panels are produced in various sizes, but they typically have a solar collecting area in the range of about 0.5 m 2 to about 6 m 2 . One particular example of such a PV solar panel has dimensions of about 1 .6 m x 1 .0 m and a mass of about 25 kg. As mentioned above, it is apparent that the installation of solar panels on a pitched or inclined roof can present major challenges for an efficient installation procedure. To address many of these issues, the applicant has developed a variety of systems for mounting solar panels, examples of which are described in co-pending International Patent Application Nos. PCT/EP2009/002480 and PCT/EP2009/008593, the content of which is incorporated herein by reference. Each of those systems, however, was specifically developed for frameless photovoltaic modules.
It therefore remains an aim to provide a new and improved solar panel mounting system that enables an array of framed PV solar panels to be integrated into a roof structure such that the array forms part of the building envelope and, in a simple and cost-effective manner, substantially prevents the ingress of rainwater into the roof structure after the panels have been installed. Furthermore, the solar panel mounting system should provide an easy and efficient installation procedure that can be performed by a single person, and that minimises the risk to the health and safety of the person performing the installation, e.g. on a pitched roof or an angled structure, as well as to the health and safety of bystanders in the vicinity. Clearly, it would also be desirable to minimise the risk of damage to the solar panels themselves during the installation procedure.
Summary of the Invention
According to one aspect, the present invention provides a mounting system for mounting solar panels on a support structure, such as a roof, the system comprising: a mounting framework having a plurality of elongate mounting members adapted to be arranged and secured spaced apart and substantially parallel to one another, with each of the mounting members being adapted to receive and support an edge region of a solar panel such that each solar panel extends between two spaced apart and substantially parallel mounting members. Further, the mounting system includes a plurality of fastening devices for securely fastening the solar panel to the mounting members, with each of the fastening devices comprising a clip component for attachment to a respective one of the mounting members, and a clamping member provided on or carried by the clip component for engagement with an edge region of the solar panel. In this regard, the fastening device is configured to bias or press the clamping member with respect to the clip component so as to clamp and securely hold the solar panel in position on the respective mounting member. In particular, the clamping member is configured to be biased, drawn or pressed towards the clip to clamp and hold the solar panel in position.
In a preferred form of the invention, the clip component of the fastening device is configured for clipped or snap-fit attachment to the respective one of the mounting members. In this way, the clip component (also simply called "clip") of the fastening device may provide a significantly faster and easier of assembly of the mounting system and solar panel array as the fastening devices may be positioned on, and attached to, the respective mounting members quickly and reliably without the need for special tools. That is, the attachment of the clip component may desirably be performed by hand (i.e. without use of a tool) with the clip designed to simply 'slot' or 'click' into place to provide a robust and reliable connection with the mounting member for clamping the solar panel thereto using the clamping member.
In this respect, each of the fastening devices typically includes an operating member which is adapted to bias or apply pressure to the clamping member with respect to the clip thereby to impart a clamping force to the solar panel. The operating member may connect the clamping member with the clip component and may be adapted to apply the bias or pressure to the clamping member incrementally. In this regard, the operating member may include screw means for effecting a threaded connection between the clamping member and the clip component. For example, the operating member may comprise a threaded bolt which interconnects the clamping member and the clip. The head of the bolt may bear upon the clamping member, with the threaded shaft of the bolt in threaded engagement with the clip, or vice versa. By turning the bolt (i.e. the operating member), the screw thread may operate to bias or to press the clamping member incrementally to effect the clamping engagement with the edge region of the solar panel. The clamping member may comprise a plate-like member and is preferably designed to engage the edge regions of two solar panels at opposite ends or sides thereof. That is, opposite end or side portions of the clamping member may be configured to engage a respective framed edge region of a solar panel. Furthermore, the clamping member may have a hole or aperture for receiving the operating member.
It will be noted that each mounting member is an elongate structural element, such as a beam or "rail", upon which the solar panels are mounted and supported within the framework of the mounting system. In a preferred form, each mounting member or mounting rail has laterally opposite, longitudinally extending panel seating areas formed at an upper side thereof. Each of these panel seating areas is adapted to receive and support an edge region of a solar panel, with each panel seating area extending substantially parallel to the edge region of the solar polar to be received thereon. Preferably, each mounting member or mounting rail also includes means for attaching a clip component of one or more of the fastening devices between the laterally opposite panel seating areas. The attaching means may include engagement elements, e.g. in the form of one or more profile elements, configured to engage and/or interlock with the clip. In a particularly preferred form of the invention, the means for attaching the clip comprise a longitudinally extending channel that opens to an upper side of the mounting rail, and the channel incorporates engagement elements to engage and retain the clip in a snap-fit attachment, e.g. when part of the clip component is inserted into the channel.
In a preferred form of the invention, the clip component includes at least one catch member configured to engage and/or interlock with a corresponding engagement element of the respective mounting rail in the attached state to prevent the clip from separating from the mounting rail when the clamping member is biased or pressed with respect to the clip. The at least one catch member may comprise a projection, for example in the form of a hook or barb, for engaging and/or interlocking with a complementary profile element of the respective mounting rail. That profile element is preferably a flange or shoulder projection. In a particularly preferred form of the invention, the clip includes at least one limb, and more preferably, a pair of limbs, with each limb having said at least one catch member. The limb(s) of the clip is/are desirably also resiliently deformable or deflectable for effecting a snap-fit or 'click-in' attachment to the mounting rail, e.g. in the upwardly open channel located between the laterally opposite panel seating areas, as noted above. In a preferred form of the invention, the clip component has a connection member which is configured to receive and engage with the operating member, and thereby serves to connect the clip with clamping member. In this regard, the connection member may include a recess or aperture for receiving the operating member and preferably also includes thread means for threaded interaction with the operating member, as described above. Desirably, the connection member extends between and/or interconnects the limbs of the clip component. In one particular embodiment the connection member has a plate-like form, with each limb of the clip depending from the connection member. Each limb may also have a plate- or strip-like form. In a preferred form of the invention, the clip is configured to at least partially define a limit or boundary to the panel seating areas on the mounting member and/or to form a spacer between the panel seating areas. That is, when the clip is attached to the mounting rail, a body portion of the clip at least partially separates those panel seating areas. In particular, the body portion of the clip presents surfaces that define a limit or boundary of each of the panel seating areas on the mounting member, with each limiting surface of the clip to be located or positioned adjacent a peripheral edge of a solar panel that is seated and fixed on the mounting member. The clip may thus limit the extent to which the edge region of the solar panel may be received on the upper side of the mounting member.
