WO2012061796A1

WO2012061796A1 - Photovoltaic panel racking assembly for use in connection with roof installation of panels

Info

Publication number: WO2012061796A1
Application number: PCT/US2011/059481
Authority: WO
Inventors: Gregory W. Sponseller
Original assignee: Individual
Current assignee: Individual
Priority date: 2010-11-05
Filing date: 2011-11-05
Publication date: 2012-05-10
Anticipated expiration: 2013-05-05

Abstract

A photovoltaic panel racking assembly (60) includes a cylindrically shaped standoff (70) cooperatively adjoined to a specially formed toggle (80) through an all thread rod (100). A nut (101) is sized and shaped to operatively engage with the toggle (80) to fix the relative position of the toggle (80) and the nut (101). A rubber gasket (110) is provided in order to promote watertight sealing upon installation and during use of the racking assembly (60). A relief plate (112) may be provided in order to prevent installation damage to more generally fragile roofing materials such as asphalt shingles or like composite roofing (128). A rubber sleeve (102) is provided in order to facilitate positioning of the toggle (80) during installation of the racking assembly (60). Brackets (180, 200) are described for affixing one or more photovoltaic panels (170) to the racking assembly (60).

Description

PHOTOVOLTAIC PANEL RACKING ASSEMBLY

FOR USE IN CONNECTION WITH ROOF INSTALLATION OF PANELS

RELATED APPLICATIONS:

This application claims all available benefit of priority to U.S. provisional patent application Serial No. 61/456,330 filed November 5, 2010; U.S. provisional patent application Serial No. 61/459,701 filed December 17, 2010; and U.S. provisional patent application Serial No. 61/575,436 filed August 22, 201 1. By this reference, the full disclosures, including the drawings, of U.S. provisional patent application Serial No. 61/456,330, U.S. provisional patent application Serial No. 61/459,701 and U.S. provisional patent application Serial No. 61/575,436 are incorporated herein as though now set forth in their respective entireties.

TECHNICAL FIELD:

The present invention relates to building construction. More specifically, the present invention relates to a novel racking system for roof installation of photovoltaic panels.

BACKGROUND ART:

After much improvement in the efficiency of photovoltaic panels and decease in cost technological cost, implementation of photovoltaic panel systems remains greatly hampered by installation costs and potential for damage to the roof section upon which a system is to be installed.

As a result, the overriding object of the present invention is to improved over the prior art by setting forth an assembly and method of its use for fast, easy and cost effective roof installation of a photovoltaic panel system including, among other advantages, the ability for a single installer to deploy the assembly without need for locating underlying rafters.

DISCLOSURE OF THE INVENTION:

In accordance with the foregoing objects, the present invention - a photovoltaic panel racking assembly for use in connection with roof installations of photovoltaic panels - generally comprises a cylindrically shaped standoff cooperatively adjoined to a specially formed toggle through an all thread rod, or similar hardware, and having positioned at an end opposite the standoff a nut that is sized and shaped to operatively engage with the toggle to fix the relative position of one to the other. A rubber or like material gasket is also provided in order to promote watertight sealing upon installation and during use of the racking assembly. Additionally, a relief plate may be provided in order to prevent installation damage to more generally fragile roofing materials such as, for example, asphalt shingles or like composite roofing. Likewise, in at least some embodiments of the present invention, a rubber or like material sleeve may be provided in order to facilitate positioning of the toggle during installation of the racking assembly.

Many other features, objects and advantages of the present invention will be apparent to those of ordinary skill in the relevant arts, especially in light of the foregoing discussions and the following drawings, exemplary detailed description and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS:

Although the scope of the present invention is much broader than any particular embodiment, a detailed description of the preferred embodiment follows together with illustrative figures, wherein like reference numerals refer to like components, and wherein:

Figure 1 shows, in a perspective view, the preferred embodiment of the photovoltaic panel racking assembly of the present invention;

Figure 2 shows, in a front elevational view, the photovoltaic panel racking assembly of Figure 1 ;

Figure 3 shows, in a perspective view, details of the preferred embodiment of a standoff as implemented in the photovoltaic panel racking assembly of Figure 1 ;

Figure 4 shows, in a cross sectional view taken through cut line 4— 4 of Figure 3, various additional details of the standoff of Figure 3;

Figure 5 shows, in a top perspective view, details of the preferred embodiment of a toggle as implemented in the photovoltaic panel racking assembly of Figure 1 ;

