METHOD OF INSTALLATION

TECHNICAL FIELD

The present disclosure relates generally to roofing systems, for example, suitable for covering the roof of a house or other building. The present disclosure relates more particularly to a roofing system including a plurality of panels attached to a surface structure. BACKGROUND ART

Roofing systems typically include a roof surface structure formed by a roofing frame that provides the overall shape of the roof. A surface layer may then be formed over and supported by the frame. The surface layer frequently includes a decking or sheathing that is covered by one or more weather resistant layers. For example, roofs are often covered with shingles that shed water and protect the roof from weather. Moving up the slope of the roof, rows of shingles are placed on top of lower rows so that water may be directed away from the surface structure. Various types of shingles can be secured directly to the surface structure, for example, by using roofing nails.

In other roofing systems there may be advantages to indirect attachment of the weather resistant layer to the surface structure. For example, with some types of roofing panels, such as various types of roofing tiles or solar panels, a direct connection to the surface structure may be less appropriate.

The present inventors have determined that a roofing system configured to secure roofing panels to a surface structure that is effective and easy to install would be attractive to builders and customers.

SUMMARY OF THE DISCLOSURE

In one aspect, the present disclosure provides a roofing assembly comprising: a support frame having a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure and a front surface configured to face away from the surface structure, wherein the support frame includes a clip receptacle; and a roofing panel including a front side, a rear side, and a clip extending from the rear side, wherein the clip of the roofing panel engages the clip receptacle of the support frame so as to secure the roofing panel to the support frame.

In another aspect, the present disclosure provides a roofing assembly comprising: a support frame having a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure and a front surface configured to face away from the surface structure and to support a roofing panel, wherein the support frame includes a first bracket slot at the lower edge; a bracket secured in the first bracket slot and extending downward from the lower edge of the support frame; and a hook coupled to the bracket, wherein the hook bends to form an upward facing opening configured to receive a lower edge of the roofing panel.

In another aspect, the disclosure provides a roofing system comprising: a surface structure of a roof; and a plurality of roofing assemblies according to the disclosure secured to the surface structure, the plurality of roofing assemblies including: a first row of roofing assemblies including a first roofing assembly, and a second row of roofing assemblies positioned above the first row of roofing assemblies on the surface structure, the second row of roofing assemblies including a second roofing assembly.

In another aspect, the disclosure provides a method of installing a roofing system according to the disclosure, the method comprising: positioning a group of support frames according to any of the roofing assemblies of the disclosure in a first row on a surface structure; positioning a group of support frames according to any of the roofing assemblies of the disclosure in a second row on the surface structure above the first row; securing the support frames to the surface structure; and securing roofing panels to the support frames.

Additional aspects of the disclosure will be evident from the disclosure herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are included to provide a further understanding of the methods and devices of the disclosure, and are incorporated in and constitute a part of this specification. The drawings are not necessarily to scale, and sizes of various elements may be distorted for clarity. The drawings illustrate one or more embodiment(s) of the disclosure, and together with the description serve to explain the principles and operation of the disclosure.

FIG. 1 is a schematic perspective view of a roofing assembly according to an embodiment of the disclosure;

FIG. 2 is a schematic perspective view of a support frame of the roofing assembly of

FIG. 1; FIG. 3 is a rear perspective view of a roofing panel of the roofing assembly of FIG. 1;

FIG. 4 is a detailed view of a portion of components of the roofing assembly of FIG. 1 during installation;

FIG. 5 is detailed view of a portion of a roofing panel of the roofing assembly of FIG. 1;

FIG. 6 is a perspective view of a roofing assembly according to another embodiment of the disclosure;

FIG. 7 is a detailed view of a portion of the roofing assembly of FIG. 6;

FIG. 8 is a perspective view of a bracket and hook of the roofing assembly of FIG. 6;

FIG. 9A is a perspective view of a portion of a roofing system positioned on a surface structure according to an embodiment of the disclosure;

FIG. 9B is a perspective view of another portion of the roofing system of FIG. 9A positioned on the surface structure; and

FIG. 9C is a perspective view of another portion of the roofing system of FIG. 9A positioned on the surface structure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

As described above, the present inventors have noted that a roofing system configured to secure roofing panels to a surface structure that is effective and easy to install would be attractive to builders and customers.

Accordingly, one aspect of the disclosure is a roofing assembly including a support frame configured to receive a roofing panel. The support frame provides a convenient structure for securing the roofing panel to the surface structure of the roof without damaging the roofing panel. Moreover, the support frame may be used to secure roofing panels of various different materials to the surface structure. For example, as explained further below, in some embodiments, the roofing assembly may include a solar roofing panel secured to the support frame. On the other hand, in some embodiments, the roofing assembly may include a non-solar roofing panel secured to the support frame. In either case, the support frame can support the roofing panel and secure it to the surface structure, allowing easier and more consistent installation that a direct coupling of the roofing panels to the surface structure.

Further, the use of the support frame can elevate the roofing panels from the surface structure while maintaining a low visibility profile. By elevating the roofing panels from the surface structure, a gap can be provided between the roof surface formed by the roofing panels and the underlying surface structure. This gap can provide ventilation and allow moisture draining underneath the roofing panels. Moreover, the gap can also provide a space for certain equipment, such as components of a solar roofing system like wiring, junction boxes, and inverters, as well as other components or equipment.

The support frames can also assist in laying out the roofing panels across the surface structure. For example, as explained further below, the support frames may be placed over the roof surface structure in an abutting relationship that lays out the spacing for the roofing panels. Accordingly, once a first row of the support frames is properly placed on the roof, the remaining support frames and corresponding roofing panels can be installed without careful measuring steps.