In a preferred form of the invention, the clip component of each fastening device is, in the attached state, movable in a longitudinal direction along the mounting rail to which it is attached. That is, the clip component may be configured for slotted or snap-fit attachment to the mounting rail with sufficiently little retained or residual tension to allow the clip to be moved longitudinally without application of an undue force. This may assist the person assembling the solar panel array to properly place and position the fastening devices. For example, where each mounting rail includes a longitudinal channel configured to receive and engage and/or interlock with the clip component of each fastening device in clipped or snap-fit attachment therewith, the clip component could potentially be moved, e.g. slid, axially along that channel to ensure the fastening device is in the desired position. The ease of doing so will be dependent upon the degree of resilient tension retained in the clip after its clipped or snap-fit attachment to the mounting rail, as will be explained in more detail later.
In a preferred form of the invention, the mounting system further comprises a lateral support member configured to support the clamping member of the fastening device at a laterally outer periphery of the solar panel array. The lateral support member is adapted to be positioned in a panel seating area on the mounting rail in place of the edge region of a solar panel, as no further solar panel is present at an outer periphery of the array. The lateral support member desirably includes an elongate rail element, which extends parallel to the mounting member upon which it is seated. This lateral support member or support rail may also include one or more abutment elements against which the clamping member of the fastening devices can directly bear. In this regard, a main purpose of the lateral support member is to support the clamping member of the fastening device on the side of the laterally outermost mounting rail where there is no solar panel to be clamped. The one or more abutment elements may be adjustably positioned and/or fixed along the length of the support rail, and may also be adjustable vertically (i.e. height adjusted) in order to match a position of the clamping member. As the mounting system of the invention has been designed principally for use with framed PV solar panels, and the frames have a height that may vary in the rage of about 30 mm to 50 mm, the lateral support member has been conceived to ensure a balanced application of clamping force via the fastening devices to avoid an unwanted tipping or tilting of the fastening devices at an outermost lateral periphery of the solar panel array. Thus, the elongate lateral support rails may not only finish the look of the array at the lateral sides thereof, but also support the clamping members of the fastening devices along those sides.
In a preferred form of the invention, the mounting system further comprises at least one elongate capping member or capping rail configured to be arranged along an edge region of a solar panel extending transverse to the mounting rails. The capping member or capping rail is adapted to be secured at an edge region of the solar panel for guiding rainwater over an upper surface of the solar panel array and to prevent the ingress or penetration of rainwater between adjoining edge regions of the solar panels. To this end, each capping rail desirably includes a cover member for bearing and sealing against an upper side of a solar panel along the edge region thereof. When attached to the edge region of the solar panel, the cover member may extend or project from the edge region of that panel for overlapping the upper surface of an adjoining solar panel and preferably also sealing against that adjoining panel. In this regard, the cover member may be formed as a cover plate, and the capping rail may include one or more sealing element, such as a strip of synthetic rubber or elastomer material, which is adapted to cushion and seal the cover member against the edge region of the panel to which it is secured. Each capping rail may include a recess or opening for receiving and/or attaching the sealing element under the cover member. Furthermore, bracket means are provided to clamp the capping rail, and in particular the cover member thereof, against the upper edge region of the solar panel. In this regard, the bracket means typically includes a bracket member, such as an angle bracket, and a fixing member, such as a bolt, for respectively engaging both the capping rail and the frame of the solar panel at an edge region thereof and clamping the two together.
In one particular preferred embodiment, the capping rail includes a retaining slot formed on a top side thereof (e.g. above the cover member) for receiving an edge of flashing material, e.g. an overturned edge of flashing sheet. The slot is desirably a blind slot and, when the capping rail is arranged along an upper periphery of the solar panel array (i.e. along the high-side of a pitched or angled rooftop), the slot is oriented with its opening facing towards an upper surface of the solar panel to which the capping rail is attached. In this way, rainwater that runs off the flashing material is guided directly onto the upper surface of that solar panel.
According to another broad aspect, the present invention provides a fastening device for securely fastening a solar panel to a mounting rail in a solar panel mounting system. The fastening device comprises a clip component configured for attachment to the mounting rail, and a clamping member provided on the clip for engagement with an edge region of the solar panel. The clamping member is configured to be biased or pressed with respect to the clip component to clamp and securely hold the solar panel in position on the mounting rail.
As noted above, in a particularly preferred form of the invention, the clip component is configured for clipped or snap-fit attachment to the mounting rail. In this way, the clip component of the fastening device may provide a significantly simpler assembly of the mounting system as the fastening devices may be positioned on, and attached to, the respective mounting members quickly and reliably without the need for tools. That is, attachment of the clip component can be performed by hand, with the clip designed to 'slot' or 'click' into place for a robust and reliable connection with the mounting rail.
