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Patent 2832861 Summary

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(12) Patent: (11) CA 2832861
(54) English Title: MODULAR ROOF SOLAR PANEL FOR CONVENTIONAL SLOPING ROOF AND ROOFING INTEGRATION
(54) French Title: PANNEAU SOLAIRE MODULAIRE DE TOIT POUR TOIT EN PENTE CLASSIQUE ET INTEGRATION DE COUVERTURE
Status: Granted
Bibliographic Data
(51) International Patent Classification (IPC):
  • H02S 20/23 (2014.01)
  • H02S 30/10 (2014.01)
(72) Inventors :
  • RICHARDSON, ROBERT (Canada)
(73) Owners :
  • RICHARDSON, ROBERT (Canada)
(71) Applicants :
  • RICHARDSON, ROBERT (Canada)
(74) Agent: CASSAN MACLEAN IP AGENCY INC.
(74) Associate agent:
(45) Issued: 2016-06-21
(22) Filed Date: 2013-11-08
(41) Open to Public Inspection: 2015-05-08
Examination requested: 2015-01-27
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): No

(30) Application Priority Data: None

Abstracts

English Abstract

There is provided an improved roof solar panel, embodying a photovoltaic panel mounted on a frame for easy installation onto a conventional sloped roof and integration with conventional roof coverings. Such panel includes a roof covering mounting surface on an outside support of the frame, a photovoltaic panel mounting surface on an inside support of the frame, and when installed on the roof, a retainer trim for securing the roof covering and photovoltaic panel mounted on said supports while mounting to the frame. The frame also serves to provide means for securing the panel onto roof trusses. Integration with the conventional roof covering provides, inter alia, an attractive low profile with improved water shedding, wind resistance, and thermal regulation properties. The invention also relates to a kit comprising, inter alia, said roof solar panel, and to a method of installing said roof solar panel.


French Abstract

Linvention propose un panneau solaire de toit amélioré, comportant un panneau photovoltaïque installé sur un châssis pour une installation facile sur un toit en pente classique et une intégration avec des couvertures de toit classiques. Un tel panneau comprend une surface de montage qui couvre le toit sur un support extérieur du châssis, une surface de montage du panneau photovoltaïque sur un support intérieur du châssis, et lorsquil est installé sur le toit, une garniture de maintien pour fixer la couverture du toit et le panneau photovoltaïque fixés sur lesdits supports pendant le montage sur le châssis. Le châssis sert également à fournir des moyens de fixer le panneau sur les fermes de toit. Lintégration avec la couverture de toit classique offre, entre autres, un profil bas attractif avec des propriétés améliorées dévacuation des eaux, de résistance au vent et de régulation thermique. Linvention concerne également une trousse qui comprend, entre autres, ledit panneau solaire de toit et une méthode dinstallation dudit panneau solaire de toit.

Claims

Note: Claims are shown in the official language in which they were submitted.


I claim:
1. A modular roof solar panel for installation on a sloped roof, the solar
panel
comprising:
a rigid photovoltaic panel;
a rectangular frame comprising:
a width and a lower surface respectively configured for mounting of the solar
panel on a plurality of adjacent roof trusses, said trusses having
construction
industry standard separation;
an inside support, wherein said photovoltaic panel is mounted on said inside
support of the rectangular frame;
an outside support configured, for when the modular roof solar panel is
installed
on a sloped roof, for mounting of an overlapping part of a roof covering; and
a thickness which is about the same as a combined thickness of a roof
sheathing
and roof covering of an adjacent part of the roof;
a retainer trim mounted on top of the frame and overlapping the photovoltaic
panel so
as to secure said photovoltaic panel on the inside support, and also
overlapping the
outside support for securing said overlapping part of the roof covering when
the modular
roof solar panel is installed on a roof.
16

2. The solar panel of claim 1, wherein the photovoltaic panel is sealingly
mounted onto
the inside support of the frame using a sealing adhesive.
3. The solar panel of claim 1, wherein the frame and retainer trim are made of

aluminum.
4. The solar panel of claim 1, wherein the retainer trim further comprises
fasteners for
securing the retainer trim to the frame.
5. The solar panel of claim 1, further comprising a spacer between the frame
and the
retainer trim.
6. The solar panel of claim 1, wherein the outside support is for mounting an
overlapping part of a roof covering that is either a shingle or steel roofing.
7. The solar panel of claim 1, wherein when the solar panel is installed on a
roof, the
retainer trim is sealingly mounted to the frame, photovoltaic panel, and roof
covering
using a sealing adhesive.
17

