Note: Descriptions are shown in the official language in which they were submitted.
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Apparatuses and Methods for Fastening Roofing Straps
and Structural Members to Roofs
Technical Field
The present invention relates to the field of solar panels and more
particularly to
apparatuses and methods for attaching solar panel straps and structural
members on
surfaces, including roofs, walls and the ground. Further definition of solar
panel straps and
structural members may be found in US Patents Nos. 7,814,899 and 8,870,139;
and PCT
Patent Application No. PCT/US2013/025622 (published as WO 2014/123547); the
entire
specifications, claims and drawings of which are included in this document by
reference.
Background Art
Solar panels can be of the photovoltaic type, of the thermal type or
combinations. They can
be installed as is or contained within a frame. Solar panels must be mounted
correctly in
order to maximize power production and to prevent movement of the panels from
the force
of wind and, in earthquake prone area, earthquake. The proper solar panel
mounting
provides stability and the proper directional and latitudinal orientation for
the solar array.
Different mounting systems are available depending on whether the modules will
be
mounted on a roof, a wall, the ground, or a pole. For mounting on a roof or
the ground there
are ballast mounts, flush mounts (such as Modular IronRidge XRS available from
IronRidge
in Willits, CA) standing seams mounts, and adjustable mounts (such as those
available from
Unirac in Albuquerque, NM). These usually include a tilted rack, firmly
attached to the
substrate surface, on which the modules are firmly mounted; or brackets of at
least two
different heights, firmly attached to the substrate surface, to which the ends
of the modules
are firmly attached.
Such systems are heavy and expensive to fabricate and time consuming to
install. They
also involve penetration of the roof membrane, which has the potential to
cause leakage of
water. What is needed is a mounting system which is cheaper to fabricate and
less time
consuming to install. Preferably the improved system can be easily fabricated
on site or
provided as a kit. The inventor has developed three improvements on the state
of the art:
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US Patents Nos. 7,814,899 and 8,870,139, and PCT Patent Application
No. PCT/US2013/025622.
This inventor has now developed another improvement on the state of the art.
This
improvement provides a positive mechanical connection of the solar panel
mounting system
to the roof, without penetrating the membrane. This improvement meets all
requirements for
structural strength, wind resistance and earthquake resistance. See attached
report entitled
"STRUCTURAL CALCULATIONS for Forever 21 Project", which is incorporated in
this
application by reference.
Roof Mounted Solar PV Design. Development of a solar panel mounting system
which is
cheaper to fabricate and less time consuming to install represents a great
improvement in
the field of solar panel mounting and satisfies a long felt need of the solar
panel installer and
owner.
Disclosure of Invention
The objects of this invention are to:
provide a positive seal which prevents moisture from penetrating the roof;
provide strength sufficient to provide wind resistant to the solar panels; and
provide a positive mechanical connection between the solar panels and the
roof.
This invention is encompasses a number of different embodiments.
First Embodiment
The first embodiment is intended to be used on roofs that are made of material
that cannot
be welded. The first embodiment comprises:
a first strip of weldable roofing material below a solar panel mounting strap
perpendicularly crossing the strap, the bottom of the first strip being
adhesively bonded
to the roof;
a metal plate, smaller than the first strip, on top of the first strip and
below or adjacent
the strap, nailed or screwed through the first strip and the roof and into the
roof
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substrate (which is typically made from plywood, concrete, or metal) or into a
roof
rafter;
a second strip of weldable roofing material, perpendicular to the strap, lined
up end to
end with one end of the first strip and welded to the first strip thus
encapsulating the
metal plate; and
a third strip of weldable roofing material laid over the strap, perpendicular
to the strap,
crossing the strap, perpendicular to the strap, lined up end to end with the
other end of
the first strip and welded to the first strip .
The strips can be square, rectangular, hexagonal, octagonal, or any other
shape and can be
any convenient size.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment. One suitable waterproof sealant is RTV silicone
rubber
available from a number of manufacturers, such as GE, of Wilton, CT; and Dow
Corning of
Midland, MI. Another is Henry's roofing compound, available from Henry
Company, El
Segundo, CA.
Second Embodiment
The second embodiment is intended to be used on roofs that are made of
material that can
be welded. The second embodiment comprises:
a metal plate, treated to weld to weldable roof material, nailed or screwed
through the
roof and into the roof substrate (which can be made of plywood, concrete, or
metal) or
into a roof rafter, adjacent or below a solar panel mounting strap;
a first strip of weldable roofing material, larger than the metal plate ,
welded to the top
of the metal plate and the roof, perpendicular to and adjacent the mounting
strap thus
encapsulating the metal plate; and
a second strip of weldable roofing material of width similar to the first
strip,
perpendicular to and crossing the strap, in line with the first strip and
bonded to the
roof.