According to a further aspect, the present invention provides a mounting rail for mounting a solar panel thereto, comprising laterally opposite panel seating areas at an upper side of the mounting rail, each of the panel seating areas being adapted to receive and support an edge region of a respective solar panel, wherein each of the panel seating areas extends substantially parallel to the edge region of the respective solar polar to be received thereon. The mounting rail further comprises a channel or recess which extends longitudinally thereof between the panel seating areas and opens to the upper side of the mounting rail. The channel or elongate recess is configured for clipped or snap-fit attachment of a fastening device for clamping the solar panels to the mounting rail.
Thus, the channel or recess in the mounting rail may include engagement means designed to interact and/or interlock with a clip component of the fastener device for securely holding or retaining the fastener device when a clamping member of the fastener device is tensioned or biased to clamp the solar panel fixed in position in the seating area of the mounting rail. In a particularly preferred form of the invention the engagement means include profile elements at opposite sides of the channel or recess, e.g. which project inwardly into the channel or recess, which are configured to engage and/or interlock with complementary catch members provided on the clip component in clipped slot-in or snap-in attachment. Each profile element may, for example, comprise an inwardly projecting flange or shoulder, and may be formed with a bead- or barb-like profile. Further, these bead- or barb-like profile elements may be provided at an upper rim of the channel or elongate recess.
In a preferred form of the invention, the said channel or elongate recess for attaching the clip component is located approximately centrally of the mounting rail and is substantially not covered by a solar panel when the edge regions of the solar panels are received and supported in the panel seating areas.
In a preferred form of the invention, each panel seating area on the mounting rail includes a seating element, such as a pad or strip, which is adapted to cushion the edge region of the solar panel received in the panel seating area. The seating element is preferably formed of a relatively soft and resilient material, such as a synthetic rubber or an elastomeric material. Each panel seating area on the mounting rail may have a recess or opening for receiving and/or attaching the seating element. According to yet another aspect, the present invention provides a capping rail which is adapted to be secured extending along an edge region of a solar panel for guiding rainwater over an upper surface of a solar panel array and for preventing the ingress or penetration of rainwater at the transverse edge regions of adjoining solar panels in the array. For this purpose, the capping rail includes a cover member, such as cover plate, for bearing and sealing against an upper side of a solar panel. When attached to the edge region of a solar panel, the cover member preferably projects or extends from that edge region to overlap the upper surface of an adjoining solar panel and preferably also seals against that adjoining panel. In this regard, the capping rail may include one of more sealing element, such as a strip of a relatively soft and resilient synthetic rubber or elastomeric material, which is adapted to cushion and seal the cover member against the edge region of the solar panel to which it is secured and/or the adjoining panel which it overlaps. Each capping rail may include a recess or opening for receiving and/or attaching the sealing element under the cover plate. Furthermore, bracket means may be provided to clamp the capping rail against the upper edge region of the solar panel. In this regard, the bracket means typically includes a bracket member, such as an angle bracket, and a fixing member, such as a bolt, for respectively engaging both the capping rail and a frame at the edge region of the solar panel and clamping the two together.
In one particularly preferred embodiment, the capping rail includes a retaining slot formed on a top side thereof (e.g. above the cover member) for receiving an edge of flashing material. The retaining slot is desirably a blind slot and, when the capping rail is arranged along an upper periphery of the solar panel, the slot is oriented with its opening facing towards an upper surface of the solar panel to which the capping rail is attached. In this way, rainwater running off the flashing material may be guided directly onto the upper surface of the adjoining solar panel. The retaining slot is preferably integrally formed in the cross-sectional profile of the capping rail, e.g. by a C-section or similar profile above the cover member.
According to yet a further aspect, the present invention provides an elongate frame member adapted to be secured along an edge region of a PV solar panel for framing that solar panel. The frame member comprises a capping projection in the form of a flange or web that extends away from the edge region of the framed solar panel for overlapping the frame and/or upper surface of an adjoining panel and preferably also sealing against that adjoining panel. Therefore, when the frame member is attached along an edge region of a solar panel, the capping projection is configured to guide rainwater from the upper surface of the solar panel to which it is attached onto the upper surface of an adjoining solar panel in the array and to prevent the ingress or penetration of rainwater between the edge regions of the adjoining solar panels in the array. Thus, the capping projection forms a cover member for guiding rainwater from the upper side of one solar panel to the next and preferably sealing against the next adjacent panel also. For this purpose, the frame member desirably includes one of more sealing element, such as a pad or strip, which is adapted to cushion and seal the capping projection (i.e. the flange- or web-like projection) against the adjoining solar panel, as for the capping rail described above.
In an alternative aspect, instead of a capping projection, the elongate frame member just described includes a retaining slot formed on a upper side thereof for receiving and holding an overturned edge of flashing material. The retaining slot is desirably a blind slot and, when the frame member extends along a peripheral edge of the solar panel, the slot extends parallel to the peripheral edge of the panel and is oriented so that it opens towards an upper surface of the panel to which the frame member is to be attached. In this way, a sheet of flashing material may be readily connected in overlap with the solar panel such that rainwater running off the flashing material is guided directly onto the upper surface of the solar panel.
It should be noted that the terms "upper", "lower", "above", "below", "top", "bottom", "lateral", "laterally" and other similar terms used herein in respect of various parts of the mounting system of the invention are intended to be given their ordinary meaning in view of the normal or in-use orientation of the mounting system described herein. It will be appreciated, however, that other interpretations of these terms may be appropriate depending on the particular orientation of the system and/or its respective parts at the time.