In one aspect, the disclosure provides a roofing assembly including a support frame and a roofing panel. The support frame has a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure, a front surface configured to face away from the surface structure, and a clip receptacle. The roofing panel includes a front side, a rear side, and a clip extending from the rear side. The clip of the roofing panel engages the clip receptacle of the support frame so as to secure the roofing panel to the support frame.

An embodiment of such a roofing assembly is shown in perspective view in FIG. 1. Roofing assembly 100 includes a support frame 110 and a roofing panel 170. Support frame 110 is shown more clearly in FIG. 2, where roofing panel 170 is removed. As shown in FIG. 2, support frame 110 has a first end 112, a second end 114, an upper edge 116, a lower edge 118, a rear surface 120, and a front surface 122. Rear surface 120 is configured to be disposed on a surface structure 102, as shown in FIG. 1, while front surface 122 is configured to face away from surface structure 102. Support frame 110 also includes several clip receptacles 124, explained in more detail below. Roofing panel 170 is shown isolated in FIG. 3 from a rear view. Roofing panel 170 includes a front side 172, a rear side 174, and several clips 184 extending from rear side 174. Clips 184 of roofing panel 170 respectively engage clip receptacles 124 of the support frame 110 so as to secure roofing panel 170 to support frame 110. FIG. 4 shows a portion 180 of a roofing panel in place over support frame 110 with two of the clips 184 positioned for insertion into respective clip receptacles 124. To secure the roofing panel to support frame 110, the roofing panel is pushed down from the position shown in FIG. 4 so that clips 184 engage clip receptacles 124 and the roofing panel lies against the front surface 122 of support frame 110.

The terms front and rear, as used herein, refer to a direction that is perpendicular to a surface of the surface structure. In contrast, the directions along the slope of the surface structure are referred to herein as upper and lower. In certain embodiments of the roofing assembly as otherwise described herein, the roofing panel comprises a panel body and an attachment frame that includes the clip. For example, as shown in FIG. 3, roofing panel 170 includes panel body 176 and an attachment frame 180 positioned behind panel body 176. Attachment frame 180 extends over the rear side 174 of roofing panel 170 and forms clips 184. The inclusion of clips on an attachment frame provides a convenient manner for securing the clips to the rear side of panel body. For example, the attachment frame can provide a substantial foundation for attachment to the panel body while the smaller clips extend rearward at desired locations. Further, the attachment frame may be formed of a different material than the panel body, which allows these components to have different performance characteristics. For example, where the roofing panel is a solar panel, the panel body may be substantially formed of glass, while the attachment frame it clips are formed of another material, such as plastic. The plastic material may be more resilient for providing a secure attachment of the clips to the support frame. Moreover, if a portion of the attachment frame breaks, such as one of the clips, the attachment frame may be replaced without the entire roofing panel.

Alternatively, in some embodiments, the clips are individually secured to the rear of the panel body without the use an attachment frame. Further, in some embodiments, the clip is integrally formed with the panel body of the roofing panel. For example, in some embodiments, the roofing panel, including the panel body and clips, is formed as a single integral piece. Such a roofing panel may be formed of a material that is appropriate for both the front surface of the roofing panel and the clip(s), such as a reinforced polymer, metal, ceramic, or other material.

In certain embodiments of the roofing assembly as otherwise described herein, a front surface of the panel body forms the front side of the roofing panel and a rear surface of the panel body is secured to the attachment frame. Further, in some embodiments, the rear surface of the panel body is secured to the attachment frame with a layer of adhesive. For example, in attachment frame 180 of roofing panel 170 is secured to the rear surface of panel body 176 by a layer of adhesive disposed between attachment frame 180 and panel body 176. The use of adhesive to couple the attachment frame to the panel body allows these components to be connected without the need to penetrate the panel body. Accordingly, the rear surface of the panel body can be formed as a flat monolithic surface without the need for any interruptions across the surface, such as for fasteners.

Using an adhesive also allows the attachment frame to be secured to the panel body without extending around the edges of the panel body. This allows the attachment frame to be entirely contained behind the panel body and obscured from view. As a result, a roofing system formed with such an assembly can provide a roofing surface that is entirely formed by the panel bodies of roofing panels, without any visible attachment hardware.

On the other hand, in other embodiments, the attachment frame extends around the edges of the panel body to hook onto the panel body. Further, in some embodiments, the attachment frame is secured to the panel body using clips or fasteners.

In certain embodiments of the roofing assembly as otherwise described herein, the clip is disposed toward a lower edge of the attachment frame. For example, as shown in FIG. 3, clips 184 of attachment frame 180 are positioned along the lower edge of attachment frame 180. This position allows for a secure attachment of roofing panel 170 to support frame 110. The upper edge of roofing panel 170 may be overlapped by one or more additional panels that are positioned higher on the roof. Accordingly, the upper edge of the roofing panel 170 can be secured with a hook or other structure that will be obscured by the overlapping roofing panel(s). Therefore, placing clips 184 toward the lower edge of the roofing panel 170, and at the lower edge of the attachment frame 180, can help ensure that the lower portion of roofing panel 170 is securely held on the roof. As shown in FIG. 3, clips 184 of the illustrated embodiment are spaced from the lower edge of roofing panel 170 so that it may overlap another roofing panel that is placed lower on the roof.