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The second strip may also overlap and be welded to the first strip. Finally,
the edges may
be sealed with a waterproofing sealant in order to prevent entrance of water
into this
embodiment.
Third Embodiment
The third embodiment is intended to be used on roofs that are made of material
that can be
welded. The third embodiment comprises:
a first strip of weldable roofing material adjacent and perpendicular to a
solar panel
mounting strap, the bottom of the first strip being welded to the roof;
a metal plate, smaller than the first strip, on top of the first strip and
under or adjacent
the strap, nailed or screwed through the first strip and the roof and into the
roof
substrate such as plywood, concrete, or metal, or into a roof rafter with
mechanical
fasteners such as screws or nails;
a second strip of weldable roofing material, perpendicular to the strap, lined
up in
vertical registration with the first strip and welded to the first strip, thus
encapsulating
the metal plate; and
a third strip of weldable roofing material of the same size as the first strip
perpendicular
to and crossing the strap, and welded to the roof.
The strips can be square, rectangular, hexagonal, octagonal, or any other
shape and of any
convenient size. The second and third strips may overlap each other.
The metal plate may be treated to be weldable to weldable roofing material and
then welded
to the first and second strips. Finally, the edges may be sealed with a
waterproofing sealant
in order to prevent entrance of water into this embodiment.
Fourth Embodiment
The fourth embodiment comprises two strips of weldable roofing material that
can be
square, rectangular, hexagonal, octagonal, or any other shape of any
convenient size.
They are perpendicular to and cross the strap, one above and the other below
the strap. If
the roof is made of weldable material the lower strap is welded to the roof.
Otherwise the
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lower strap is bonded to the roof. The upper strip is bonded to the lower thus
trapping the
strap between them. Finally, the edges may be sealed with a waterproofing
sealant in order
to prevent entrance of water into this embodiment.
Fifth Embodiment
5 The fifth embodiment comprises one strip, of weldable roofing material.
It is perpendicular
to across and above the strap. If the roof is made of weldable material the
strip is welded to
the roof. Otherwise the strip is bonded to the roof. A plate may be fastened
to the roof with
mechanical fasteners such as roofing nails, screws, lag bolts, etc. This traps
the strap
between the strip and the roof and allows for a mechanical connection.
Finally, the edges
may be sealed with a waterproofing sealant in order to prevent entrance of
water into this
embodiment.
Alternative for First Through Fifth Embodiments
Any of the first through the fifth embodiments of this invention may be
reinforced with a top
metal plate. If the top metal plate is treated to be weldable to weldable
roofing material and
the strips are made of weldable roofing material, it can be welded onto the
other
embodiments. Otherwise, it can be adhesively bonded to the other embodiments.
Alternatively, it may be fastened with the same mechanical fasteners used in
the assembly.
Sixth Embodiment
The sixth embodiment of this invention is intended to fasten rails or other
structural
members to a roof. Such devices have much more depth than a strap. The sixth
embodiment comprises a strip of roofing material with a raised section in the
middle. The
raised section is intended to cross a structural member perpendicularly. The
raised section
has a top which is larger than the width of the top of the structural member.
Above and
below the top of the raised section are metal strips. The lower strip is sized
and shaped to fit
snugly over the top of the structural member. The upper strip is sized and
shaped to fit the
top.
The metal strips are preferably also coated with a weldable material. Then all
the
components of this embodiment can be welded to each other. Otherwise they can
be
adhesively bonded to each other. Alternatively, they can be fastened to each
other and the
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structural member with fasteners. If the roofing is made of weldable material
then the strip
of roofing material can be welded to the roof. If not, the strip can be
adhesively bonded to
the roof or attached with fasteners.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment
Seventh Embodiment
The seventh embodiment of this invention is intended to fasten straps to a
roof. The
seventh embodiment comprises a strip of roofing material with a raised section
in the
middle. The raised section is intended to cross a strap perpendicularly. The
raised section
has a top which is larger than the width of the strap. Above and below the top
are metal
strips. The lower strip is sized and shaped to fit snugly over the top of the
strap. The upper
strip is sized and shaped to fit the top.