Brief Description of the Drawings
The above and further features and advantages of the invention will become more readily apparent from the following detailed description of preferred embodiments of the invention with reference to the accompanying drawings, in which like reference characters identify like features, and in which:
Fig. 1 is a perspective view of a mounting system for solar panels according to a preferred embodiment of the invention, shown assembled with the solar panels for a pitched or angled rooftop; Fig. 2 is a detailed perspective view of an end of a mounting member in the region indicated by the arrow "A" in the mounting system shown in Fig. 1 ;
Fig. 3 is an end elevation of the mounting system shown in Fig. 1 in the direction of the arrow "B";
Fig. 4 is a detailed perspective view of an end of a mounting member in the region indicated by the arrow "D" in the mounting system shown in Fig. 3; Fig. 5 is a detailed perspective view illustrating the operational interrelationship between the clip of a fastening device according to an embodiment of the invention and the mounting member of the invention;
Fig. 6 is a detailed perspective view of an end of the mounting member essentially corresponding to the view in Fig. 2;
Fig. 7 is a perspective view of a lateral support member and abutment elements for the solar panel mounting system of the invention; Fig. 8 is a perspective view of a capping member according to one embodiment for the solar panel mounting system of the invention;
Fig. 9 is a cross-sectional view of the mounting system shown in Fig. 1 taken in the direction of the arrows IX-IX;
Fig. 10 is a cross-sectional view of the mounting system shown in Fig. 1 taken in the direction of the arrows X-X;
Fig. 1 1 is a perspective view of flashing material and a capping member according to another embodiment for the solar panel mounting system of the invention; Fig. 12 is a cross-sectional view of the mounting system shown in Fig. 1 taken in the direction of the arrows XII-XII;
Fig. 1 3 is a view of the capping member of Fig. 1 1 in the direction of the arrow "E" and mounted on a mounting rail in the mounting system of the invention;
Fig. 14 is an end view of a mounting member according to an embodiment of the invention for the mounting system of the invention in Fig. 1 ; Figs. 1 5a and 1 5b are perspective and end views respectively of a clip component of a fastening device according to an embodiment of the invention for the mounting system in Fig. 1 ;
Figs. 1 6a and 1 6b are perspective and end views respectively of a clamping member of a fastening device according to an embodiment of the invention for the mounting system in Fig. 1 ;
Fig. 1 7a and 1 7b are perspective and end views respectively of a modified clamping member of a fastening device according to an embodiment of the invention for the mounting system in Fig. 1 ;
Fig. 1 8 is an end view of a lateral support member for the mounting system of the invention shown in Fig. 1 ; Fig. 1 9 is an end view of a capping member according to one embodiment of the invention for use in the mounting system shown in Fig. 1 ;
Figs. 20a and 20b are perspective and side views respectively of a bracket member for the capping member shown in Fig. 1 9; and
Fig. 21 is an end view of a capping member according to another embodiment of the invention for use in the mounting system shown in Fig. 1 . Detailed Description of the Preferred Embodiments
With reference firstly to Fig. 1 of the drawings, a mounting system 100 according to a preferred embodiment of the invention is illustrated in an assembled state as it may be installed on a rooftop (not shown). The mounting system 100 shown in Fig. 1 includes four rectangular solar panels S securely fixed to a mounting framework 1 0 of the mounting system in a rectangular array.
The solar panels S in this embodiment comprise glass photovoltaic panels, each of which is individually surrounded and enclosed by a frame F of robust elongate frame members typically comprised of extruded aluminium sections. Indeed, the mounting system 100 of this embodiment has been specifically designed for use with framed solar panels S. This does not mean, however, that the mounting system of the present invention is not suitable for use with other kinds of solar panels. The solar panels S in this embodiment are rectangular and typically present a solar collecting surface with an area in the range of about 0.5 m 2 to about 4 m 2 , although the area and the precise dimensions of the panels are not critical to the present invention.
The framework 10 of the mounting system 100 shown in Fig. 1 includes a plurality of elongate mounting members 20, which in this particular embodiment comprise individual straight elements having a substantially uniform or constant cross-section, and which are formed, for example, as extruded aluminium sections. Thus, the mounting members 20 are elongate structural elements upon which the solar panels are mounted and supported within the framework 10 of the mounting system 100. In the present embodiment, the mounting members 20 will hereafter also be referred to as mounting "rails", as they are often known in the art.
The rooftop (not shown) upon which the mounting system 100 of the invention is to be installed will typically include a roof cladding, e.g. in the form of tiles, corrugated sheeting (e.g. galvanized or coated steel sheeting) or synthetic (e.g. plastic) sheeting. The roof cladding is usually supported on, and securely affixed to, a series of roof beams within the roof structure of the building and those roof beams (e.g. rafters, battens, purlins or stringers) are typically timber elements, although steel beams are also known. The mounting system 100 in this embodiment has been conceived with features that make it particularly suitable for use on an angled or inclined rooftop or similar structure. When installing and assembling the mounting system 100 for solar panels shown in Fig. 1 , an area of the roof cladding is firstly removed to expose the beams of the roof structure on which the mounting system 100 is to be secured.
The mounting rails 20 are arranged such that they extend substantially parallel to the general plane of the roof and are inclined at about the same angle as the roof itself. Thus, with reference to Fig. 1 , the mounting system 100 is angled or pitched from a high side H to a low side L. In other words, the mounting rails 20 are arranged such that they extend directly up the incline of the pitched roof, and the mounting rails 20 are also arranged substantially parallel to one another and spaced apart at regular intervals approximately corresponding to the width of the individual solar panels S. The mounting rails 20 are rigidly secured to the roof structure (e.g. roof beams) with the aid of components of the mounting frame 10 (e.g. angled brackets and screws) as will be explained in more detail later. It will be noted that, depending on the size of the solar panel array to be installed, the mounting rails 20 may also be arranged in longitudinal alignment with one another to achieve a greater overall length, as will be understood by an ordinary practitioner.