8. The solar panel of claim 1, wherein the inside support, the outside
support, or the
inside support and the outside support are comprised of a recessed perimeter
ledge.
9. A kit of parts for installation of a modular roof solar panel for
installation on a sloped
roof, said kit comprising:
a solar panel comprising:
a rigid photovoltaic panel;
a rectangular frame comprising:
a width and a lower surface respectively configured for mounting of the
solar panel on a plurality of adjacent roof trusses, said trusses having
construction
industry standard separation;
an inside support, wherein said photovoltaic panel is mounted on said
inside support of the rectangular frame;
an outside support configured, for when the modular roof solar panel is
installed on a sloped roof, for mounting of an overlapping part of a roof
covering; and
a thickness which is about the same as a combined thickness of a roof
sheathing and roof covering of an adjacent part of the roof;
a retainer trim for mounting on top of the frame and overlapping the
photovoltaic panel
so as to secure said photovoltaic panel on the inside support, and also
overlapping the
18

outside support for securing said overlapping part of the roof covering when
the modular
roof solar panel is installed on a roof;
one or more roof truss braces;
mounting hardware; and
one or more shingle strips.
10. A method of installing the modular roof solar panel according to claim 1
onto a
sloping roof so as to provide a roof solar panel, said method comprising:
selecting an area for mounting the modular roof solar panel;
installing mounting spacers on roof trusses around a perimeter of said area;
mounting the solar panel onto the roof trusses of said area;
securing the roof covering over said outside support and adjacent mounting
spacers; and
mounting the retainer trim on said frame, roof covering and photovoltaic
panel.
11. The method of claim 10 further comprising, after selecting the area for
mounting the
modular roof solar panel, installing roof truss braces between the roof
trusses and
preparing said roof truss braces for contact with the photovoltaic panel.
19

12. The method of claim 10 wherein said securing of the roof covering
comprises using
sealing adhesive on an underside of the roof covering, and wherein said
mounting of
said retainer trim comprises using sealing adhesive between said retainer trim
and each
of said frame, roof covering, and photovoltaic panel.
13. The method of claim 10 wherein two or more abutting modular roof solar
panels are
installed using a connecting strip, and sealing adhesive between the outside
supports of
abutting sides of said abutting panels.
14. The method of claim 10, wherein the mounting spacers comprise strapping
and the
roof covering comprises steel roofing
15. The method of claim 10, wherein the mounting spacers comprise roof
sheathing and
the roof covering comprises shingles or steel roofing.
16. The method of claim 15, in which the roof covering comprises shingles,
further
comprising, after mounting of the retainer trim, integrating surrounding
shingles on
adjacent roof sheathing to said shingles on which said retainer trim has been
mounted.

17. The method of claim 15, in which the roof covering comprises shingles,
wherein
some of said shingles are shingle strips, said shingle strips being secured
onto said
outside support along both lateral sides and top side of the frame of the
modular roof
solar panel, and wherein other of said shingles are shingles secured onto said
outside
support along a bottom side of the frame of the modular roof solar panel such
that top
edges of said other shingles abut against an inside edge of said outside
support.
18. The method of claim 17 wherein said shingle strips are prepared from
shingles by
cutting away at least part of a showing surface of said shingles.
21

Description

Note: Descriptions are shown in the official language in which they were submitted.


CA 02832861 2013-11-08
,
,
MODULAR ROOF SOLAR PANEL FOR CONVENTIONAL SLOPING
ROOF AND ROOFING INTEGRATION
Field of the Invention
[0001] The present invention relates to an improved roof solar panel,
embodying
photovoltaic cells, that can be readily and easily installed into a
conventional sloping
roof and that integrates with a conventional roof covering so as to provide,
inter alia,
an attractive low profile with improved water shedding, wind resistance, and
thermal
regulation properties. Further, the invention relates to a kit comprising,
inter alia, said
roof solar panel, and to a method of installing said roof solar panel.
Background
[0002] Both non-structural and structural roof elements incorporating solar
collectors
such as an array of photovoltaic cells are well known. However, structural
roof
panels are generally of specialized and costly configuration and installation,
often
complex and/or heavy and requiring modification or replacement of existing
conventional roof structures. The combination of non-structural substrates and
solar
panels is also well known as substitutes for roofing materials such as
shingles and
tiles, but such are also typically costly and requiring specialized
installation. Solar
panels for installation over existing roof components are also well known, but
such
pose undesirable profile and aesthetic factors, and challenges for mounting
securely
on the roof without compromising existing roof components or their function.
[0003] In addition, as the temperature of a photovoltaic cell increases, its
power
output drops. As such, it is important to ensure that photovoltaic cells are
kept cool
to ensure an optimal operating environment.
[0004] PCT/CA2012/050305 describes a modular roof solar which is mounted onto
conventional modular roof sheathing. This integration reduces the complexity,
and
1