The metal strips are preferably coated with a weldable material. Then all the
components of
this embodiment can be welded to each other. Otherwise they can be adhesively
bonded to
each other. Alternatively, they can be fastened to each other and the strap
with fasteners.
If the roof is made of weldable material then the strip of roofing material
can be welded to
the roof. If not, the strip can be adhesively bonded to the roof or attached
with fasteners.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment.
Usage Examples
The sixth or seventh embodiments can be attached to a roof with a seismic
anchor. A
seismic anchor is a washer of minimum 2" diameter with a self-tapping 1/4"
screw, with
length sufficient to adequately penetrate the roof, through its central hole.
The washer is
made of metal and may be weldable to weldable roofing material.
The sixth or seventh embodiments are placed over a structural member or strap
on the roof.
One flap is raised and a seismic anchor fully installed in the roof near the
middle of the flap.
Raising parts of the embodiments is possible because they are made out of
roofing material
which is flexible. Next the roofing material is bonded or welded to the top of
the washer and
the roof. If additional support is needed a second seismic anchor may be
installed under the
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other side. Finally, the edges may be sealed with a waterproofing sealant in
order to prevent
entrance of water into the sixth and seventh embodiments.
The eighth embodiment comprises a seismic plate including a stud pointing
upwards, below
the strap, which is modified with a hole for allowing the stud to pass
through. Screws
through the plate fasten the plate to the roof substrate or a roof rafter.
Between the roof and
the plate and between the plate and the strap is placed a layer of elastomeric
roof coating.
After assembly in the proper order, tightening the nut on the stud causes the
elastomeric
layers to compress, which provides an effective seal, and prevents moisture
from entering
the interfaces and percolating down the screws.
Roofing is sometimes referred to as a membrane. Weldable roofing material is
thermoplastic polyolefin (TPO), available from a number of companies
including: Firestone
Building Products of Indianapolis, IN; Carlisle Syntec Systems of Carlisle,
PA; and Johns
Manville of Denver, CO. TPO can be made of polyvinyl chloride (PVC) or
ethylene-
propylene-diene-monomer (EPDM).
Brief Description of Drawings
Figure 1 is an exploded, isometric view of a first embodiment of this
invention as used to
fasten a mounting strap. For clarity, some mechanical fasteners are not shown.
See US
Patents Nos. 7,814,899 and 8,870,139; and PCT Patent Application No.
PCT/US2013/025622 for examples of the usage of straps in mounting of solar
panels.
Figure 2 is a top view of the first embodiment of this invention. For clarity,
mechanical
fasteners are not shown.
Figure 2A is a side elevational view of this first embodiment.
Figure 2B is an end elevational view of this first embodiment.
Figure 3 is an exploded, isometric view of a second embodiment of this
invention as used to
fasten a mounting strap. For clarity, some mechanical fasteners are not shown.
Figure 4 is a top view of the second embodiment of this invention. For clarity
the mechanical
fasteners are not shown.
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Figure 4A is a side elevational view of this second embodiment.
Figure 4B is an end elevational view of this second embodiment.
Figure 4C is a cross section showing the preferred mechanical fastening system
used in all
embodiments of this invention
Figure 5 is an exploded, isometric view of a third embodiment of this
invention as used to
fasten a mounting strap. For clarity some mechanical fasteners are not shown.
Figure 6 is a top view of the third embodiment of this invention. For clarity
the mechanical
fasteners are not shown.
Figure 6A is a side elevational view of this third embodiment.
Figure 6B is an end elevational view of this third embodiment.
Figure 7 is an isometric view of a fourth embodiment of this invention as used
to fasten a
mounting strap with angled solar panels.
Figure 7A is an enlarged view of the area annotated A on Figure 7.
Figure 8 is an isometric view of a fifth embodiment of this invention as used
to fasten a
mounting strap with angled solar panels.
Figure 8A is an enlarged view of the area annotated A on Figure 8.
Figure 9 is an isometric view of any of the first through the fifth
embodiments of this
invention reinforced with a top metal plate. For clarity the mechanical
fasteners are not
shown.
Figure 10 is a close up, isometric view of the alternative shown in Figure 9
as installed on a
mounting strap. For clarity some mechanical fasteners are not shown.
Figure 11 is an isometric view of a sixth embodiment of this invention, which
is intended to
fasten rails or other structural members to a roof. For clarity the mechanical
fasteners are
not shown.
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Figure 11A is an enlarged view of the area annotated A on Figure 11. For
clarity the
mechanical fasteners are not shown.