Significantly, this embodiment of the solar panel mounting system 100 has been designed to be integrated into the rooftop in such a way that the roof cladding, which was removed over the area of the solar panel array to expose the roof beams, does not need to be replaced or substituted. That is, in the mounting system 100 of the invention, the solar panels S themselves can effectively form a weather-resistant part of the building envelope without separately or additionally covering and sealing the rooftop area covered by the solar panels with a weather-proof layer. In other words, the mounting system 100 has been developed so that the solar panels S are able to guide rainwater and/or snow-melt over the roof area without permitting any significant ingress of water into the roof space below. With reference now to Figs. 3 to 5 of the drawings, specific features of the mounting system 100 relating to the fixation of the solar panels S to the mounting rails 20 will be explained in detail. The particular form or cross-section of the mounting rails 20 can be clearly seen in Figs. 4 and 5 and is specifically shown in isolation in Fig. 14. In the embodiment illustrated, each mounting rail 20 has the same configuration, with each mounting rail 20 having a generally hollow or tubular cross-section and important mounting and connection features along its upper- or top-side and its lateral sides. For example, on each of its opposite lateral sides each mounting rail 20 has ribbed upper and lower flange members 2, 3 bordering a slot-like opening into a longitudinally extending side channel 4. As is clear from Figs. 2 to 4, these parts of the mounting rails 20 are used to rigidly secure the rails 20 to the beams of the roof structure after the mounting rails 20 have been placed on the rooftop by the person assembling the mounting system 100. The fixing arrangement includes angle brackets or L-shaped brackets 5 having a ribbed profile designed to complement and engage the ribbed surfaces of the upper and lower flange elements 2, 3 on the laterally opposite sides of the mounting rails 20, with the angle brackets 5 being fixed to a roof beam using screws 6. A bolt-type fastener 7 (e.g. hammer-head bolt) is provided having a plate-like head element 8 for insertion into the side channels 4 of the mounting rail 20, with a threaded end of the bolt 7 extending through the angle bracket 5 for securing with a complementary nut 9.
Each of the mounting rails 20 is adapted to receive a side edge region E of a solar panel S for securely fixing that side edge region E at laterally opposite sides of the mounting rail. Accordingly, as is clear from Fig. 1 , when mounted within the mounting system 100 of the invention, each solar panel S extends between two parallel mounting rails 20. The mounting rails 20 at the outer lateral periphery of the solar panel array, however, (i.e. as shown in Fig. 2 and Fig. 6) will typically receive and securely fix the edge region E of a solar panel at one side only. Referring now to Figs 4 and 14, the configuration of the mounting rail 20 and the manner in which the respective edge regions E of the solar panels S are received on the mounting rails 20 will be described. As shown in Fig. 14, the mounting rail 20 comprises two seating areas 21 formed at an upper side thereof. Each of the seating areas 21 is adapted to receive and support the edge region E of a solar panel S, with each of these two panel seating areas 21 extending along the length of the mounting rail 20 parallel to the edge region E of the solar panel it receives and supports. In this connection, it will be noted that the width of each of the panel seating areas 21 and correspondingly, therefore, the width of the edge region E of each solar panel S to be supported and fixed to the mounting rail 20, is typically in the range of about 10 mm to 50 mm, and preferably in the range of about 20 mm to 40 mm. Thus, the overall width of the mounting rails 20 (i.e. the width dimension of the cross-section shown in Fig. 14) is typically in the range of about 30 mm to 120 mm, and preferably in the range of about 60 mm to 90 mm.
Each of the panel seating areas 21 has a small outer flange element 22 and a small inner flange element 23, the upper surfaces of which are arranged in essentially the same plane and are adapted to receive and support the edge region E of the solar panel S. A longitudinally extending gap between each of the outer and inner flange elements 22, 23 opens into a v-shaped channel 24 extending along the length of the mounting rail 20 in each of the panel seating areas 21 . As can be seen with attention to the detail of Fig. 4, the edge regions E of each of the solar panels S are not seated in direct contact with the mounting rails 20. Rather, seating elements 25 comprising long rectangular strips of relatively soft and resilient synthetic rubber are provided in each of the panel seating areas 21 to cushion contact with, and/or clamping of, the edge regions E of the solar panels. These seating elements 25 include attachment projections which extend into the channels 24 and engage with an underside of the outer and inner flange members 22, 23 to connect the seating elements 25 with the mounting rail 20. The rectangular strip of each seating element 25 has an overall width which is essentially the same as the width of the respective panel seating area 21 and extends in each case from an inner side of inner flange 23 to an outer edge of the outer flange 22. To ensure an even support of the solar panels S in the panel seating areas 21 , the seating elements 25 typically extend over the full length dimension of the edge region E of the solar panels S received in and supported on the seating areas 21 . The seating elements 25 may be combined with the mounting rails 20 in a pre-assembly procedure so that the installation of the solar panel array, i.e. performed on the roof, is simplified for the person carrying out the installation.
Extending longitudinally of the mounting rail 20 and arranged centrally between the two laterally opposite panel seating areas 21 is a main or primary channel 26 which opens to an upper side of the mounting rail 20. Thus, the two panel seating areas 21 extend parallel to the channel 26 on laterally opposite sides of the mounting rail 20. The channel 26 is generally rectangular, with a pair of substantially parallel walls 27 that are upstanding from a generally flat base. An upper end or rim of one of those channel walls 27 has an inwardly projecting flange or lip 28 which is formed with and/or terminates in a curved or rounded bead. The opposite channel wall 27 also has an inwardly projecting flange or lip 29 at an upper end or rim thereof, but this time it forms a short barb-like edge in the profile view of Fig. 14. As is apparent from Fig. 4, each flange or lip element 28, 29 at the upper rim of the channel 26 extends longitudinally along the length of the mounting rail 20, just like the channel 26 itself. The purpose and operation of these elements 28, 29 will be explained in detail with reference to Figs. 4 and 5 of the drawings.