In certain embodiments of the roofing assembly as otherwise described herein, the attachment frame extends across a majority of the rear surface of the panel body. For example, as shown in FIG. 3, attachment frame 180 extends substantially across the entire length of panel body 176 from one end to the other, and from the upper edge to the lower portion of panel body 176. Having the attachment frame extend across most of the panel body provides a large area for an adhesive bond to be formed between the panel body and the attachment frame, which allows a strong bond to be established with a variety of different adhesive materials. In other embodiments, the attachment frame may have a smaller footprint. Such an attachment frame may be secured with a material that has a strong adhesive bond or using another attachment method.

In certain embodiments of the roofing assembly as otherwise described herein, the clip includes a pair of prongs, each prong having an angled surface and a catch. FIG. 5 shows a detailed view of one of clips 184 of attachment frame 180 on the rear side of roofing panel 170. As shown, clip 184 includes two prongs 186 that each include an angled surface 187 and a catch 188 formed by a sharp edge at the inner end of angled surface 187. Prongs 186 of clip 184 are resilient so that they flex inwardly as clip 184 is inserted into the corresponding clip receptacle of the support frame. As the angled surfaces 187 engage the clip receptacle they are urged inward by the slope of the angled surfaces until the catch 188 passes a corresponding engagement structure and latches into place. While the prongs 186 of clip 184 are resilient, in other embodiments, the prongs may be relatively rigid while a portion of the clip receptacle is resilient and flexes upon insertion. Further, in some embodiments, both the prongs and the clip receptacle may flex upon insertion. Likewise, while the angled surfaces and catches of prongs 186 point outwardly, in other embodiments they may point inwardly or in the same direction. Further still, in some embodiments, the clip may include a single prong. Likewise, the clip may have another configuration entirely, such as a circular post with an attachment head or a latch.

In certain embodiments of the roofing assembly as otherwise described herein, the clip is one of a group of clips of the roofing panel. For example, roofing panel 170 includes a group of five clips 184 spaced across the length of roofing panel 170. In other embodiments, the roofing panel may include a group of more or fewer clips. Likewise, while roofing panel 170 includes a single row of clips, in other embodiments, the roofing panel may include two or more rows of clips. Further, in some embodiments, the roofing panel may include a single clip that secures the roofing panel to the support frame.

In another aspect, the disclosure provides a roofing assembly including a support frame, a bracket secured to the support frame, and a hook coupled to the bracket. The support frame has a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure, and a front surface configured to face away from the surface structure and to support a roofing panel. The support frame also includes a first bracket slot at the lower edge. The bracket secured in the first bracket slot and extends downward from the lower edge of the support frame. The hook, which is coupled to the bracket, bends to form an upward facing opening configured to receive a lower edge of the roofing panel.

An embodiment of such a roofing assembly is shown in FIG. 6. Roofing assembly 600 includes a support frame 610 with a first end 612, a second end 614, an upper edge 616, a lower edge 618, a rear surface 620 configured to be disposed on surface structure 602, and a front surface 622 configured to face away from the surface structure 602. Support frame 610 includes a plurality of bracket slots 630 along lower edge 618 that are each configured to hold a bracket. For example, bracket 680 is secured in one of the bracket slots 630 and extends downward from lower edge 618 of support frame 610. A hook 690A is coupled to bracket 680 and bends upward. Accordingly, hook 690A forms an upward facing opening 692 (see FIG. 8). As shown in FIG. 6, the front surface 622 of support frame 610 is configured to support a roofing panel while hook 690A holds the roofing panel in place and prevents the roofing panel from sliding down the roof.

FIG. 7 shows a detailed view of two bracket slots 630 of support frame 610 with bracket 680 inserted in one of the slots, while FIG. 8 shows bracket 680 and hook 690A in isolation from the support frame.

In certain embodiments of the roofing assembly as otherwise described herein, the support frame is formed of a first material and the bracket is formed of a second material that is different from the first material. Further, in some embodiments, the hook is formed of a third material that is also different from the first material. Moreover, in some embodiments, the second and third material may be the same or similar.

In certain embodiments of the roofing assembly as otherwise described herein, at least one of the second material or third material has a yield strength that is at least 2x the yield strength of the first material, e.g., at least 3x, e.g., at least 5x. In some embodiments, as explained further below, portions of the bracket and hook extend in a gap between two overlapping roofing panels. Accordingly, using a material with a higher yield strength allows the material of the bracket and hook to be positioned within the gap and support the upper roofing panel without the need to substantially increase the size of the gap between the panels. For example, in some embodiments, the support frame is formed of a plastic material while the bracket and hook are formed of a metal material. Likewise, in some embodiments, the bracket and hook are formed of the same metal, while in other embodiments the bracket and hook are formed of different metals. For example, in some embodiments, the bracket is formed of aluminum, galvanized steel, or galvalume, while the hook is formed of another alloy. Alternatively, in some embodiments, the support frame is formed of a first plastic material, while the bracket and/or hook are formed of a stronger plastic material, such as an engineering or reinforced plastic. Other combinations of materials are also possible.

In certain embodiments of the roofing assembly as otherwise described herein, the bracket includes a platform configured to support a lower portion of the roofing panel. For example, as shown in FIGS. 7 and 8, bracket 680 includes a platform 682 configured to support a lower portion of a roofing panel placed on support frame 610 and bracket 680. Platform 682 is substantially flat to support a roofing panel but is grooved along its length. These grooves help increase the strength of bracket 680 and provide channels for directing moisture down the slope of the roof. In other embodiments, the platform may include other protrusions or variations to increase strength, or may be flat. In certain embodiments of the roofing assembly as otherwise described herein, the bracket includes legs that extend down from the platform and are configured to support the bracket against the surface structure. For example, bracket 680 includes legs 684 that extend down from platform 682 to meet the surface structure and to support bracket 680 against the surface structure. As a result, the weight of the roofing panel may be directly transferred to the surface structure through the bracket. In other embodiments, the bracket may attach to the support frame in a manner that allows the platform of the bracket to be supported by the support frame without any legs that extend to the surface structure.