Figure 6 shows, in a bottom perspective view, various additional details of the toggle of Figure 5;

Figure 7 shows, in a top plan view, various still further details of the toggle of Figure

5;

Figure 8 shows, in a front elevational view, the toggle of Figure 5 as oriented in a first generally extreme position with respect to an all thread rod implemented in the photovoltaic panel racking assembly of Figure 1;

Figure 9 shows, in a left side elevational view, the toggle of Figure 5 as oriented with respect to the all thread rod in the position of Figure 8;

Figure 10 shows, in a front elevational view, the toggle of Figure 5 as oriented in a second generally extreme position with respect to the all thread rod implemented in the photovoltaic panel racking assembly of Figure 1 ; Figure 1 1 shows, in a right side elevational view, the toggle of Figure 5 as oriented with respect to the all thread rod in the position of Figure 10;

Figure 12 shows, in a partially exploded perspective view, the photovoltaic panel racking assembly of Figure 1 as configured and positioned for installation on a roof section;

Figure 13 shows, in a perspective view, the photovoltaic panel racking assembly of

Figure 1 as initially installed through a mounting hole in a roof section;

Figure 14 shows, in a front elevational view, the photovoltaic panel racking assembly of Figure 1 as initially installed through a mounting hole in a roof section as shown in Figure 13 and, in particular, shows the toggle in a state of transition during the course of installation of the racking assembly;

Figure 15 shows, in a front elevational view generally corresponding to the view of Figure 14, the photovoltaic panel racking assembly of Figure 1 in a further state of installation on a roof section;

Figure 16 shows, in a front elevational view generally corresponding to the view of Figure 14, the photovoltaic panel racking assembly of Figure 1 in a still further state of installation on a roof section;

Figure 17 shows, in a front elevational view generally corresponding to the view of Figure 14, the photovoltaic panel racking assembly of Figure 1 in a final state of installation on a roof section;

Figure 18 shows, in a perspective view, the photovoltaic panel racking assembly of

Figure 1 in the final state of installation of Figure 17;

Figure 19 shows, in a cross sectional view taken through cut line 19— 19 of Figure

18, various additional details of the photovoltaic panel racking assembly of Figure 1 in the final state of installation of Figure 17;

Figure 20 shows, in a partially exploded perspective view, the preferred embodiment of an extension of the present invention for providing an extended mounting surface for one or more photovoltaic panels;

Figure 21 shows, in a perspective view, the preferred embodiment of an assembly jig as particularly adapted for use in connection with the extension of Figure 20;

Figure 22 shows, in a bottom plan view, the various details of the assembly jig of

Figure 21 ;

Figure 23 shows, in a perspective view, various details of the installation of the extension of Figure 20 and, in particular, shows the manner of use of the assembly jig of Figure 21 ;

Figure 24 shows, in a perspective view, the extension of Figure 20 in a final state of installation;

Figure 25 shows, in a partially exploded perspective view, the preferred embodiment of a further extension of the present invention for securing a photovoltaic panel to the mounting surface of Figure 20 and, in particular, shows a panel mounting bracket as particularly useful for securing an end panel the mounting surface of Figure 20;

Figure 26 shows, in a detail view located by reference 26 of Figure 25, various details of the panel mounting bracket of Figure 25 and its associated hardware;

Figure 27 shows, in a perspective view, the panel mounting bracket of Figure 25 as utilized to secure an end photovoltaic panel atop the mounting surface of Figure 20;

Figure 28 shows, in left side elevational view, various details of the utilization of

Figure 27;

Figure 29 shows, in a detail view located by reference 29 of Figure 28, various additional details of the of the utilization of Figure 27;

Figure 30 shows, in a partially exploded perspective view, the preferred embodiment of a still further extension of the present invention for securing a pair of photovoltaic panels to the mounting surface of Figure 20 and, in particular, shows an integrated inter-panel mounting bracket and grounding clip as particularly useful for securing a pair of end panels to the mounting surface of Figure 20;

Figure 31 shows, in a top perspective view, various details of the integrated inter-panel mounting bracket and grounding clip of Figure 30;

Figure 32 shows, in a bottom perspective view, various details of the integrated inter-panel mounting bracket and grounding clip of Figure 30;

Figure 33 shows, front elevational view, various details of the integrated inter-panel mounting bracket and grounding clip of Figure 30;