As can be seen in Fig. 4, the mounting system 100 includes a plurality of fastening devices 30 for securely fastening the solar panels S to the mounting rails 20. Indeed, as is apparent from Fig. 1 , a number of fastening devices 30 may be employed along the edge regions E of each of the solar panels S. After the solar panels S have been properly placed and positioned on the seating elements 25 of panel seating areas 21 spanning two parallel mounting rails 20, the fastening devices 30 are employed to clamp and securely hold the panels in those positions on the associated mounting rails 20. Stated briefly, and visible in Fig. 4, each of the fastening devices 30 includes a clip component 31 which is configured for clipped or snap-fit attachment to the mounting rails 20, and a clamping member 41 which is configured to clamp and securely hold the solar panel S in position on the respective mounting rail.
To understand the nature and operation of the fastening device 30 fully, however, reference is made to Figs. 1 5a-b and Figs. 1 6a-b of the drawings, which respectively show the clip component 31 and the clamping member 41 of the fastening device in isolation. Referring firstly to Figs. 15a-b, the clip component 31 in this embodiment is (like the mounting rails 20) formed as a metal (e.g. aluminium) element of constant cross-section. In particular, each clip component 31 has a pair of opposed limbs 32 (e.g. legs) which depend from a central, substantially flat plate member 33. Thus, plate member 33 interconnects the pair of opposed limbs 32. In an upper region, each of the limbs or legs 32 has an outer surface 34 which is substantially flat and extends generally perpendicular to the plate member 33. The free end of one of the limbs 32 is angled inwardly somewhat from the upper surface 34 and terminates in a curved or rounded hook-like catch member 35. Similarly, the free end of the other limb or leg 32 is set slightly inwardly of the upper surface 34 and terminates in a tapered barb-like catch member 36.
With reference to Figs. 4 and 5 of the drawings, it will be appreciated that the clip component 31 is designed for attachment in the upwardly opening main channel 26 of the mounting rails 20, and the manner in which the clip 31 operates and interacts with that channel 26 can be seen in Fig. 5. In particular, before the solar panels S are placed and positioned in the panel seating areas 21 on the mounting rails 20, the clip components 31 (optionally with the rest of the fastening device 30 connected to them, but preferably just the clips 31 initially) are attached to the mounting rails 20 at positions spaced apart along the channel 26. To do this, the curved, hook-like catch member 35 at the end of one limb 32 of the clip component is hooked under the bead of the inwardly projecting flange or lip 28 at one side of the channel 26 and then the clip 31 is pivoted to bring the tapered barb-like catch member 36 at the free end of the other limb 32 into engagement with the inwardly angled edge profile of the flange or lip 29 at the opposite side of the channel 26. When the tapered outer surface 37 of the barb-like catch member 36 contacts the inwardly angled flange or lip element 29, the resiliently deformable limb 32 is deflected inwardly towards the hook 35 as the clip is rotated (by hand) in the direction of arrow R in Fig. 5.
Once the widest part of the barb-like catch member 36 passes the edge of the angled flange or lip element 29, the limb or leg 32 snaps back under its own elasticity, with the barb-iike edge of the flange or lip element 29 at the upper rim of the channel 26 then being held within the longitudinal slot or recess 38 formed adjacent the catch member 36 in the clip. In this state, the hook and barb catch members 35, 36 on the resilient limbs 32 of the clip component 31 have interacted or interlocked with the engagement elements 28, 29 of the channel 26 to secure the clip 31 to the mounting rail 20. Because this snap-fit attachment of the clip 31 can be effected by an operator by hand, a speedy assembly of the mounting system 100 is promoted. The degree of residual tension in the limbs 32 of the clip component after the snap-fit attachment to the mounting rail 20 can be adjusted by appropriate selection of the dimensions and the material of the clip 31 . Desirably, however, a certain amount of resilient tension remains in the clip in the attached state (i.e. some resilient deformation is retained) to ensure that the clip maintains a reliable interlocked connection with the mounting rail 20 and does not readily slip out of position along the channel 26 of the mounting rail 20 which is pitched at the angle of the rooftop. It may, however, be possible to slide the clip along the channel 26 upon the application of some force (perhaps with the assistance of a tool) if it becomes necessary to alter its position. Additionally, the clip may be removed from its engagement with the channel 26 by the application of an appropriate force, e.g. with use of a tool. While not forming a preferred embodiment of this invention, a slotted attachment of the clip by inserting it axially into the channel 26 at an end of the mounting rail 20 is conceivable, but is clearly less desirably from a practical view point than snap-in or click-in attachment described above.
After the snap-in attachment of the clips 31 , the outer surfaces 34 at the upper part of each leg 32 are approximately aligned with respective outer surfaces of the channel walls 27. In this way, the body of the clip 31 (i.e. formed by the upper parts of the limbs 32 and the plate member 33) forms a spacer between the laterally opposite, longitudinally extending panel seating areas 21 on each mounting rail 20. In other words, the body of the clip component 31 acts to partially limit or bound the panel seating areas 21 on each mounting rail. Specifically, each of the surfaces 34 at the upper part of the limbs 32 of the clip limit and abut the frame F at a peripheral edge of the solar panel S, as can be seen in Fig. 4 of the drawings. In addition, the upper outer sides of the channel walls 27 also abut and engage the frame F of the solar panels in the seating areas 21 . With the clip component 31 as spacer and abutment member between the peripheral edges of the solar panels S, the proper placement and positioning of the panels is simplified and can occur more quickly.