In certain embodiments of the roofing assembly as otherwise described herein, the legs include feet that extend under attachment flanges of the support frame. For example, as shown in FIG. 7, support frame 610 includes attachment flanges 626 on opposing sides of the bracket slot 630 that include apertures for securing support frame 610 to the surface structure using mechanical fasteners, such as screws. Further, the legs 684 of bracket 680 include feet 686 that extend laterally outward. As shown in FIG. 7, when bracket 680 is coupled to the bracket slot 630, the feet 686 of legs 684 extend under the attachment flanges 626. Further, the feet 686 also include apertures that align with the apertures of attachment flanges 626 so that bracket 680 and support frame 610 can be secured together to the surface structure using the same fastener. The attachment flanges 626 of support frame 610 also include ridges 628 to slightly elevate most of the attachment flange 626 from the surface structure and provide a space for the feet 686 of bracket 680. These ridges allow for even support across the rear surface of the support frame regardless of which bracket slots are occupied by brackets, because the ridges 628 directly contacts the surface structure regardless of whether a bracket is disposed in the bracket slot.

In certain embodiments of the roofing assembly as otherwise described herein, the support frame includes a central projection that extends into the bracket slot, and wherein the platform of the bracket covers the central projection. For example, as shown with respect to the empty bracket slot 630 on the right side of FIG. 7, the bracket slot 630 of support frame 610 is formed by a pair of side walls 632 with an opening therebetween. The support frame 610 also includes a central projection 634 that extends into the bracket slot 630 and is spaced from both side walls 632. When bracket 680 inserted in bracket slot 630, as shown on the left side of FIG. 7, platform 682 covers central projection 634. Legs 684 extend rearward from platform 682 at opposing sides of central projection 634 such that each leg is positioned between central projection 634 and a respective side wall 632. In certain embodiments of the roofing assembly as otherwise described herein, the hook is formed by a wire clip coupled to the bracket. For example, hook 690A is formed by the end of wire clip 694, which is bent and shaped to form upward facing opening 692. Wire clip 694 extends upward behind platform 682 toward the upper portion of bracket 680 where it is connected to bracket 680. In other embodiments, the hook is formed by a cast, molded, carved or printed component, or a bent sheet, such as a bent metal sheet. Further still, in some embodiments, the hook is integrally formed with the bracket in a single piece of material.

In certain embodiments of the roofing assembly as otherwise described herein, the wire clip includes a second hook, the hook is disposed at a first end of the wire clip, and the second hook is disposed at a second end of the wire clip. For example, as shown in FIG. 7, wire clip 694 includes a second end that forms a second hook 690B extending downward from bracket 680. First hook 690A and second hook 690B cooperate to hold a roofing panel in two locations at the same elevation, providing a stable support for the roofing panel. From each hook 690A, 690B, wire clip 694 extends upward toward an upper end of bracket 680 where a central portion of wire clip 694 is secured. Accordingly, wire clip 694 has a substantially U-shaped configuration.

In certain embodiments of the roofing assembly as otherwise described herein, the bracket includes a first tab that secures the wire clip. For example, as shown in FIG. 8, bracket 680 includes tabs 688 that extend inward from legs 684 in order to hold wire clip 694 in place. Tabs 688 of bracket 680 are formed by flaps of material that are cut from legs 684 and folded inward to engage wire clip 694. In other embodiments, the tabs may be formed in another manner, such as molded flange that extends from the legs, or a separate piece that is coupled to the legs. Moreover, in some embodiments, the tab or tabs may be located on another portion of the bracket, such as the platform or another area.

In certain embodiments of the roofing assembly as otherwise described herein, the first bracket slot is one of a plurality of bracket slots disposed along the lower edge of the support frame, and wherein each of the bracket slots is configured to receive the bracket. For example, as shown in FIG. 6, support frame 610 includes a plurality of bracket slots 630 that are arranged in a row along its lower edge 618. In the illustrated arrangement, a bracket 680 is positioned in the bracket slot 630 that is second from the left-most bracket slot in the row and another bracket 680 is positioned in the bracket slot 630 that is second from the rightmost bracket slot in the row. While many of the bracket slots 630 in FIG. 6 are unoccupied, each of the bracket slots 630 of support frame 610 has the same configuration and could receive a brackets. However, adequate support of a roofing panel can be provided without providing a bracket in each of the bracket slots. For example, the two brackets 680 shown in FIG. 6 can securely hold a roofing panel. The use of additional bracket slots 630 allows the position of the brackets to be adapted as needed. For example, in some embodiments, the brackets may be positioned within bracket slots that are aligned with framing members of the surface structure, in order to provide a solid surface for the support frame. Further, the row of bracket slots allow flexibility if the support frame is to be used with a shorter roofing panel, such as at the edge of a roof. For example, the support frame can be cut down to the size of the shorter roofing panel and still provide adequate locations for the bracket in view of the row of available bracket slots.

In certain embodiments of the roofing system as otherwise described herein, an outer surface of the support frame is formed of a polymer material. For example, in some embodiments, the support frame is entirely formed of a polymer material. Further, in some embodiments the polymer material includes reinforcing fibers, such as a fiberglass material. In other embodiments, the support frame is formed of a first material with a polymer coating that forms the outer surface of the support frame. For example, in some embodiments, the support frame is formed of a metal, such as aluminum, which is covered with a polymer coating, shell or overlay. The use of a polymer on the exterior surface of the support frame can reduce the conductivity of the support frame, which may help avoid requirements to electrically bond or ground the batten. In other embodiments, the support frame is formed from another insulating material, such as a wood, ceramic or composite material. Further, in some embodiments, the support frame is formed of a conductive material, such as metal. For example, in some embodiments, the support frame is formed of aluminum, steel or iron.