Figure 34 shows, in a right side elevational view, various details of the integrated inter-panel mounting bracket and grounding clip of Figure 30;

Figure 35 shows, in a left side elevational view, the integrated inter-panel mounting bracket and grounding clip of Figure 30 as utilized to secure a pair of photovoltaic panels atop the mounting surface of Figure 20;

Figure 36 shows, in a perspective view, various details of the utilization of Figure 35;

Figure 37 shows, in a top plan view, various additional details of the utilization of Figure 35;

Figure 38 shows, in a perspective view, various details for utilization of the photovoltaic panel racking assembly of Figure 1 in connection with a tile roof and, in particular, shows various details of the initial step for preparation of the tile roof for use of the photovoltaic panel racking assembly;

Figure 39 shows, in a perspective view generally corresponding to the view of Figure 38, various details of a further step for preparation of the tile roof for use of the photovoltaic panel racking assembly;

Figure 40 shows, in a top plan view generally corresponding to the view of Figure 38, various details of a still further step for preparation of the tile roof for use of the photovoltaic panel racking assembly;

Figure 41 shows, in a top plan view generally corresponding to the view of Figure 38, various details of the final step for preparation of the tile roof for use of the photovoltaic panel racking assembly;

Figure 42 shows, in a front elevational view, the photovoltaic panel racking assembly of Figure 1 as installed for use in connection with a tile roof;

Figure 43 shows, in a perspective view, the installation of Figure 42;

Figure 44 shows, in a partially exploded perspective view, various details of an alternatively preferred embodiment of the photovoltaic panel racking assembly of the present invention;

Figure 45 shows, in a detail view located by reference 45 of Figure 44, various additional details of the photovoltaic panel racking assembly of Figure 44;

Figure 46 shows, in a front elevational view, various details of the photovoltaic panel racking assembly of Figure 44 as installed on a roof section;

Figure 47 shows, in a perspective view, various additional details the photovoltaic panel racking assembly of Figure 44 as installed on a roof section;

Figure 48 shows, in a perspective view, various details of a first preferred embodiment of a standoff as implemented in a second alternatively preferred embodiment of the photovoltaic panel racking assembly of the present invention;

Figure 49 shows, in a right side elevational view, various additional details of the standoff of Figure 48;

Figure 50 shows, in a cross sectional view taken through cut line 50— 50 of Figure 49, various still further details of the standoff of Figure 48;

Figure 51 shows, in a perspective view, various details of the installation and use of the second alternatively preferred embodiment of the photovoltaic panel racking assembly of the present invention and, in particular, shows utilization of the standoff of Figure 48;

Figure 52 shows, in a front elevational view, various further details of the installation and use of Figure 51 ;

Figure 53 shows, in a perspective view, various details of a second preferred embodiment of a standoff as implemented in the second alternatively preferred embodiment of the photovoltaic panel racking assembly of the present invention;

Figure 54 shows, in a right side elevational view, various additional details of the standoff of Figure 53;

Figure 55 shows, in a perspective view, various details of the installation and use of the second alternatively preferred embodiment of the photovoltaic panel racking assembly of the present invention and, in particular, shows utilization of the standoff of Figure 53; and

Figure 56 shows, in a front elevational view, various further details of the installation and use of Figure 55.

BEST MODE FOR CARRYING OUT THE INVENTION:

Although those of ordinary skill in the art will readily recognize many alternative embodiments, especially in light of the illustrations provided herein, this detailed description is exemplary of the preferred embodiment of the present invention - a photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels, the scope of which is limited only by the claims appended hereto.

Referring now to the figures and to Figures 1 and 2 in particular, a first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention is shown to generally comprise a generally cylindrically shaped standoff 70 cooperatively adjoined to a specially formed toggle 80 through an all thread rod 100 having positioned at an end opposite the standoff 70 a nut 101 that is sized and shaped to operatively engage with the toggle 80 as will be better understood further herein. In the most preferred embodiment of the first implementation of the present invention, as will be better understood further herein, a rubber or like material gasket 1 10 is also provided in order to promote watertight sealing upon installation and during use of the present invention. Additionally, and also as will be better understood further herein, a relief plate 1 12 may be provided in order to prevent installation damage to more generally fragile roofing materials such as, for example, asphalt shingles or like composite roofing 125. Likewise, a rubber or like material sleeve 102 is provided in order to facilitate positioning of the toggle 80 during installation of the racking assembly 60.