Once the solar panels S have been properly positioned in the panel seating areas 21 in abutment with the clips 31 forming spacers between the individual solar panels, the fastening devices 30 are then assembled and used to securely fix and hold the solar panels S in position within the array. In particular, the clamping member 41 referred to previously is positioned above the clip component 31 such that stepped wing portions 42 at opposite ends of the clamping member 41 sit or rest on an upper side of the frame F over the edge regions E of the two solar panels S received in the two seating areas 21 of the mounting rail 20, and a central plate-like portion 43 of the clamping member 41 is positioned above the correspondingly dimensioned plate member 33 of the clip 31 . A threaded bolt 44 is provided through a hole 45 formed in the central plate-like portion 43 of the clamping member 41 and extends into a threaded socket or bore 40 provided in the clip 31 . In this particular embodiment, the threaded socket 40 is provided attached to a hole or aperture 39 formed in the plate member 33, e.g. by riveting. Alternatively, however, the plate member may for example be formed with greater thickness and the hole or aperture 39 provided with an internal thread. In any case, the bolt 44 is in threaded connection with the clip component 31 snap-fitted to the mounting rail 20 and by turning the bolt 44, the head of the bolt 46 bears down upon and biases or presses the clamping member 41 relative to and towards the clip 31 , which itself is held in interlocking engagement with the respective elements 28, 29 at the upper rims of the channel 26 by the hook and barb-like catch members 35, 36. In this way, each fastening device 30 clamps and securely hold the solar panel S in position on the respective mounting rail 20, and by arranging a number of fastening devices 30 along the edge region E of each solar panel S, the clamping force can be distributed along that edge region.
With reference to Figs. 6 and 7 of the drawings, a particular variation of the fastening device 30 is illustrated for use at the outermost lateral periphery of the solar array. As will be appreciated, each mounting rail 20 at the lateral outer periphery of the array receives and carries a solar panel at only one of its two panel seating areas 21 . As the solar panels S in the mounting system 100 are framed modules, the stepped wing portions 42 of the clamping member 41 engage the upper side of each solar panel S at a height in the range of about 30 to 50 mm (corresponding to the height of the frame F) above the mounting rail 20 and spaced slightly to one side of the bolt 44. If the wing portions 42 of the clamping member 41 at the side of the mounting rail 20 with no solar panel (i.e. at this outer periphery of the array) were not supported, the fastening device 30 would tend to twist or turn outwardly away from the solar panel under the action of the clamping force via the threaded bolt 44, i.e. as a result of a moment generated by the force.
According to this embodiment, therefore, the mounting system 100 includes a lateral support rail 50 that is designed to be received in the laterally outermost panel seating area 21 of the array. This lateral support rail 50 is again a metal section, e.g. of Al. extruded, which is generally formed as a U-shaped channel section having two upright walls 51 , but which also has two webs 52 extending vertically downwardly from a base 53 of the channel section and a small lateral flange or web 54 extending laterally from the outer of the two downward webs 52. The small lateral flange or web 54 is configured to seat and bear against the outer flange 22 of the panel seating area 21 , while the downwardly extending webs 52 are received in the channel 24 of the seating area 21 . In addition, the lateral support rail 50 includes one or more abutment elements 55 which are provided in the form of flat-headed studs or bolts. These flat-headed stud or bolt elements 55 are not only displaceable (e.g. slidable) along the support rail 50 but are also vertically adjustable, e.g. via a screw thread, to accommodate height variations which depend upon a height of the particular frame F of the solar panels S mounted in the solar panel array. As will be understood by an ordinary practitioner, the stud or bolt abutment elements 55 are provided with one threaded nut 56 for locating the bolt/stud longitudinally within a slot 57 (i.e. formed between pairs of opposed web or flange projections) in the U-shaped channel of the support rail 50 and adjusting the height h thereof, and a second locking nut 58 for fixing the height and position of the stud or bolt abutment elements 55 once they have been appropriately adjusted to the frame F.
With reference to Figs. 1 7a-b, the form of the clamping member 41 for the extreme outer lateral periphery of the solar panel array is also slightly modified. In particular, one wing portion 42' is somewhat wider, having been adapted to the top of the flat- headed stud or bolt 56. By virtue of the lateral support rail 50, the bolt 44 of the fastening device 30 can be tensioned in the regular manner to apply a clamping force to the panel under the wing portion 42 of the clamping member 41 without the risk of the fastening device 30 overturning or twisting away from the panel S. In particular, the modified wing portion 42' bears upon the head of the abutment stud or bolt 55 which is locked in position in the channel of the lateral support rail 50. As will also be seen in Figs. 6 and 7 of the drawings, the lateral support rail 50 includes an angled web or skirt 59 which is simply designed to cover the remainder of the mounting rail 20, both for aesthetic reasons and also for directing any rainwater to flashing material, e.g. sheeting, provided at the lateral sides of the solar panel array.