In certain embodiments of the roofing assembly as otherwise described herein, the support frame includes an upper frame member that extends along the upper edge, a lower frame member that extends along the lower edge, and a plurality of joists that extends between the upper frame member and the lower frame member. For example, as shown in FIG. 2, support frame 110 includes an upper frame member 146 that extends the length of support frame 110 along upper edge 116 and a lower frame member 148 that extends the length of support frame 110 along lower edge 118. Moreover, a row of joists 140 extend between upper frame member 146 and lower frame member 148 to form the structure of the frame. Two of the joists 140 are positioned at opposing ends of support frame 110 and, with upper frame member 146 and lower frame member 148, for a perimeter around the outer edge of support frame 110. Likewise, as shown in FIG. 6, support frame 610 also includes an upper frame member 646 along upper edge 616 and a lower frame member 648 along lower edge 618. A plurality of joists 640 extend between upper frame member 646 and lower frame member 648. Again, the upper frame member 646, lower frame member 648 and joists 640 form the structure of support frame 610.

In some embodiments, all the joists are parallel and run perpendicularly to the upper frame member and lower frame member. For example, joists 140 of support frame 110 all extend straight along the slope of the roof in parallel from upper frame member 146 to lower frame member 148. In other embodiments, at least some of the joists are angled with respect to each other or with respect to the slope of the roof. For example, joists 640 of support frame 610 are disposed at an angle with respect to upper frame member 646 and lower frame member 648 that is not perpendicular. Specifically, most of joists 640 of support frame 610 are angled to form a series of trusses along the length of support frame 610. This configuration may provide added structural integrity to the support frame.

In certain embodiments of the roofing assembly as otherwise described herein, each joist includes a leg that extends from the rear surface to the front surface and a support flange that extends laterally outward from the leg at the front surface. For example, as shown in FIG. 2, each joist 140 includes a leg 145 that extends from rear surface 120 to front surface 122. At the front surface 122, a support flange 144 extends laterally outward from leg 145. Support flange 144 forms a portion of front surface 122 and is configured to support the rear side of a roofing panel. Leg 145 transfers weight applied to support flange 144 to the rear surface 120 of support frame 110 where it may be transferred to the surface structure.

In certain embodiments of the roofing assembly as otherwise described herein, the joists include a foot that extends laterally outward from the leg at the rear surface. For example, as shown in FIG. 2, each joist 140 includes a foot 142 that extends laterally outward from leg 145 at rear surface 120. Each foot 142 forms a portion of rear surface 120 and is configured to transfer loads to the surface structure. Further, in some embodiments, the feet of the joists are configured to secure the support frame to the surface structure. For example, in some embodiments, the feet include apertures configured to receive mechanical fasteners for fastening the support frame to the surface structure.

Each of the leg, support flange, and foot of a joist may extend the entire length of the joist. Alternatively, portions of these parts of the joists may be provided in segments. For example, the support flanges 144 of joists 140 extend the entire distance between upper frame member 146 and lower frame member 148, while the legs 145 and feet 142 are provided in segments. In certain embodiments of the roofing assembly as otherwise described herein, the support frame includes attachment tabs at the rear surface that extend above the upper frame member. For example, as shown in FIG. 2, support frame 110 includes attachment tabs 150 that extend upward from upper frame member 146 and are positioned at rear surface 120. Attachment tabs 150 are configured to secure support frame 110 to the surface structure, for example, using a mechanical fastener such as a screw or nail. The position of the attachment tabs 150 is conveniently located to allow tools to be used install support frame 110 away from the rest of support frame 110. This allows installation to be easier and reduces the likelihood that parts of the support frame might be damaged. In other embodiments, the support frame may exclude such attachment tabs. For example, in some embodiments, the support frame is attached to the surface structure using the feet of the joists or another section of the support frame.

In certain embodiments of the roofing assembly as otherwise described herein, the upper frame member is spaced from the rear surface of the support frame. For example, in some embodiments, the upper frame member is supported by the joists at a distance from the rear surface of the support frame. This prevents the upper frame member from forming a moisture barrier at the face of the surface structure, thereby allowing moisture to drain through the support frame.

In certain embodiments of the roofing assembly as otherwise described herein, a depth of the support frame is greater at the lower edge than at the upper edge. For example, support frame 110 has a greater depth at the lower edge 118 and a smaller depth at the upper edge 116, thereby causing the front surface 122 of support frame 110 to be angled in relation to the rear surface 120. The angled front surface 122 of support frame 110 allows the lower edge of a roofing panel placed on support frame 110 to overlap the upper edge of a neighboring roofing panel.

In certain embodiments of the roofing assembly as otherwise described herein, the front surface of the support frame includes a drain channel along the first end. For example, as shown in FIG. 6, support frame 610 includes a drain channel 652 in the upper surface of one of the joists that extends from upper frame member 646 to lower frame member 648. The drain channel can help to guide water that falls on the roofing panel down the slope of the roof. For example, one side edge of the roofing panel may be spaced from the end of the support frame so as to be positioned over the drain channel. Accordingly, water that runs off the side edge of the roofing panel will fall into the drain channel. On the other hand, the opposing side edge of the roofing panel may pass the other end of the support frame so as to form an overhang over the other end of the roofing panel. This opposing side edge of the roofing panel may then be positioned over the drain channel of a neighboring support frame.