CA 02832861 2013-11-08
cost of incorporating a photovoltaic cell, while still providing a highly
secure
integration into a conventional roof structure. However, this modular panel is
still
somewhat heavy, and the roof sheathing acts as an insulator against the back
of the
photovoltaic cell, increasing the difficulty in maintaining an optimal
operating
temperature.
[0005] There is therefore a need for a low cost, easy to install roof solar
panel
offering highly secure integration into conventional roof structures and
consequent
functional and aesthetic advantages while maintaining proper temperature
control for
the solar panel.
Summary of the Invention
[0006] In a first aspect, the invention provides a modular roof solar panel
for
installation on a sloping roof, the panel comprising a rigid photovoltaic
panel, a
rectangular frame and a retainer trim. The frame comprises a width and lower
surface respectively configured for mounting of the solar panel on a plurality
of
adjacent roof trusses, the trusses having construction industry standard
separation.
In addition, the frame has an inside support, preferably a recessed perimeter
ledge,
on which the photovoltaic panel is mounted, and an outside support, preferably
a
recessed perimeter ledge, for mounting of an overlapping part of a roof
covering.
The frame has a maximum thickness which is about the same as a combined
thickness of a roof sheathing and roof covering of an adjacent part of the
roof. The
retainer trim is mounted on top of the frame and overlapping the photovoltaic
panel
so as to secure the photovoltaic panel on the inside support, and also
overlaps the
outside support for securing the overlapping part of the roof covering when
the
modular roof solar panel is installed on a roof.
[0007] In a preferred embodiment the photovoltaic panel is sealingly secured
to the
inside support using a sealing adhesive, preferably a urethane sealer.
Additionally,
2

CA 02832861 2013-11-08
when the panel is installed on a roof, the retainer trim is preferably
sealingly secured
to the photovoltaic panel, frame and roof covering using a sealing adhesive,
preferably a silicone sealer.
[0008] In yet another preferred embodiment, the frame and retainer trim are
made of
aluminum.
[0009] In yet another preferred embodiment, the retainer trim further
comprises
fasteners for securing the retainer trim to the frame.
[0010] In yet another preferred embodiment the solar panel comprises a spacer
between the frame and the retainer trim.
[0011] In yet another preferred embodiment, the roof covering comprises either
shingles or steel roofing.
[0012] In a second aspect, the invention provides a kit of parts for the
installation of a
modular roof solar panel on a sloped roof, the kit comprising the above
described
solar panel, one or more roof truss braces for providing extra structural
support to the
panel and roof trusses, mounting hardware for assembling and attaching the
panel to
the roof trusses and finally, shingle strips for placement in the outside
support of the
frame during a shingled installation.
[0013] In a third aspect, the invention also provides a method for installing
the
modular roof solar panel described above onto a sloping roof. The method
comprises the following steps: selecting an area for mounting the modular roof
solar
panel; installing mounting spacers on roof trusses around a perimeter of the
area;
mounting the panel onto the roof trusses of the area; securing the roof
covering over
the outside support and adjacent mounting spacers; and mounting the retainer
trim
on the frame, roof covering, and photovoltaic panel.
3

CA 02832861 2013-11-08
'
[0014] In a preferred embodiment the method of installation also includes,
after
installing the mounting spacers, installing roof truss braces between the roof
trusses
and preparing the roof truss braces for contact with the photovoltaic panel.
Summary of the Drawings
[0015] In drawings which illustrate preferred embodiments of the invention:
[0016] Figure 1 is a side perspective view of the roof solar panel according
to the
invention, installed on a roof;
[0017] Figure la is a front perspective view of a roof solar panel according
to the
invention, installed on a roof;
[0018] Figure 2 is a cross section view from side to side of the inventive
roof solar
panel installed on a roof using steel roofing;
[0019] Figure 2a is a close-up, cross section view of the right side of the
inventive
solar panel installed on a shingled roof;
[0020] Figure 3 is a cross section view through abutting sides of a pair of
adjacent
roof solar panels according to the invention, installed on a roof;
[0021] Figure 4 is a cross section view of a retainer trim component of the
invention;
[0022] Figure 5 is a cross section view of the frame component of the
invention;
[0023] Figure 6 is a cross section view of an acrylic foam connecting strip
component
of the invention;
4