Referring now to Figs. 8 to 10, as well as to Figs. 19 and 20a-20b of the drawings, a further aspect of the mounting system 100 according to this embodiment relates to the provision of a capping rail 60 along adjoining edge regions of two solar panels in a direction transverse or perpendicular to the mounting rails 20. The capping rails 60 in this embodiment are once again typically formed as extruded metal sections and have a shape as shown in Figs. 8, 10 and 19. That is, each capping rail 60 includes a cover member 61 generally comprising an elongate plate, which - as seen in Fig. 10 - is configured for bearing and sealing against an upper side of a solar panel S (i.e. of the frame F) along a transverse edge region thereof. In this regard, the capping rail 60 includes sealing elements 62 formed as strips of synthetic rubber inserted below the cover plate 61 for cushioning and sealing the cover plate 61 against the edge of the frame F of the solar panel S. The sealing strips 62 have an L-shaped cross-section to embrace a corner at the top edge of the frame F with an attachment projection for receipt and engagement in a respective longitudinal slot 63 formed below the cover plate 61 , which holds the sealing strip 62. Each capping rail 60 has two generally parallel web members 64 which depend from the cover plate 61 to form a vertical channel there-between. As can be seen, these web members 64 are configured to cooperate with a bracket member 70 for securing the capping rail 60 to the frame F along the transverse edge of one of the solar panels S. In this regard, the bracket member 70 has two parallel upstanding flange members 71 configured to receive the parallel depending web members 64 of the capping rail 60 between them. Further, the bracket member 70 receives a threaded clamping bolt 72 in a hole or aperture 73 formed through a base 74 thereof such that the bolt 72 extends vertically into the channel formed between the depending web members 64. Between the parallel depending web members 64, the capping rail 60 has a longitudinal slot 65 which is formed by pairs of opposing projections 66. This slot 65 is designed to receive a nut or retainer 76 for the clamping bolt 72 that operates with the bracket member 70 in such a manner that the nut 76 is displaceable longitudinally of the capping rail 60 in a direction L along the slot 65 when positioning the bracket member70. A projecting element 75 of the bracket member 70 is configured to engage an underside of the frame F of a solar panels S and to hold that frame F firmly under the application of a clamping force via the threaded bolt 72. By providing a suitably long bolt 72, the bracket member 70 may cooperates with the capping rail 60 to be adjustable in the height direction h to suit different sized panel frames F.
In use, the attachment of the capping rail 60 is performed before the solar panels S are arranged on the mounting rails 20 in the rectangular array. In this regard, it will be appreciated that one side or edge 67 of the cover plate 61 (i.e. that side or edge which is not clamped against the frame F) is a free edge that is configured to extend or project away from the solar panel. As a result, that longitudinal edge 67 of the cover plate 61 is free to overlap an adjoining panel. Thus, when arranging the solar panels on the mounting rails 20, the transverse edge region of each panel having the capping rail 60 is arranged as the lower edge in the inclined array. In this way, the free edge 67 of the cover plate 61 in the capping rail 60 then overlaps and overlies the upper edge region of the frame F of the adjoining solar panel S in the array. While the capping rail 60 is not directly clamped to the adjoining solar panel S, the presence of the sealing strip element 62, together with the attachment of the solar panels to the mounting rails 20 via the fastening devices 30, nevertheless creates a satisfactory seal with those adjoining panels. In this manner, the capping rails 60 in the mounting system 100 of this embodiment ensure the integrity and continuity of rainwater run-off and drainage so that the solar panel array may effectively function as part of the building envelope. In particular, the capping rails 60 direct rainwater for the upper surface of one solar panel onto the upper surface of an adjoining panel in the array and prevent the ingress or penetration of water between the adjoining transverse edge regions of the solar panels by covering and sealing these regions of the array. Thus, the unwanted infiltration of rainwater, snowmelt or condensate into the roof cavity or roof structure is essentially inhibited.
Around an outer periphery of the solar panel array, flashing material G is provided to ensure a weather-proof transition between the original roof cladding and the solar panel array installed in the area where the cladding was removed. In Fig. 1 of the drawings, for example, a section of flashing sheet material G is illustrated at the high side H of the array. To provide a suitable interconnection between the sheet material G and the mounting system 100 of this embodiment, and to ensure proper run-off of rainwater, the mounting system 1 00 also includes a modified capping rail 60' for the edge region of the solar panels S at the upper periphery of the array. With reference to Figs. 1 1 to 1 3 and Fig. 21 of the drawings, it will be appreciated that the modified capping rail 60' incorporates a cover plate 61 and the same securing arrangement via bracket member 70 as the capping rail 60 just described. The primary difference in this case is the provision of a retaining slot 68 above the cover member 61 for receiving and retaining an overturned edge region N of the flashing sheet material G. In particular, the capping rail 60' is again an extruded section, but this time includes a curved C-profile 69 formed above the cover member 61 to create the retaining slot 68, which is thus formed as a blind slot. The opening O of the slot 68 is directed towards the upper surface of the solar panel S to which the capping rail 60' is attached, which in turn requires the edge of the flashing sheet G to be overturned to be inserted into the slot. In this way, any rainwater run-off tends to flow off the edge N of the flashing and directly onto the upper surface of the panel S. If some water does flow into the slot 68, however, the closed or "blind" slot 68 does not allow the water to flow anywhere other than back out though the opening O.
With regard to the capping rails 60, 60', it will be appreciated that the features of the cover plate 61 and the retaining slot 68 could also desirably be integrated directly into new frame members F for the framed PV modules. In this way, it would not be necessary to retro-fit the capping rails 60, 60' to the solar panels S as elements of the mounting system 100. Instead, they would already be integral with the solar panels themselves. For this reason, the present invention also contemplates a frame member for a PV solar panel having features of the cover plate 61 and/or the retaining slot 68 described above in connection with the capping rails 60,60'.
It will be appreciated that the above description of the preferred embodiments of the invention with reference to the drawings has been made by way of example only. Thus, a person skilled in the art will appreciate that various changes, modifications and/or additions may be made to the parts particularly described and illustrated without departing from the scope of the invention defined in the appended claims.
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