In certain embodiments of the roofing assembly as otherwise described herein, the support frame has substantially hollow interior. For example, in support frame 110 and support frame 610, the joists are formed as thin-walled components and are spaced apart from one another. Accordingly, much of these support frames are hollow. This allows the support frames to be lightweight, which reduces the load on the roof and makes installation easier. Further, the hollow construction can provide space for other components under the roofing panels, such as wiring. Moreover, the hollow construction can also allow for drainage underneath the roofing panels.

In certain embodiments of the roofing assembly as otherwise described herein, the front surface of the support frame provides support across the rear surface of the roofing panel. For example, in some embodiments, every point on the rear surface of the roofing panel is no more than 6 inches from a supporting surface of the support frame, e.g., no more than 4 inches. On the other hand, in other embodiments, larger spaces are provided between areas of support for the roofing panel.

In certain embodiments of the roofing system as otherwise described herein, the roofing panel is a solar roofing panel. For example, in some embodiments, the roofing panel includes a panel body and photovoltaic elements disposed in the panel body. For example, in some embodiments, the roofing panel includes a glass panel body that incorporates photovoltaic elements. In other embodiments, the panel body is formed of a variety of materials.

In other embodiments of the roofing assembly as otherwise described herein, the roofing panel is a non-solar roofing panel. For example, in some embodiments, the roofing panel is a standard roofing panel without any electrical activity or connections. Further, in some embodiments, the roofing panel is formed of glass, metal, ceramic or a polymer material.

In another aspect, the disclosure provides a roofing system. The roofing system includes a surface structure of a roof and a plurality of roofing assemblies of the disclosure secured to the surface structure. The plurality of roofing assemblies includes a first row of roofing assemblies and a second row of roofing assemblies positioned above the first row of roofing assemblies on the surface structure. The first row of roofing assemblies includes a first roofing assembly and the second row of roofing assemblies includes a second roofing assembly. Such a roofing system is shown in FIG. 9C and uses several of the roofing assemblies 100 shown in FIGS. 1-5. FIGS. 9A and 9B illustrate steps in a method of installing the roofing system. As shown in FIG. 9C, roofing system 104 includes a surface structure 102 and a plurality of roofing assemblies 100A-100D secured to surface structure 102. A first roofing assembly 100A is positioned on surface structure 102 in a first row with another roofing assembly 100C. A second roofing assembly 100B is positioned on surface structure 102 in a second row 108 that is located above first row 106. Second row 108 also includes another roofing assembly 100D. While the illustrated system shows a total of four roofing assemblies 100A-100D in other embodiments, the roofing assembly includes additional rows. Likewise, in some embodiments each of the rows include additional roofing assemblies.

In certain embodiments of the roofing system as otherwise described herein, each of the support frames of the first row of roofing assemblies is positioned adjacent to at least one other support frame in the first row of roofing assemblies. For example, as shown in FIG. 9B, the support frames 110A and 110C of the respective roofing assemblies are positioned adjacent to one another in the first row 106. The phrase adjacent, as used herein, means spaced within one inch of one another, e.g., within * inch from one another. Moreover, adjacent support frames may also abut one another or overlap one another.

In certain embodiments of the roofing system as otherwise described herein, the support frame of the first roofing assembly is positioned adjacent to the support frame of the second roofing assembly. For example, as shown in FIG. 9B, support frame 110C of the second roofing assembly is positioned directly above support frame 110A of the first roofing assembly on surface structure 102, such that support frame HOC is adjacent to support frame 110A. By placing the support frames within a certain row adjacent to one another, and by placing the rows adjacent to one another, the roofing system can be easily laid out and certain measurement steps can be avoided, which makes installation straightforward.

In certain embodiments of the roofing system as otherwise described herein, a portion of the support frame of the second roofing assembly overlaps a portion of the support frame of the first roofing assembly. For example, as shown in FIG. 9B, second support frame 110B includes a row of overhang projections 154 and a drain channel 152 that extend over first support frame 110A. Drain channel 152 of second support frame 110B may be configured to project over the roofing panel supported by first support frame 110A in order to guide water down the exterior surface of the roofing system.

In certain embodiments of the roofing system as otherwise described herein, a portion of a roofing panel of the second roofing assembly overlaps a portion of the support frame of the first roofing assembly. For example, as can be appreciated from FIG. 9C, the roofing panel 170B of second roofing assembly 100B extends down past the lower edge of the second support frame of second roofing assembly 100B to overlap an upper portion of the first support frame of first roofing assembly 100A. Accordingly, water than runs down roofing panel 170B will drain onto the surface of roofing panel 170A.

In certain embodiments of the roofing system as otherwise described herein, the support frame of each of the roofing assemblies is secured to the surface structure with mechanical fasteners. For example, the support frames of the roofing assemblies may be secured to the surface structure with nails, screws, staples, or other fasteners. In other embodiments, the support frames may be secured by another method, such as using adhesive.

In certain embodiments of the roofing system as otherwise described herein, each of the roofing assemblies in the plurality of roofing assemblies has the same configuration. For example, each of the roofing assemblies in roofing system 104 has the same configuration. In other embodiments, the roofing assemblies have different configurations. Further, in some embodiments, the roofing system includes a plurality of roofing assemblies with the same configuration, and additional edge assemblies at the end of one or more of the rows of roofing assemblies. Such an edge assembly may include a support frame and roofing panel that is shorter in length. For example, the support frame and roofing panel of the edge assemblies may be cut to be shorter than those of the plurality of roofing assemblies.