CA 02832861 2013-11-08
[0024] Figure 7 is a sequence diagram illustrating steps for installing an
intermediate
roof solar panel on a roof so as to provide an installed roof solar panel,
according to
the invention;
[0025] Figure 8 is a plan view of a pair of adjacent roof solar panels
according to the
invention, showing particulars of preferred shingle integration along the
lower edge of
the roof solar panels before installation of the retainer trim component; and
[0026] Figure 8a is a cross section view of the bottom (lower) end of one of
the roof
solar panels of Figure 8, after installation of the retainer trim component.
Detailed Description of the Invention
[0027] There is disclosed herein a prefabricated modular roof solar panel that
is
configured to be installed onto conventional roof trusses, a kit of parts for
the
installation of such a roof solar panel, and a method of installing such roof
solar
panel. The roof solar panel is described as modular as its width is
specifically
chosen to allow for easy installation on a roof using construction industry
standard
size roof trusses at construction industry standard separation. This choice of
size
reduces the complexity involved in installing the roof solar panel.
[0028] The modular roof solar panel is comprised of a frame, preferably made
of
aluminum. The frame is preferably rectangular in shape, i.e. with four sides
(upper,
lower and two lateral sides). Each side of the frame preferably has a width,
approximately 30 mm, and a lower surface which, as shown in Figure 3, is
configured
to allow for the lateral sides of two adjacent frames to be securely attached,
side by
side, to a single underlying construction industry standard size roof truss
(approximately 3.8 cm (11/2") wide) with each lateral side overhanging the
edge of the
truss. The frame is also configured to have a total width which allows for
each lateral
5

CA 02832861 2013-11-08
side to be attached to a separate roof truss, when the trusses are at an
industry
standard separation (approximately 40.6 cm center to center (16" center to
center)).
For example, as shown in Figure 2, a frame configured to span four roof
trusses
would attach to the first roof truss at approximately the midpoint of that
truss, extend
over three truss separations, two trusses, and attach to a fourth roof truss
at the
midpoint of that truss. While the exemplified values reflect North American
construction industry standards, the invention may also be modified for use
with a
roof built according to different standards or requirements.
[0029] The frame has an inside support and an outside support, preferably a
recessed inside perimeter ledge and a recessed outside perimeter ledge
respectively. The recessed inside perimeter ledge supports a rigid
photovoltaic panel
comprised of a conventional photovoltaic cell array sealed onto much of its
upper
surface and covered by a rigid, transparent protective sheet such as glass,
plexiglass, or most preferably low iron glass. Such protective sheet is for
protecting
the array from the usual physical stresses caused by weather (wind, water,
snow
etc.) and atmospheric debris, while allowing sunlight to pass through to the
surface of
the photovoltaic array for conversion into electricity. Preferably the
photovoltaic
panel is mounted to the recessed inside perimeter ledge with a sealing
adhesive,
preferably urethane. The recessed outside perimeter ledge provides a surface
on
which a standard roof covering may be mounted, so that it is flush with an
adjacent
roof sheathing panel which is covered with the same roof covering
[0030] Preferably the roof covering comprises either shingles or steel
roofing. Either
of these roof coverings may be installed over standard roof sheathing,
although steel
roofing does allow for some roofs which do not require an underlying layer of
sheathing. In such installations, additional strapping would be secured to the
trusses
adjacent to the frame to provide for an adjacent mounting surface which is
flush with
the recessed outside perimeter ledge of the frame.
6

CA 02832861 2013-11-08
[0031] Finally, the roof solar panel comprises a retainer trim, preferably
made from
aluminum, which is mounted on the frame and overlaps the photovoltaic panel
and
roof covering so as to secure both when the panel installation is complete.
[0032] During installation on a shingled roof, after the modular roof solar
panel has
been secured to the trusses, a preferably single shingle layer (preferably a
shingle
strip prepared from a shingle by cutting away a show surface of the shingle)
is
secured around the top and sides of the aforementioned recessed outside
perimeter
ledge of the frame. The shingle layer is also sized so that it overlaps onto
adjacent
regular roof sheathing. Along the lower side of the roof solar panel, shingles
are
installed so that their upper edges overlap the recessed outside perimeter
ledge of
the frame, preferably subject to cutting them so as to avoid overlap of the
shingle
strips at the sides of the roof solar panel near and at the bottom thereof.
Sealer (e.g.
silicone) is applied over the shingle strips along the sides and top of the
roof solar
panel, the upper ends of the regular shingles along the bottom of the roof
solar panel,
and the frame and photovoltaic panel, after which the retainer trim is then
mounted.
After installation of the retainer trim, conventional shingling of the roof to
points
abutting the retainer trim at the sides and top, and under the shingle along
the bottom
of the roof solar panel is performed. During an installation using steel
roofing, the
steel roofing is similarly secured to the frame following which the retainer
trim is
attached. With steel roofing there is no need to prepare shingle strips as
detailed
above.
[0033] It is noted that the inventive roof solar panel has the advantage of
allowing a
solar panel to be quickly and easily installed on a conventional existing
roof, or on a
new roof construction without the usual time consuming aspects of adapting a
solar
panel for installation over existing conventional roof panels and coverings.
Also, use
of familiar materials requires less training, skill and cost for installation
compared to
other systems.
7