Figure 11B is a side elevational view of the sixth embodiment. For clarity the
mechanical
fasteners are not shown.
Figure 11C is a top view of the sixth embodiment. For clarity the mechanical
fasteners are
not shown.
Figure 11D is an end view of the sixth embodiment. For clarity the mechanical
fasteners are
not shown.
Figure 11F is an exploded, end view of the sixth embodiment. For clarity the
mechanical
fasteners are not shown.
Figure 12 shows the sixth embodiment used to fasten a structural member to a
roof. It also
shows a variation of this sixth embodiment incorporating ballast trays.
Figure 13 is an isometric view of a seventh embodiment of this invention. For
clarity the
mechanical fasteners are not shown.
Figure 13A is a top view of the seventh embodiment. For clarity the mechanical
fasteners
are not shown.
Figure 13B is an enlarged view of the area annotated B on Figure 13. For
clarity the
mechanical fasteners are not shown.
Figure 13C is an end view of the seventh embodiment. For clarity the
mechanical fasteners
are not shown.
Figure 13D is a side elevational view of the seventh embodiment. For clarity
the mechanical
fasteners are not shown.
Figure 13E is an exploded, end view of the seventh embodiment. For clarity the
mechanical
fasteners are not shown.
Figure 14 is an isometric view of the seventh embodiment in use to fasten a
strap to a roof.
For clarity the panel support brackets are not shown. See US Patents Nos.
7,814,899 and
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8,870,139, and PCT Patent Application No. PCT/US2013/025622 for examples of
the usage
of straps in mounting of solar panels.
Figure 15 is an isometric view of a seismic anchor.
Figure 15A is a top isometric view of the sixth embodiment used with a seismic
anchor. For
5 clarity the mechanical fasteners are not shown.
Figure 15B is a bottom isometric view of the sixth embodiment used with a
seismic anchor.
For clarity the mechanical fasteners are not shown.
Figure 15C is a top isometric view of the seventh embodiment used with a
seismic anchor.
For clarity the mechanical fasteners are not shown.
10 Figure 15D is a bottom isometric view of the seventh embodiment used
with a seismic
anchor. For clarity the mechanical fasteners are not shown.
Figure 16 illustrates that the strips in this invention may be circular
instead of rectangular.
Figure 17 is a three dimensional exploded view of the fourth embodiment used
with circular
seismic anchors.
Figure 17A is a closer view of Figure 17.
Figure 17B is a cross section along the lines 17B-17B on Figure 17 with parts
assembled.
Figure 18 is a three dimensional exploded view of the fourth embodiment used
with
rectangular seismic anchors.
Figure 18A is a closer view of Figure 18.
Figure 18B is a cross section along the lines 18B-18B on Figure 18 showing
with parts
assembled.
Figure 19 is a three dimensional exploded view of an eighth embodiment used
with
rectangular seismic anchors and latex roof coating.
Figure 19A is a closer view of Figure 19.
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Figure 19B is a cross section along the lines 19B-19B on Figure 19 with the
parts
assembled.
Best Mode for Carrying Out Invention
First Embodiment
The first embodiment 100 is intended to be used on roofs 22 that are made of
material that
cannot be welded. Referring to Figures 1, 2, 2A and 2B, it can be seen that
the first
embodiment 100 of this invention comprises:
a first strip 110 of weldable roofing material below a solar panel mounting
strap 18
perpendicularly crossing the strap 18, the bottom 116 of the first strip 110
being
adhesively bonded to the roof 22;
a metal plate 120, smaller than the first strip 110, on top of the first strip
110 and
adjacent the strap 18, screwed through the first strip 110 and the roof 22,
and into a
roof substrate (which is typically made of plywood, concrete, or metal) or
into roof rafter
using appropriate fasteners, such as screws or nails;
a second strip 130 of weldable roofing material of width similar to the first
strip 110 but
of length about half that of the first strip 110, perpendicular to the strap
18, lined up end
134 to end 114 with one end 114 of the first strip 110 and welded to the first
strip 110;
and
a third strip 140 of weldable roofing material of width similar to the first
strip 110 but of
length about half that of the first strip 110, perpendicular to the strap 18,
crossing the
strap 18, lined up end 148 to end 112 with the other end 118 of the first
strip 110 and
welded to the first strip 110, thus encapsulating the metal plate 120.
In addition there are fastening systems 26 fastening the strap 18 to the
second strip 130.