As particularly shown in Figures 3 and 4, the standoff 70 is formed of a structural solid such as, for example, aluminum or steel and, in a critical aspect of the present invention, is generally cylindrical in shape. Additionally, as also shown in the figures, the standoff 70 of the first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention comprises at its first, top end 71 a first preferably tapped, longitudinally oriented hole 72, which, as will be better understood further herein, is adapted for receiving various mounting hardware such as, for example, a self-tapping machine screw 151 or the like as may be utilized in the further use of the racking assembly 60. Likewise, the standoff 70 of the first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention also comprises and at its second, bottom end 73 a second preferably tapped, longitudinally orient hole 74, which, as will also be better understood further herein, is a sized, threaded and otherwise adapted to operatively receive therein one end of the all thread rod 100.

As particularly shown in Figures 5 through 10, the toggle 80 as implemented in accordance with the photovoltaic panel racking assembly 60 of the present invention is specially sized and shaped to exhibit various operative characteristics. In particular, the top 81 of the toggle 80 preferably comprises a plurality of coplanar edges 82 and, in any case, is formed to enable generally planar engagement with a substantially flat surface such as, for example, the underside of a roof deck 122 such as may comprise sheathing material. Additionally, the toggle 80 is provided with a central aperture 90 oriented and extending through the toggle 80 from the top 81 of the toggle to the bottom 83 of the toggle 80. Further, the central aperture 90 generally divides the toggle into a first side 85 toward a first end 84 of the toggle and a second side 88 toward a second end 87 of the toggle. In a critical aspect of the present invention, the second side 88 of the toggle 80, as otherwise herein described, is formed to have a mass appreciably greater than the mass of the first side of the toggle 80, also as otherwise herein described.

As particularly shown in Figures 5 and 6, the toggle 80 is defined to comprise a vertical axis A running generally through the center of the central aperture 90 and oriented substantially normal to the plane defined by the coplanar edges 82 of the top 81 of the toggle 80. Additionally, the toggle 80 is defined to comprise a longitudinal axis B running from the center of the first end 84 of the toggle 80 perpendicularly through the vertical axis A to the center of the second end 87 of the toggle 80. Finally, the toggle 80 is defined to comprise a transverse (or lateral) axis C running orthogonally through the vertical axis A and the longitudinal axis B.

As shown in the figures, the toggle 80 comprises in its first side 85 a generally downwardly oriented, open-ended trough 86 positioned slightly above and about the longitudinal axis B and further comprises in its second side a generally C-shaped, upwardly oriented channel 89 having an open top and ends. As particularly shown in Figures 8 and 9, the trough 86 and channel 89 are sized and otherwise configured such that the toggle 80 is adapted to snuggly but freely receive the all thread rod 100 along the longitudinal axis B through the toggle 80. Additionally, the trough 86 and channel 89 are sized and otherwise configured such that the toggle 80 may freely translate along and roll about the all thread rod 100 when the all thread rod 100 is positioned along the longitudinal axis B, but, when the all thread rod 100 is so positioned, is generally prevented from yawing about the vertical axis A. As particularly shown in Figures 10 and 1 1, the central aperture 90, trough 86 and channel 89 are also sized and otherwise configured such that the toggle 80 is adapted to closely but freely receive the all thread rod 100 along the vertical axis A or along any axis perpendicular to the transverse axis and within the 90 degree arc between the vertical axis and the longitudinal axis extending above the second side 88 of the toggle 80 and below the first side 85 of the toggle. Additionally, the central aperture 90, trough 86 and channel 89 are also sized and otherwise configured such that the toggle 80 may freely translate along and yaw about the vertical axis A when the all thread rod 100 is positioned along the vertical axis A. Further still, the central aperture 90, trough 86 and channel 89 are sized and otherwise configured such that the toggle 80 is generally constrained to approximately 90 degrees pitch about the transverse axis C. Finally, a slight burr is formed at the shoulder 91 of the toggle 80 adjacent to the bottom of the toggle 80, which burr projects toward the all thread rod 100 to loosely engage the threads thereof. With the sleeve 102 pressed into engagement with the second end 87 of the toggle 80 and with the all thread rod 100 positioned along the longitudinal axis B of the toggle 80 such that the burr engages the threads of the all thread rod 100, the toggle 80 is prevented from translating along in its longitudinal axis B along the all thread rod 100. As will be appreciated by those of ordinary skill in the art, the provision of this burr feature is a critical aspect of the invention inasmuch as the described operable combination service to fix the toggle 80 into position during "blind" insertion through a mounting hole 142. As used herein, the phrase "means for constraining motion about an inserted" cylindrical object such as, for example, an all thread rod 100, a bolt 220 or the like is expressly defined to mean and be limited to the structure described in this paragraph and equivalents thereof.