CA 02832861 2013-11-08
[0034] The present invention further does not require mounting brackets and is

integrated with the roof covering so as to provide a low profile on the roof
(see Figure
1). Thus, this provides superior water shedding and is less affected by wind
compared to higher or more complex profiles. This further provides a more
aesthetically pleasing appearance.
[0035] Further, by using the inventive solar panel significant weight
reductions are
achieved compared to prior art systems and solar panels, thereby allowing for
easier
placement and installation.
[0036] The preferred use of urethane as an adhesive allows for a more flexible

control over expansion and contraction between the construction materials in
the
modular roof solar panel.
[0037] Finally, since the bottom surface of the photovoltaic panel exposed is
to the air
inside the roof (in contrast to installation on the surface of a roof), the
panel is in
contact with a large volume of air allowing for improved temperature
regulation of the
photovoltaic array.
[0038] The modular roof solar panel, its installation on a roof and the kit of
parts for
installation of the modular roof solar panel will now be described with
reference to the
Figures.
[0039] Figures 1 and la illustrate the inventive roof solar panel installed on
a roof.
The perspective view of Figure 1 conveys the low profile of the roof solar
panel as
well as its integration into the surrounding conventional shingles. While
these
Figures illustrate a single roof solar panel so installed, two or more
inventive roof
solar panels may be installed on the roof either separated from or, more
preferably,
abutting each other.
8

CA 02832861 2013-11-08
[0040] Figures 2 and 2a illustrate the components of the inventive roof solar
panel
when installed on a roof. Conventional sheathing 8 and the inventive roof
solar panel
9 are mounted on roof trusses 1 using fasteners, e.g. screws. Roof solar panel
9 has
photovoltaic panel 3 (having silicon photovoltaic cells and tag wires) mounted
on the
recessed inside perimeter ledge 4 of the frame 2. Preferably, the photovoltaic
panel
3 is sealed to the recessed inside perimeter ledge 4 using sealing adhesive
12.
Sealing adhesive 12 is preferably urethane. Wiring of the array is attached to
a
control box on the underside of the panel (not shown) which may be easily
accessed
from the area under the roof.
[0041] In some embodiments roof truss braces 7 may be installed between the
roof
trusses 1 using appropriate fasteners 10, preferably screws. The roof truss
braces 7
are preferably notched 11 at either end and fitted with a flexible tape 11a to
allow for
the roof truss braces 7 to support the photovoltaic panel 3 and roof trusses 1
against
an increased load, or to conform with local building code requirements. One
example
of where roof truss braces 7 might be appropriate is for a roof in an area
which has a
significant snowfall during the winter.
[0042] As shown in Figure 2a, during a shingled installation, shingle strips
6, which
preferably are cut from conventional shingles, are mounted during installation
of the
roof solar panel 9 on the roof, preferably in a single layer on the sides and
top of the
roof solar panel 9 on the recessed outside perimeter ledge 17 of the frame 2
and
over the abutting areas of the adjacent sheathing 8. In contrast, Figure 2
shows a
continuous adjacent roof covering 16, such as steel roofing, overlapping the
recessed outside perimeter ledge 17 of the frame 2. Once again referring to
the
shingled installation shown in Figure 2a, along the sides and top of the roof
solar
panel 9, retainer trim 5 is mounted (during installation of the roof solar
panel 9 on the
roof), on the shingle strips 6, the frame 2, and photovoltaic panel 3. Along
the bottom
area of the roof solar panel, retainer trim 5 is mounted (also during such
installation
on the roof) on a conventional shingle 30, the frame 2 and the photovoltaic
panel 3
9