The fastening systems 26 comprise a flush head, self-clinching threaded stud
40 clinched
pointing upwards through a hole 32 (not visible) in the strap 18. The stud 40
is long enough
to pass through a hole 34 in the second strip 130 where a washer 38 and nut 42
are
screwed onto it thus securely fastening the second strip 130 to the strap 22.
The nut 42
may be castellated and secured through a hole in the end of the stud 40 by a
cotter pin, as
is well known, to prevent rotation of the nut 42. An example of the fastening
system is
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shown in Figure 4C. The ends of the straps 18 also have holes 52 for insertion
of studs 40
so that the straps 18 can be easily fastened together end to end with nuts 42
and washers.
As a consequence of this construction the metal plate 120 is in the same plane
as the strap
18 and, depending on the thickness of the strap 18, the second 130 and third
140 strips
may be co-planar. The roofing material used for the first 110, second 130 and
third 140
strips is the kind that can be welded, typically with heat.
The metal plate 120 clamps the first strip 110 in place and is satisfactory
for seismic
installations. Finally, the edges may be sealed with a waterproofing sealant
in order to
prevent entrance of water into this embodiment 100. One suitable waterproof
sealant is RTV
silicone rubber available from a number of manufacturers, such as GE, of
Wilton, CT; and
Dow Corning of Midland, MI. Another is Henry's roofing compound, available
from Henry
Company, El Segundo, CA.
Second Embodiment
The second embodiment 200 is intended to be used on roofs 22 that are made of
material
that can be welded. Referring to Figures 3, 4, 4A, 4B and 4C, it can be seen
that the
second embodiment 200 of this invention comprises:
a metal plate 220, treated to weld to weldable roof material, welded to the
roof 22 and
nailed or screwed through the roof 22 into a the roof substrate (which is
typically made
of plywood, concrete, or metal) or into a roof rafter with appropriate
fasteners such as
nails or screws, adjacent a solar panel mounting strap 18;
a first strip 230 of weldable roofing material, larger than the metal plate
220, welded to
the top 224 of the metal plate 220 and the roof 22, perpendicular to and
adjacent the
mounting strap 18; and
a second strip 240 of weldable roofing material of width similar to the first
strip 230,
perpendicular to and crossing the strap 18 overlapping the first strip 230, in
line with the
first strip 230 and welded to the roof 22 and the first strip.
The roofing material used for the first 110, second 130 and third 140 strips
is the kind that
can be welded, typically with heat. The metal plate 120 is in the same plane
as the strap 18
and, depending on the thickness of the strap.
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In addition there are fastening systems 26 fastening the strap 18 to the
second strip 130.
The fastening systems 26 comprise a flush head, self-clinching threaded stud
40 clinched
pointing upwards through a hole 32 (not visible) in the strap 18. The stud 30
is long enough
to pass through a hole 34 in the second strip 240 where a washer 38 and nut 42
are
screwed onto it thus securely fastening the second strip 240 to the strap 22.
The nut 42
may be castellated and secured through a hole in the end of the stud 40 by a
cotter pin, as
is well known, to prevent rotation of the nut 42. An example of the fastening
system is
shown in Figure 4C.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 200.
Third Embodiment
The third embodiment 300 is intended to be used on roofs 22 that are made of
material that
can be welded. Referring to Figures 5, 6, 6A and 6B, it can be seen that the
third
embodiment 300 of this invention comprises:
a first strip 310 of weldable roofing material adjacent and perpendicular to a
solar
panel mounting strap 18, the bottom 316 of the first strip 310 being welded to
the roof
22;
a metal plate 320, smaller than the first strip 310, on top of the first strip
310 and
adjacent the strap 18, screwed through the first strip 310 and the roof 22 and
into a roof
rafter with wood screws;
a second strip 330 of weldable roofing material of the same size as the first
strip 310,
perpendicular to the strap 18, lined up in vertical registration with the
first strip 310 and
welded to the first strip 310, thus encapsulating the metal plate 320; and
a third strip 340 of weldable roofing material of the same size as the first
strip 310
perpendicular to and crossing the strap 18 overlapping the first 310 or second
strip
330, and welded to the roof 22 and the first 310 or second 330 strip.
The roofing material used for the first 310, second 330 and third 340 strips
is the kind that
can be welded, typically with heat. The second 330 and third 340 strips may
overlap each
other.