In another aspect the disclosure provides a method of installing a roofing system according to the disclosure. The method includes positioning a group of support frames according to any of the roofing assemblies of the disclosure in a first row on a surface structure and positioning a group of support frames according to any of the roofing assemblies of the disclosure in a second row on the surface structure above the first row. The method also includes securing the support frames to the surface structure and securing roofing panels to the support frames.

Such a method is depicted in FIGS. 9A-9C. As shown in FIG. 9A, a first row 106 of support frames 110A and HOC are positioned on surface structure 102. As shown in FIG. 9B, a second row 108 of support frames HOB and HOD is then positioned on surface structure 102 above first row 106. The method also includes securing the support frames 110A-110D to the surface structure 102 and securing roofing panels to the support frames, as shown in FIG. 9C.

In certain embodiments of the method as otherwise described herein, the support frames in the first row are secured to the surface structure before positioning the support frames in the second row. In other embodiments, all of the support frames are positioned on the surface structure before any of the support frames are secured to the surface structure. Further still, in some embodiments, the support frames are secured to the surface structure as they are positioned on the surface structure. Likewise, in some embodiments, the roofing panels are secured to the support frames after all of the support frames are secured to the surfaces structure. In other embodiments, the roofing panels are secured to the support frames in the first row before positioning the support frames in the second row.

In certain embodiments of the method as otherwise described herein, positioning the support frames in the first row includes placing each of the support frames adjacent to at least one other support frame in the first row. Likewise, in some embodiments, positioning the support frames in the second row includes positioning a second support frame in the second row adjacent to a first support frame in the first row. As explained above, by placing each support frame in the roofing system adjacent to or overlapping another support frame, the installation of the support frames can be completed efficiently while avoiding certain measuring steps.

In certain embodiments of the method as otherwise described herein, the support frames are secured to the surface structure with mechanical fasteners. For example, in some embodiments, the support frames are secured to the surface structure using nails, screws, or staples.

In certain embodiments of the method as otherwise described herein, securing the roofing panels to the support frames includes inserting clips of the roofing panels into clip receptacles in the support frames. For example, support frames 110A-110D include clip receptacles, and securing the roofing panels to the support frames includes inserting clips of the roofing panels into the clip receptacles, as explained above. In other embodiments, securing the roofing panels to the support frames includes inserting the roofing panels into hooks that are coupled to the support frames. For example, in some embodiments, the roofing assemblies of the roofing system include features similar to those of roofing assembly 600, shown in FIGS. 6-8, and securing the roofing panels to the support frames includes inserting the roofing panels into hooks that are coupled to brackets attached to the support frames, as explained above.

It will be apparent to those skilled in the art that various modifications and variations can be made to the processes and devices described here without departing from the scope of the disclosure. Thus, it is intended that the present disclosure cover such modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.

Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

Embodiment 1. A roofing assembly comprising: a support frame having a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure and a front surface configured to face away from the surface structure, wherein the support frame includes a clip receptacle; and a roofing panel including a front side, a rear side, and a clip extending from the rear side, wherein the clip of the roofing panel engages the clip receptacle of the support frame so as to secure the roofing panel to the support frame.

Embodiment 2. The roofing assembly according to embodiment 1, wherein the roofing panel comprises a panel body and an attachment frame that includes the clip.

Embodiment 3. The roofing assembly according to embodiment 2, wherein a front surface of the panel body forms the front side of the roofing panel and a rear surface of the panel body is secured to the attachment frame.

Embodiment 4. The roofing assembly according to embodiment 3, wherein the rear surface of the panel body is secured to the attachment frame with a layer of adhesive.

Embodiment 5. The roofing assembly according to any of embodiments 2 to 4, wherein the attachment frame extends across a majority of the rear surface of the panel body.

Embodiment 6. The roofing assembly according to any of embodiments 2 to 5, wherein the clip is disposed at a lower edge of the attachment frame.

Embodiment 7. The roofing assembly according to any of embodiments 1 to 6, the clip includes a pair of prongs, each prong having an angled surface and a catch.

Embodiment 8. The roofing assembly according to any of embodiments 1 to 7, wherein the clip is one of a group of clips of the roofing panel.

Embodiment 9. A roofing assembly comprising: a support frame having a first end, a second end, an upper edge, a lower edge, a rear surface configured to be disposed on a surface structure and a front surface configured to face away from the surface structure and to support a roofing panel, wherein the support frame includes a first bracket slot at the lower edge; a bracket secured in the first bracket slot and extending downward from the lower edge of the support frame; and a hook coupled to the bracket, wherein the hook bends to form an upward facing opening configured to receive a lower edge of the roofing panel.

Embodiment 10. The roofing assembly according to embodiment 9, wherein the support frame is formed of a first material and the bracket is formed of a second material that is different from the first material.

Embodiment 11. The roofing assembly according to embodiment 10, wherein the hook is formed of a third material that is different from the first material.

Embodiment 12. The roofing assembly according to embodiment 10 or embodiment 11, wherein at least one of the second material or third material has a yield strength that is at least 2x the yield strength of the first material, e.g., at least 3x, e.g., at least 5x.

Embodiment 13. The roofing assembly according to any of embodiments 9 to 12, wherein the bracket includes a platform configured to support a lower portion of the roofing panel.

Embodiment 14. The roofing assembly according to embodiment 13, wherein the bracket includes legs that extend down from the platform and are configured to support the bracket against the surface structure.

Embodiment 15. The roofing assembly according to embodiment 14, wherein the legs include feet that extend under attachment flanges of the support frame.

Embodiment 16. The roofing assembly according to any of embodiments 13 to 15, wherein the support frame includes a central projection that extends into the bracket slot, and wherein the platform of the bracket covers the central projection.