CA 02832861 2013-11-08
(see Figure 8a). Preferably, retainer trim 5 is so mounted using sealing
adhesive,
preferably silicone 13. Also preferably, the retainer trim 5 has fastener
openings for
installing fasteners, preferably screws, through the retainer trim 5, and into
the
underlying frame 2 as shown in Figure 3.
[0043] In Figure 3 there is shown in cross section across abutting sides, a
preferred
configuration of a pair of adjacent roof solar panels according to the present

invention. Thus, instead of a shingle strip 6 or continuous adjacent roof
covering 16
covering the joint 14 between the abutting panels (as in Figures 2a and 2
respectively), there is a resilient strip 15, preferably water impermeable and
preferably made of an acrylic foam, mounted over and along the length of such
joint
with adhesive sealant. The retainer trim 5 is mounted, when the abutting roof
solar
panels are being installed on the roof, over such resilient strip 15 in the
place of
shingle strips 6 or continuous adjacent roof covering 16 along the abutting
recessed
outside perimeter ledges 17 of each frame 2 (as well as the frames 2, and
photovoltaic panels 3 as described above).
[0044] Figure 4 shows a preferred configuration of the retainer trim 5 for use
in the
roof solar panel of the present invention. Preferably such retainer trim 5 is
made of
aluminum. The retainer trim 5 is shown having a height (preferably 3.5 mm
tall) and
a width (preferably 26.5 mm wide), adapted for sealing engagement with the top
of
the frame 2, photovoltaic panel 3, and the roof covering (Figure 2 and 2a). In
one
embodiment a spacer (not shown) may be placed between the retainer trim 5 and
the
frame 2 to provide for a proper engagement when a thicker photovoltaic panel 3
or
roof covering is used.
[0045] Figure 5 shows a preferred configuration of the frame 2, which is
preferably
made of aluminum and is preferably about 30 mm wide and 12 mm high. The
recessed inside perimeter ledge 4 is preferably about 8 mm wide and 7 mm high
while the recessed outside perimeter ledge 17 is preferably about 7 mm wide
and 2

CA 02832861 2013-11-08
mm high. These preferred dimensions allow for the recessed outside perimeter
ledge 17 of the frame 2 to be approximately level with a standard thickness
adjacent
sheathing 8 (approximately 0.95 cm (3/8")) in order to facilitate the
placement and
integration of the roof covering which is mounted on the frame 2 with the
adjacent
roof covering on the adjacent sheathing 8. These values may be adjusted to
accommodate integration with other sheathing or roof coverings of other
standard, or
even non-standard thickness.
[0046] Figure 6 shows a preferred configuration of the resilient strip 15,
preferably of
made of an acrylic foam and preferably about 13 mm wide and 2 mm high.
[0047] The inventive method of installation of the subject roof solar panel on
a roof is
illustrated in Figure 7. While this illustrates the mounting of three abutting
roof solar
panels, the process for mounting a single roof solar panel is similar, as will
be
indicated in the following discussion when appropriate.
[0048] Thus, in step 1, the planned configuration of three roof solar panels
is shown
on a roof section in which the vertical lines represent trusses, a peak of the
roof is at
the top and bottom edge of the roof is at the bottom. In a shingled
installation, the
location of the bottom edge of the roof solar panels between the top and
bottom of
the roof section is preferably at a distance above the bottom edge of the roof
section
which is approximately a whole multiple of the height (distance from lower to
upper
edges) of the finished showing surface of a shingle for the roof. This is to
provide for
a full shingle showing surface in the first row of shingles abutting the lower
edge of
the recessed outside perimeter ledge 17 along the bottom of the roof solar
panel. In
Step 2, a border for the roof solar panels is marked, as illustrated, on the
trusses to
ensure correct positioning of the panels to be mounted. In Step 3, mounting
spacers
are mounted onto the roof trusses around the marked opening for the roof solar

panels. In a shingled installation, or an installation using steel roofing and
roof
sheathing, the mounting spacers comprise regular roof sheathing, which is
mounted
11