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The metal plate 320 may be treated to be weldable to weldable roofing material
and then
welded to the first 310 and second 330 strips. The plate 320 clamps the first
strip 310 in
place and is satisfactory for seismic installations.
In addition there are fastening systems 26 fastening the strap 18 to the
second strip 130.
The fastening systems 26 comprise a flush head, self-clinching threaded stud
40 clinched
pointing upwards through a hole 32 (not visible) in the strap 18. The stud 30
is long enough
to pass through a hole 34 in the third strip 340 where a washer 38 and nut 42
are screwed
onto it thus securely fastening the second strip 340 to the strap 22. The nut
42 may be
castellated and secured through a hole in the end of the stud 40 by a cotter
pin, as is well
known, to prevent rotation of the nut 42. An example of the fastening system
is shown in
Figure 4C.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 300.
Fourth Embodiment
Figure 7 is an isometric view of a fourth embodiment 400 of this invention as
used to fasten
a mounting strap 18 with angled solar panels 26 via support brackets 50.
Figure 7A is an
enlarged view of the area annotated A on Figure 7. As can be seen from these
figures, the
fourth embodiment comprises two strips 410, 440 of weldable roofing material
of the same
size. They are perpendicular to and cross the strap 18, one 440 above and the
other 410
below the strap 18. If the roof 22 is made of weldable material the lower
strap 410 is welded
to the roof 22. Otherwise the lower strap 410 is bonded to the roof 22 or
fastened to the
roof 22 with mechanical fasteners such as roofing nails, screws, lag bolts,
etc. The upper
strip 440 is bonded to the lower strip 410 thus trapping the strap 18 between
them.
In addition there are fastening systems 26 (not illustrated) fastening the
strap 18 to the
second strip 440. The fastening systems 26 comprise a flush head, self-
clinching threaded
stud 40 clinched pointing upwards through a hole 32 (not visible) in the strap
18. The stud
is long enough to pass through a hole 34 in the second strip 440 where a
washer 38 and
nut 42 are screwed onto it thus securely fastening the second strip 440 to the
strap 22.
The nut 42 may be castellated and secured through a hole in the end of the
stud 40 by a
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cotter pin, as is well known, to prevent rotation of the nut 42. An example of
the fastening
system is shown in Figure 4C.
Figures 17, 17A and 17B illustrate the fourth embodiment 400 used with
circular seismic
anchors 70.
5 Figures 18, 18A and 18B illustrate the fourth embodiment 400 used with
rectangular seismic
anchors 70.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 400.
Fifth Embodiment
10 Figure 8 is an isometric view of a fifth embodiment 500 of this
invention as used to fasten a
mounting strap 18 with angled solar panels 26 via support brackets 50. Figure
8A is an
enlarged view of the area annotated A on Figure 8. As can be seen from these
figures, the
fifth embodiment comprises one strip 510, of weldable roofing material. It is
perpendicular
to across and above the strap 18. If the roof 22 is made of weldable material
the strip 510 is
15 welded to the roof 22. Otherwise the strip 510 is bonded to the roof 22
or fastened to the
roof 22 with mechanical fasteners such as roofing nails, screws, lag bolts,
etc. This traps
the strap 18 between the strip 510 and the roof 22.
In addition there are fastening systems 26 fastening the strap 18 to the strip
510. The
fastening systems 26 comprise a flush head, self-clinching threaded stud 40
clinched
pointing upwards through a hole 32 (not visible) in the strap 18. The stud is
a Pem Stud,
available from Penn Engineering of Danboro, PA, or equivalent. The stud 40 is
long enough
to pass through a hole 34 in the strip 510 where a washer 38 and nut 42 are
screwed onto it
thus securely fastening the second strip 130 to the strap 22. The nut 42 may
be castellated
and secured through a hole in the end of the stud 40 by a cotter pin, as is
well known, to
prevent rotation of the nut 42. An example of the fastening system is shown in
Figure 4C.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 500.
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Alternative for First Through Fifth Embodiments
Figure 9 is an isometric view of any of the first through the fifth
embodiments of this
invention 100, 200, 300, 400, 500 reinforced with a top metal plate 30. Figure
10 is a close
up, isometric view of the alternative shown in Figure 9 as installed on a
mounting strap. If
the top metal plate is treated to be weldable to weldable roofing material it
can be welded
onto the other embodiments100, 200, 300, 400, 500. Otherwise, it can be
adhesively
bonded to the other embodiments 100, 200, 300, 400, 500. Alternatively, it may
be
fastened with the same fastening systems 26 used in the assembly.