In any case, referring now to Figures 12 through 19 in particular, installation on a typical roof section 120 of the first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention is described. As shown in Figure 12, the installation begins with preassembly of the various required and optional components of the racking assembly 60. In particular, the all thread rod 100 is inserted into the tapped hole 74 at the second, bottom end 73 of the standoff 70. Preferably, in order to facilitate a watertight seal upon installation on the roof section 120 of the assembly 60, the gasket 1 10 is then placed in the assembly 60 by inserting the free end of the all thread rod 100 through the mounting hole 1 1 1 provided through the gasket 1 10. In the case of the racking assembly 60 being prepared for use in connection with a roof section comprising composite roofing 125 such as, for example, asphalt shingles or the like, the relief plate 1 12 is most preferably then next placed in the assembly 60 by inserting the free end of the all thread rod 100 through the mounting hole 1 13 provided through the relief plate 1 12, thereby distributing the tightening force of the assembly 60 over a greater area of the composite roofing 125. Next, in order to facilitate positioning of the toggle 80 during installation, as will be better understood further herein, the rubber or like material sleeve 102 is then be added to the assembly 60 by placing the sleeve 102 over the free end of the all thread rod 100. In any case, the toggle 80 is then added to the assembly 60 by running the free end of the all thread rod 100 from top to bottom through the central aperture 90 of the toggle 80. Finally, the provided nut 101 threaded onto the all thread rod 100 to complete the preassembly of the various required and optional components of the racking assembly 60.

If not already prepared, the roof section 120 is then prepared for installation of the racking assembly 60 by drilling a mounting hole 142 through the composite roofing 125 (and any moisture barrier 123 such as, for example, roofing felt 124 or like tar paper) and the roof deck 122. In a particular advantage of the present invention over the prior art, the mounting hole 142 is placed between rafters 121 rather than being constrained to being centered on a rafter 121. In any case, the preassembled racking assembly 60 is then configured as generally shown in Figure 12 by orienting the longitudinal axis B along the all thread rod 100 with the first end 84of the toggle 80 resting atop the nut 101. In order to maintain this positioning, the sleeve 102 is pressed down along the all thread rod 100 into firm contact with the second end 87 of the toggle 80. In any case, the end of the assembly 60 generally opposite the standoff 70 is then inserted through the prepared mounting hole 142 into position beneath the roof deck 122 as generally shown in Figure 13. As the assembly 60 is inserted through the mounting hole 142, the sleeve 102 is manually restrained to free the toggle 80 whereafter the greater mass of the second side 88 of the toggle 80 with respect to the first side 85 of the toggle 80 will cause the toggle 80 to pitch within its previously described constrained motion, as shown in Figure 14, and fall into the position of Figure 15.

With the toggle 80 in the position of Figure 15, jostling or the like will readily bring the toggle 80 into position about the nut 101 such that an edge of the nut 101 abuts against the shoulder 91 formed at the intersection of the central aperture 90 and the channel 89 of the toggle 80. As will be appreciated by those of ordinary skill in the art, especially in light of this exemplary description, the described positioning of the toggle 80 with respect to the nut 101 will cause the rotational position of the nut 101 about the all thread rod 100 to be fixed with the rotational position of the toggle 80 about the all thread rod 100. In order to ensure maintenance of this fixed relationship, the sleeve 102 is slid into position adjacent the top 81 of the toggle 80 as also shown in Figure 15. In any case, in order to complete installation of the racking assembly 60, the all thread rod 100 is then withdrawn trough the mounting hole 142 until the top 81 of the toggle engages the underside of the roof deck 122 where only slight upward force is required to frictionally fix the position of the toggle 80 about its vertical axis A. With the toggle 80 in fixed position, the standoff 70 and consequently the all thread rod 100 are manually or mechanically rotated to thread the all thread rod 100 through the nut 101, as held in place by the toggle 80, until the assembly is in its fully installed fixed position as shown in Figures 17 through 19. As shown in Figure 19, it is noted that the sleeve 102 will in at this point be contained within the bounds of the mounting hole 142.