CA 02832861 2013-11-08
onto the trusses around the marked opening for the roof solar panels. If steel
roofing
is being used without underlying roof sheathing the mounting spacers comprise
strapping on the trusses to provide for an adjacent mounting surface which is
flush
with the recessed outside perimeter ledge 17 of the frame.
[0049] In Step 4, in appropriate situations, the installation of roof truss
braces 7 to
roof trusses that will be under intermediate areas of the first roof solar
panel to be
installed is shown. Although this is preferably performed after installation
of the
mounting spacers, the roof truss braces may be installed at any time after the
area
for mounting the modular roof panel has been selected. In Steps 5 and 6,
mounting
of the first solar panel is shown. In Step 5 the roof solar panel is placed
into position.
In Step 6 the roof solar panel is attached to the underlying roof trusses.
Preferably,
the frame 2 comprises a number of holes for receiving screws to attach the
roof solar
panel to the underlying roof trusses (as shown in Figures 3 and 5).
Preferably, after
the roof solar panel is in place, a sealing adhesive is applied into each of
said holes.
A screw is then installed in such holes, beginning with each of the four
corners of the
roof solar panel, followed by any other such holes, further preferably
providing each
of such holes with a tapered opening for the screw head. Steps 4-6 are
repeated to
install the other two roof solar panels.
[0050] In Step 7, which shows the other two panels also mounted in position, a

resilient strip (15 in Fig. 3), preferably made of acrylic foam, is mounted
along the join
between abutting roof solar panels. (This is not applicable to when a single
roof solar
panel is being installed ¨ no such resilient strip is needed in the latter
case.)
Preferably, the resilient strip 15 is mounted over silicon sealant applied
between the
respective recessed outside perimeter ledges 17 of adjacent roof solar panels.
Also
preferably, such resilient strip 15 extend from the lower ends of the upper
recessed
outside perimeter ledges 17 to the upper ends of the lower recessed outside
perimeter ledges 17 (to allow for roof covering to be installed on the upper
and lower
recessed outside ledges 17 of each of the adjacent roof solar panels).
12

CA 02832861 2013-11-08
,
,
[0051] Steps 8 through 10 detail installation procedures specific to a
shingled
installation. In Step 8 a preferred method of preparing shingle strips 6 for
installation
around the outermost sides and top perimeter areas of the three roof solar
panels is
shown. (If there is just one roof solar panel, then these shingle strips 6 are
for
installation around both sides and top perimeter areas of the roof solar
panel.) This
involves cutting away the normally exposed part of the shingle (i.e. when
conventionally installed on a roof) at about one inch below the normal glue
line, to
leave intact a shingle strip 6 preferably about from 20 to 21 cm high (about 8
inches)
i.e. from the lower to upper edge if conventionally orientated. In Step 9 is
shown the
installation of shingle strips around the top and side perimeter areas of the
roof solar
panels. Preferably, the glue side of the shingle is mounted on the recessed
outside
perimeter ledge 17. In multiple solar panel installations employing the
resilient strip
15, the shingle strip is cut so as to butt up against a side of the part of
the resilient
strip 15 that extends to the lower end of the upper recessed outside perimeter
ledges
17.
[0052] In Step 10, regular shingles 30 and 16a are shown installed from the
bottom
edge of the roof 25 up to the edge of lower recessed outside perimeter ledge
17 of
the frame 2 (best shown in Figures 8 and 8a), also configured to butt up
against the
lower edges of the resilient strips 15. In preparation for installation of the
retainer trim
5, preferably silicon sealant is applied around the perimeter areas of all the
solar
panels, i.e. over the shingle strips 6, the frames 2, photovoltaic panels 3,
the resilient
strips 15 and the shingles at the bottom adjacent the flashing strip. Also,
preferably
roof sealer is applied to all butt joints out 2 inches from the solar panel.
In Step 11,
the retainer trim 5 is mounted in position over the frames 2, shingles 6,
photovoltaic
panels 3, and, for multiple solar panel installation, resilient strips 15.
Fasteners,
preferably screws and silicon sealer, are then installed through the retainer
trim 5,
into the underlying frame 2 (as shown in Figure 3). Finally, shingling of the
roof is
performed in which conventional shingles 16a butt up against the retainer
strip 5.
13

CA 02832861 2013-11-08
[0053] In a steel roofing installation the steel roofing would be laid across
the roof
and mounted on the recessed outside perimeter ledge 17 of the frame 2. The
retainer trim 5 would then be mounted as described above.
[0054] Figure 8 shows a preferred shingle integration along the lower edge
area of a
pair of abutting roof solar panels. A normal shingling process is used from
the lower
edge of the roof 25 upwards to the lower edge of the solar panels 26, the
latter of
which has been preferably pre-arranged to be located from the former at a
distance
which is an increment of 6 %" from the former. The shingle below said lower
end of
the resilient strip 15 can be seen between the solar panels where it butts up
against
said end. In Figure 8a (which is a schematic representation, not to scale) the
lower
area of Figure 8 is shown in cross-section but with the retainer trim 5 in
position. The
top-most, shingle 30 is configured against the upper edge of the lower
recessed
outside perimeter ledge 17, beneath the retainer trim 5. The first and second
adjacent shingles 16a from the roof edge 25 are also shown.
[0055] In a preferred commercial embodiment of the invention, the roof solar
panel 9
is prepared to a pre-installation condition without the retainer strip 5
sealed in place.
This is because, as may be appreciated from the foregoing description of the
installation method, the retainer trim 5 can only be fully installed once the
roof
covering, and resilient strips 15 if applicable (i.e. for multiple panel
installations), have
been installed over the recessed outside perimeter ledge 17 of the frame 2 and