Sixth Embodiment
The sixth embodiment 600 of this invention is intended to fasten rails or
other structural
members 34 to a roof. Such devices have much more depth than a strap 18. The
sixth
embodiment 600 can be seen in Figures 11, 11A-F and 12. The sixth embodiment
600
comprises a strip of roofing material 610 with a raised section 612 in the
middle, surrounded
by a lower section 611. The raised section 612 is intended to cross a
structural member 64
perpendicularly. The raised section 612 has a top 614 which is larger than the
width of the
structural member 34. Above and below the top 614 are metal strips 620, 630.
The lower
strip 620 is sized and shaped to fit snugly over the top of the structural
member. The upper
strip 630 is sized and shaped to fit over the top 614.
The roofing material 610 is preferably weldable. If the roof 22 is made of
weldable material
then strip of roofing material 610 can be welded to the roof 22.The metal
strips are
preferably also coated with a weldable material. Then all the components of
this
embodiment 600 can be welded to each other. Otherwise they can be adhesively
bonded
to each other. Alternatively, they can be fastened to each other and the
structural member
with fasteners 26 as previously described and illustrated. If not, the strip
610 can be
adhesively bonded to the roof 22 or attached with fasteners 26 or weighted
down with
ballast 46.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 600.
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Seventh Embodiment
The seventh embodiment 700 of this invention is intended to fasten straps 18
to a roof 22.
The seventh embodiment 700 can be seen in the Figures. The seventh embodiment
700
comprises a strip of roofing material 710 with a raised section 712 in the
middle. The raised
section 712 is intended to cross a strap 18 perpendicularly. The raised
section 712 has a
top 714 which is larger than the width of the strap 18. Above and below the
top 714 are
metal strips 720, 730. The lower strip 720 is sized and shaped to fit snugly
over the top of
the strap 18. The upper strip 730 is sized and shaped to fit the top 714.
The roofing material 710 is preferably weldable. The metal strips are
preferably also coated
with a weldable material. Then all the components of this embodiment 700 can
be welded
to each other. Otherwise they can be adhesively bonded to each other.
Alternatively, they
can be fastened to each other and the structural member with fasteners 26 as
previously
described and illustrated. If the roof 22 is made of weldable material then
strip of roofing
material 710 can be welded to the roof 22. If not, the strip 710 can be
adhesively bonded to
the roof 22 or attached with fasteners 26 as previously described and
illustrated.
Finally, the edges may be sealed with a waterproofing sealant in order to
prevent entrance
of water into this embodiment 700.
Usage Examples
Figure 12 shows the sixth embodiment 600 used to fasten a structural member 34
to a roof
22. In this case the embodiment 600 is attached to the member with fasteners
26. Figure
12 also illustrates the alternative way of holding down this embodiment:
ballast trays 42.
The trays 42 are shaped to hold the member 34 down to a roof 22. In this case
hold down
is achieved with ballast 46.
Figure 14 is an isometric view of the seventh embodiment 700 in use to fasten
a strap 18 to
a roof 22.
Figure 15 is an isometric view of a seismic anchor 70. A seismic anchor 70 is
a metal
washer, of minimum 2" diameter 54 and a self-tapping 1/4" screw 78, with
length sufficient
to adequately penetrate the roof 22. The screw 78 is inserted through the hole
in the center
of the washer 54. The metal may be treated to be weldable to weldable roofing
material. An
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alternate embodiment for a seismic anchor 70 is illustrated in Figures 18,
18A, 19, and 19A.
This embodiment comprises a seismic plate 76, with, preferably, two screws 78
through it
which screw through the roof 22 and into the substrate or a roof rafter. The
plate 76 is
made of metal, which may be treated to be weldable to weldable roofing
material.
The sixth 600 or seventh 700 embodiments are placed over a structural member
34 or strap
18 on the roof 22. One side of the embodiment is raised and a seismic anchor
70 fully
installed in the roof 22 near middle of the flap. Raising parts of the
embodiments is possible
because they are made out of roofing material which is flexible. Next the
roofing material is
welded to the top of the washer 54 and welded to the roof 22. If additional
support is needed
a second seismic anchor 70 can be installed under the other side. Finally, the
edges may
be sealed with a waterproofing sealant in order to prevent entrance of water
into the sixth
600 and seventh 700 embodiments.
Figure 15A is a top isometric view of the sixth embodiment 600 fastened down
with a
seismic anchor 70.