In an extension of the present invention, as particularly shown in Figures 20 through

24, an extended mounting surface for dependency supporting one or more photovoltaic panels 170 may be implemented as an L-shaped, elongate bracket 151 preferably comprising a length of aluminum angle stock. As will be appreciated by those of ordinary skill in the art, the elongate bracket may be placed atop one or more installed photovoltaic panel racking assemblies and secured in place by driving the point 152 of a self- tapping machine screw 151 through the top of the bracket 150 and into the first tapped hole 72 previously described as being provided at the first end 71 of the standoff 70, whereafter the machine screw 151 may be tightened into the tapped hole 72 to secure the bracket 150 in place as generally depicted in Figure 24. In order to facilitate placement of the self-tapping machine screw 151, however, the present invention further contemplates the option inclusion to the assembly 60 of an assembly jig 160 specially adapted to readily and accurately locate the correct insertion point for the machine screw 151.

As shown in Figures 21 and 22, the assembly jig 160 generally comprises a U-shaped article having a top prong 161 and a bottom prong 165. As shown in the figures, the top prong comprises a preferably semicircular notch 163 at its distal edge 162, the size of this notch 163 being generally of the diameter of the machine screw 151. Similarly, the bottom prong comprises a preferably semicircular notch 167 at its distal edge 166, the size of this notch being generally of the diameter of the standoff 70. As particularly shown in Figure 23, the origins of the first semicircular notch 163 and of the second semicircular notch 167 are aligned. In this manner, as shown in Figure 23, simply pressing the distal edge 166 of the bottom prong of the assembly jig 160 against the side of the standoff while the top prong 161 rests atop the bracket 150 locates the correct location for insertion of the self-tapping machine screw 150 according to the location of the notch 163 formed in the distal edge 162 of the top prong 161.

In a further extension of the present invention, novel means for securing a photovoltaic panel 170 atop a provided extended mounting surface 150 are disclosed. In particular, a means for securing a single photovoltaic panel 170 atop a provided extended mounting surface is particularly shown in Figures 25 through 29 to generally comprise a panel mounting bracket 180 in the general form of a parallel-S type angle bracket, wherein the panel mounting bracket is provided with means 186 for adjusting the height of the bracket to accommodate a range of thicknesses of photovoltaic panels 170. In particular, as shown in the figures, the base 181 of the panel mounting bracket 180 is provided with a tapped hole 183 generally adjacent its outer edge 182 and an aperture 184 at a more interior location as particularly shown in Figures 25 and 26. As shown in Figure 25, the photovoltaic panel 170 to be mounted is positioned such that a perimetrical edge 172 of the frame 171 about the photovoltaic array 174 is rested atop a portion of the elongate bracket 150 and the panel mounting bracket 180 is positioned such that the clamping arm 185 of the mounting bracket 180 rests on the top 173 of the frame 171 of the photovoltaic panel 170. As shown in Figures 28 and 29, a hex head or like bolt 189 having a substantially flat point 190 is inserted through the tapped hole 183 provided in the base 181 of the panel mounting bracket 180 in order to adjust the height of the base 181 above the elongate bracket 150 as necessary to accommodate the height of the frame 171 of the photovoltaic panel 170. The point 188 of a self-tapping machine screw 187 is then inserted through the aperture 184 provided in the base 181 of the panel mounting bracket 180, driven into and through the elongate bracket 150 and tightened in place to secure the clamping arm 185 firmly against the top 173 of the frame 171 of the photovoltaic panel 170, thereby firmly securing the photovoltaic panel 170 in place atop the elongate bracket 150 as particularly shown in Figures 27 through 28.

A means for securing a pair of photovoltaic panels 170 atop a provided extended mounting surface 150 is particularly shown in Figures 30 through 37 to generally comprise an integrated inter-panel mounting bracket and grounding clip 200, which is preferably stamped or similarly constructed from stainless steel. In addition securing a pair of photovoltaic panels 170 in place atop the elongate bracket 150, the integrated inter-panel mounting bracket and grounding clip 200 of the present invention also provides a grounding bridge between adjacent photovoltaic panels 170. As shown in Figures 31 through 34, the integrated inter-panel mounting bracket and grounding clip 200 generally comprises a top surface 201 having formed therein a downwardly projecting mounting tab 206 such that the top surface comprises a plurality of wings 202 extending outward from the first outer edge 208 of the downwardly projecting mounting tab 206 on one side of the integrated inter-panel mounting bracket and grounding clip 200 and extending oppositely outward from the second outer edge 209 of the downwardly projecting mounting tab 206 on the opposite side of the integrated inter-panel mounting bracket and grounding clip 200. The downwardly projecting mounting tab 206 is also provided with a central aperture 207 therethrough for affixation of the integrated inter-panel mounting bracket and grounding clip 200 in place atop the elongate bracket 150, as will be better understood further herein.