Embodiment 17. The roofing assembly according to any of embodiments 9 to 16, wherein the hook is formed by a wire clip coupled to the bracket.

Embodiment 18. The roofing assembly according to embodiment 17, wherein the wire clip includes a second hook, and wherein the hook is disposed at a first end of the wire clip and the second hook is disposed at a second end of the wire clip.

Embodiment 19. The roofing assembly according to embodiment 17 or embodiment 18, wherein the bracket includes a first tab that secures the wire clip.

Embodiment 20. The roofing assembly according to any of embodiments 9 to 19, wherein the first bracket slot is one of a plurality of bracket slots disposed along the lower edge of the support frame, and wherein each of the bracket slots is configured to receive the bracket. Embodiment 21. The roofing assembly according to any of embodiments 9 to 20, further comprising a roofing panel, and wherein the hook receives and supports a lower edge of the roofing panel.

Embodiment 22. The roofing assembly according to any of embodiments 1 to 21, wherein an outer surface of the support frame is formed of a polymer material.

Embodiment 23. The roofing assembly according to any of embodiments 1 to 22, wherein the support frame includes an upper frame member that extends along the upper edge, a lower frame member that extends along the lower edge, and a plurality of joists that extends between the upper frame member and the lower frame member.

Embodiment 24. The roofing assembly according to embodiment 23, wherein each joist includes a leg that extends from the rear surface to the front surface and a support flange that extends laterally outward from the leg at the front surface.

Embodiment 25. The roofing assembly according to embodiment 24, wherein each joist includes a foot that extends laterally outward from the leg at the rear surface.

Embodiment 26. The roofing assembly according to any of embodiments 23 to embodiment 25, wherein the support frame includes attachment tabs at the rear surface that extend above the upper frame member.

Embodiment 27. The roofing assembly according to any of embodiments 23 to 26, wherein the upper frame member is spaced from the rear surface of the support frame.

Embodiment 28. The roofing assembly according to any of embodiments 1 to 27, wherein a depth of the support frame is greater at the lower edge than at the upper edge.

Embodiment 29. The roofing assembly according to any of embodiments 1 to 28, wherein the front surface of the support frame includes a drain channel along the first end.

Embodiment 30. The roofing assembly according to any of embodiments 1 to 29, wherein the support frame has substantially hollow interior.

Embodiment 31. The roofing assembly according to any of embodiments 1 to 30, wherein the front surface of the support frame provides support across the rear surface of the roofing panel.

Embodiment 32. A roofing system comprising: a surface structure of a roof; and a plurality of roofing assemblies according to any of embodiments 1 to 31 secured to the surface structure, the plurality of roofing assemblies including: a first row of roofing assemblies including a first roofing assembly, and a second row of roofing assemblies positioned above the first row of roofing assemblies on the surface structure, the second row of roofing assemblies including a second roofing assembly. Embodiment 33. The roofing system according to embodiment 32, wherein each of the support frames of the first row of roofing assemblies is positioned adjacent to at least one other support frame in the first row of roofing assemblies.

Embodiment 34. The roofing assembly according to embodiment 32 or embodiment 33, wherein the support frame of the first roofing assembly is positioned adjacent to the support frame of the second roofing assembly.

Embodiment 35. The roofing assembly according to embodiment 34, wherein a portion of the support frame of the second roofing assembly overlaps a portion of the support frame of the first roofing assembly.

Embodiment 36. The roofing assembly according to embodiment 34 or embodiment 35, wherein a portion of a roofing panel of the second roofing assembly overlaps a portion of the support frame of the first roofing assembly.

Embodiment 37. The roofing assembly according to any of embodiments 32 to 36, wherein the support frame of each of the roofing assemblies is secured to the surface structure with mechanical fasteners.

Embodiment 38. The roofing assembly according to any of embodiments 32 to 37, wherein each of the roofing assemblies in the plurality of roofing assemblies has the same configuration.

Embodiment 39. A method of installing a roofing system according to any of embodiments 32 to 38, the method comprising: positioning a group of support frames according to any of the roofing assemblies of embodiments 1 to 31 in a first row on a surface structure; positioning a group of support frames according to any of the roofing assemblies of embodiments 1 to 31 in a second row on the surface structure above the first row; securing the support frames to the surface structure; and securing roofing panels to the support frames.

Embodiment 40. The method according to embodiment 39, wherein the support frames in the first row are secured to the surface structure before positioning the support frames in the second row.

Embodiment 41. The method according to embodiment 39 or embodiment 40, wherein roofing panels are secured to the support frames in the first row before positioning the support frames in the second row.

Embodiment 42. The method according to any of embodiments 39 to 41, wherein positioning the support frames in the first row includes placing each of the support frames adjacent to at least one other support frame in the first row. Embodiment 43. The method according to any of embodiments 39 to 42, wherein positioning the support frames in the second row includes positioning a second support frame in the second row adjacent to a support frame in the first row.

Embodiment 44. The method according to embodiment 43, wherein positioning the support frames in the second row includes positioning a portion of the second support frame to overlap a portion of the first support frame.

Embodiment 45. The method according to any of embodiments 39 to 44, wherein the support frames are secured to the surface structure with mechanical fasteners.

Embodiment 46. The method according to any of embodiments 39 to 45, wherein securing the roofing panels to the support frames includes inserting clips of the roofing panels into clip receptacles in the support frames.

Embodiment 47. The method according to any of embodiments 39 to 45, wherein securing the roofing panels to the support frames includes inserting the roofing panels into hooks that are coupled to the support frames.

Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.

Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.

The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in any subcombination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.