Figure 15B is a bottom isometric view of the sixth embodiment 600 fastened
down with a
seismic anchor 70.
Figure 15C is a top isometric view of the seventh embodiment 700 fastened down
with a
seismic anchor 70.
Figure 15D is a bottom isometric view of the seventh embodiment 700 fastened
down with a
seismic anchor 70.
Eighth Embodiment
The eighth embodiment 800 is shown in Figures 19, 19A and 19B. The eighth
embodiment
800 comprises a seismic plate 76 including a stud 40 pointing upwards, below
the strap 18,
which is modified with a hole 90 for allowing the stud 40 to pass through.
Screws 86 through
the plate 76 fasten the plate 76 to the roof substrate or a roof rafter.
Between the roof 22
and the plate 76 and between the plate 76 and the strap is placed a layer of
elastomeric
roof coating 86. Such coatings are energy efficient, high quality coating
systems that
consists of a layered, watertight blanket of elastomeric roof coatings,
encapsulating a fabric.
The elastomeric coatings can be acrylic or silicone polymers. Metacrylics0
Energy Efficient
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Coatings for Commercial Properties, available from Metacrylics of Gilroy, CA,
or equivalent
can be used. After assembly in the proper order as shown in Figures 19 and
19A, tightening
the nut 42 on the stud 40 causes the elastomeric layers to compress, which
provides a
positive seal, and which prevents moisture from entering the interfaces and
percolating
down the screws.
Preferably the strips and plates of this invention are rectangular. Most of
the drawings show
square and rectangular strips and plates. However, they can be any convenient
shape such
as rectangular, square, circular, hexagonal, octagonal, oval, etc. Figure 16
shows a circular
shape for the strip 410 of the fourth embodiment 400 of this invention. This
is applicable to
all embodiments of this invention.
Roofing is sometimes referred to as a membrane. Weldable roofing material is
thermoplastic polyolefin (TPO), available from a number of companies
including: Firestone
Building Products of Indianapolis, IN; Carlisle Syntec Systems of Carlisle,
PA; and Johns
Manville of Denver, CO. TPO can be made of polyvinyl chloride (PVC) or
ethylene-
propylene-diene-monomer (EPDM).
The structural adhesive 82 used in this invention to bond strips to roofs,
strips to strips etc.
is preferably two-component polyurethane or silicone. Such adhesives are
manufactured by
a number of companies. Suitable adhesives are Dash DC polyurethane, available
from
Versico Roofing Systems of Carlisle, PA and 5CM3505 series high solids
silicone available
from Everest Systems of Houston, TX.
For further information about installing solar panels using this invention see
attached
Permacity/Orion Solar Strap installation manual, which is incorporated into
this application
by reference.
The following reference numbers are shown on the Figures:
All embodiments
18 strap
22 roof membrane
24 roof substrate
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26 fastening system
28 solar panel
reinforcing metal plate
32 hole through strap for attachment to strip with a stud, washer and
nut
5 34 hole through roofing material for insertion of stud
36 width of structural member
38 washer
stud
42 nut
10 50 solar panel support bracket
50a higher bracket
50b lower bracket
56 hole through metal plate for insertion of screw
60 hole through end of strap to allow fastening of strips end to end via
studs
15 64 structural member
70 seismic anchor
74 seismic washer ¨ circular
76 seismic plate - rectangular
78 screw
20 82 adhesive
86 latex roof coating
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90 hole
First embodiment
110 first strip
112 one end of first strip
114 other end of first strip
116 underside of first strip
120 metal plate
130 second strip
134 one end of second strip
138 other end of second strip
140 third strip
144 one end of third strip
148 other end of third strip
Second embodiment
220 metal plate
230 first strip
240 second strip
Third embodiment
310 first strip
320 metal plate
340 second strip
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Fourth embodiment
410 lower strip
420 upper strip
Fifth embodiment
510 strip
Sixth embodiment
610 shaped strip
611 lower section of strip
612 raised section
614 top of shaped portion
618 ballast tray
620 bottom metal plate
622 top of bottom metal plate
630 top metal plate
632 bottom of top metal plate
Seventh embodiment
710 strip
712 raised section
714 top of raised section
720 bottom metal plate
730 top metal plate
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Several embodiments 100, 200, 300, 400, 500, 600, 700 and 800 have been
described.
However, it should be obvious to those skilled in the art to which this
invention pertains that
other modifications and enhancements can be made without departing from the
spirit and
scope of this invention.