In order that the integrated inter-panel mounting bracket and grounding clip 200 of the present invention may adequately provide a grounding bridge between adjacent photovoltaic panels 170, a plurality of projections 204 are provided on the underside 203 of each wing 203, which projections 204 preferably each comprise a sharp point or edge 205 for embedding into the metal frames 171 of the adjacent photovoltaic panels 170. As will be appreciated by those of ordinary skill in the art, such projections 204 may be readily formed by through punching the wings 202 from the top surface 201 of the integrated inter-panel mounting bracket and grounding clip 200. In any case, the integrated inter-panel mounting bracket and grounding clip 200 of the present invention is utilized by first positioning a pair of photovoltaic panels 170 atop a provided elongate bracket 150, using the opposite outer edges 208, 209 of the downwardly projecting mounting tab 206 of an integrated inter-panel mounting bracket and grounding clip 200 as a guide for spacing of the adjacent photovoltaic panels 170. With the photovoltaic panels 170 properly positioned, as generally shown in Figure 35, appropriate mounting hardware 210 is used to secure the integrated inter-panel mounting bracket and grounding clip 200 of the present invention in place as well as to force the sharp projections 204 into the metal frames 171 of the adjacent photovoltaic panels 170. In particular, as shown in the figures, a self-tapping machine screw 21 1 with sharp point 212 is inserted through the central mounting aperture 207 of the downwardly projecting mounting tab 206, driven into and through the elongate bracket 150 and tightened in place to secure the wings 202 firmly against the tops 173 of the frames 171 of the adjacent photovoltaic panels 170, thereby firmly securing the photovoltaic panels 170 in place atop the elongate bracket 150 as particularly shown in Figures 35 through 37.

Referring now to Figures 38 through 43 in particular, a slight variation in the manner of use of the first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention is described for accommodating utilization in connection with ceramic or similar roofing tiles 126. In particular, it is first noted that because roofing tiles 126 will generally be installed directly atop a moisture barrier 123 over the roofing deck 122, the use of the relief plate 1 12 is not considered necessary. As a result, the preassembly of the various required and optional components of the racking assembly 60 is a previously described with the exception that the relief 1 12 is not added to the assembly 60. Turning then to preparation of the roof section 120, and with particular reference to Figure 38, a small pilot hole 140 is first drilled into and through a selected roofing tile 126 as well as any moisture barrier 123 such as, for example, roofing felt 124 or like tar paper and also through the roof deck 122. With the pilot hole 140 drilled, a clearance hole 141 closing matching the dimension of the standoff 70 is drilled through the selected roofing tile 126 only as particularly shown in Figures 39 and 40. With the access gained by the clearance hole 141 through the roofing tile

126 and using the previously established pilot hole 140 as a guide, a larger mounting hole 142 is then drilled through the roofing felt 124 or like tar paper and also through the roof deck 122 as previously discussed and as particularly shown in Figure 41. With the roof section 120 thus fully prepared, the remaining installation of the first preferred implementation of the photovoltaic panel racking assembly 60 of the present invention proceeds as previously discussed in order to arrive at the arrangement as particularly shown in Figures 42 and 43. In the case of this type of installation, however, those of ordinary skill in the art will of course recognize that a roof sealant or the like should be applied about the interface between the clearance hole 141 through the roofing tile 126 and the installed standoff 70.

Referring now to Figures 44 through 47, a second preferred implementation of the photovoltaic panel racking assembly 60 of the present invention, as particularly useful for mounting extra-assembly hardware 230 or other components such as, for example, a simple mounting bracket 231 is shown to substitute all of the above the roof deck components of the first implementation of the photovoltaic panel racking assembly 60 of the present invention for a washer head bolt 220 and, if required for the particular implementation, a rubber or like material gasket 221 adapted to facilitate a watertight installation. As shown in the figures, the washer head bolt 220 replaces the previously described all thread rod 100, but is otherwise installed as previously discussed.

Finally, as particularly shown in Figures 48 through 52, an alternative embodiment of the standoff 70 may be implemented for use in connection with standing seam metal roofing

127 such as commonly comprises an L-shaped seam or rib 128 where a first vertical edge 129 rises above the roof surface and is mated with and folded over a second vertical edge 130 rising from the roof surface to form inverted L-shaped profile 131. To accommodate this type of standing seam metal roofing 127, the standoff 70 comprises a slot 75through its second, bottom end 73 in place of the previously described tapped hole 75. As shown in Figures 48 through 50, a plurality of transversely oriented, threaded apertures 76 are provided through one of the tangs formed by the provision of the slot 75. In use, as particularly shown in Figures 51 and 52, the modified standoff is placed over and about the L-shaped seam 128 of the standing seam metal roofing 127 with the untapped tang against the unobstructed vertical edge 129 and the tang comprising the threaded apertures 76 positioned facing the opposite vertical edge 130. In position, an appropriate number of hex head or like bolts 78 comprising substantially flat points, or like mounting hardware 77, are utilized to fasten the modified standoff 70 securely in place as shown in Figures 51 and 52.

In a slight variation, such as is particularly useful in connection with an installation over a standing seam metal roofing 127 comprising a T-shaped seam or rib 132 wherein a first vertical edge 133 and a second vertical edge 134 are both obstructed by T-arms 135, the modified standoff 70 may be provided with a plurality of transversely oriented, threaded apertures 76 through each of the tangs formed by the provision of the slot 75. In this case, the modified standoff is centered over and about the T-shaped seam 132 of the standing seam metal roofing 127 and fastened from both sides with an appropriate number of hex head or like bolts 78 comprising substantially flat points, or like mounting hardware 77 as shown in Figures 55 and 56.

While the foregoing description is exemplary of the preferred embodiment of the present invention, those of ordinary skill in the relevant arts will recognize the many variations, alterations, modifications, substitutions and the like as are readily possible, especially in light of this description, the accompanying drawings and the claims drawn hereto. For example, those of ordinary skill in the art will recognize that if a relief plate 1 12 is used the installer should during installation apply a roof sealant or the like between the bottom of the relief plate 1 12 and the roofing material. In any case, because the scope of the present invention is much broader than any particular embodiment, the foregoing detailed description should not be construed as a limitation of the present invention, which is limited only by the claims appended hereto.

INDUSTRIAL APPLICABILITY: The present invention is applicable to building construction. Figure for publication: 1.

Claims

CLAIMS: What is claimed is:

1. A photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels, said photovoltaic panel racking assembly comprising:

a generally cylindrically shaped standoff, said standoff having a longitudinally oriented tapped hole at a first end thereof;

a threaded rod, said threaded rod being inserted at a first end thereof into said tapped hole at said first end of said standoff;

a toggle having inserted through a provided aperture a second end of said threaded rod;

a nut affixed to said second end of said threaded rod and adapted to maintain the insertion of said threaded rod through said aperture of said toggle; and

wherein:

said toggle comprises means for constraining motion about said inserted threaded rod;

said toggle comprises a greater mass on a first side of said aperture than on a second side of said aperture; and

said toggle and said nut are cooperatively adapted to lock into fixed orientation with respect to one another.

2. The photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels as recited in claim 1 , said photovoltaic panel racking assembly further comprising an extended mounting surface for supporting photovoltaic panels.

3. The photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels as recited in claim 2, said photovoltaic panel racking assembly further comprising means for securing an end photovoltaic panel to said extended mounting surface.

4. The photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels as recited in claim 2, said photovoltaic panel racking assembly further comprising means for securing an adjacent pair of photovoltaic panels to said extended mounting surface while simultaneously providing a grounding connection between said pair of photovoltaic panels.

5. The photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels as recited in claim 4, said photovoltaic panel racking assembly further comprising means for securing an end photovoltaic panel to said extended mounting surface.

6. A photovoltaic panel racking assembly for use in connection with roof installation of photovoltaic panels, said photovoltaic panel racking assembly comprising:

a bolt, said bolt having a threaded end;

a toggle having inserted through a provided aperture said threaded end of said bolt; a nut affixed to said threaded end of said bolt and adapted to maintain the insertion of said threaded end through said aperture of said toggle; and

wherein:

said toggle comprises means for constraining motion about said inserted threaded end of said bolt;