adjacent sheathing 8, or strapping in the case of a steel roofing installation
without an
underlying sheathing. Thus, such pre-installation condition of the subject
roof solar
panel may be sold as such, preferably in kit form with shingle strips 6, roof
truss
braces 7 and mounting hardware, for later installation on a roof in
combination with
the retainer trim 5.
14

CA 02832861 2013-11-08
[0054] While the foregoing describes most preferred embodiments of the subject

invention, a person skilled in the art will appreciate that variations of such

embodiments will be feasible and still be within the scope of the teachings
herein.
Thus, the substitution of different materials (e.g. metals, plastic, adhesives
etc.) for
those specifically indicated may be expected to occur to such person, and
variations
in shapes and configurations of the different components involved may be made
while sustaining the functions of components actually shown herein, such all
being
within the intended scope of the present invention.

Representative Drawing
A single figure which represents the drawing illustrating the invention.
Administrative Status

For a clearer understanding of the status of the application/patent presented on this page, the site Disclaimer , as well as the definitions for Patent , Administrative Status , Maintenance Fee  and Payment History  should be consulted.

Administrative Status

Title Date
Forecasted Issue Date 2016-06-21
(22) Filed 2013-11-08
Examination Requested 2015-01-27
(41) Open to Public Inspection 2015-05-08
(45) Issued 2016-06-21

Abandonment History

There is no abandonment history.

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Application Fee $200.00 2013-11-08
Request for Examination $400.00 2015-01-27
Maintenance Fee - Application - New Act 2 2015-11-09 $50.00 2015-11-03
Final Fee $150.00 2016-04-01
Maintenance Fee - Patent - New Act 3 2016-11-08 $50.00 2016-11-07
Maintenance Fee - Patent - New Act 4 2017-11-08 $50.00 2017-05-03
Maintenance Fee - Patent - New Act 5 2018-11-08 $100.00 2018-11-08
Maintenance Fee - Patent - New Act 6 2019-11-08 $100.00 2018-11-08
Maintenance Fee - Patent - New Act 7 2020-11-09 $100.00 2018-11-08
Maintenance Fee - Patent - New Act 8 2021-11-08 $100.00 2018-11-08
Maintenance Fee - Patent - New Act 9 2022-11-08 $100.00 2018-11-08
Maintenance Fee - Patent - New Act 10 2023-11-08 $125.00 2018-11-08
Maintenance Fee - Patent - New Act 11 2024-11-08 $125.00 2018-11-08
Maintenance Fee - Patent - New Act 12 2025-11-10 $125.00 2018-11-08
Maintenance Fee - Patent - New Act 13 2026-11-09 $125.00 2018-11-08
Maintenance Fee - Patent - New Act 14 2027-11-08 $125.00 2018-11-08
Maintenance Fee - Patent - New Act 15 2028-11-08 $225.00 2018-11-08
Maintenance Fee - Patent - New Act 16 2029-11-08 $225.00 2018-11-08
Maintenance Fee - Patent - New Act 17 2030-11-08 $225.00 2018-11-08
Maintenance Fee - Patent - New Act 18 2031-11-10 $225.00 2018-11-08
Maintenance Fee - Patent - New Act 19 2032-11-08 $225.00 2018-11-08
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
RICHARDSON, ROBERT
Past Owners on Record
None
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
Documents

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Document
Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2013-11-08 1 23
Description 2013-11-08 15 682
Claims 2013-11-08 6 140
Drawings 2013-11-08 9 104
Representative Drawing 2015-04-10 1 9
Cover Page 2015-05-19 1 43
Representative Drawing 2016-05-02 1 9
Cover Page 2016-05-02 1 42
Office Letter 2018-02-05 1 33
Assignment 2013-11-08 3 98
Prosecution-Amendment 2015-01-27 2 100
Prosecution-Amendment 2015-05-28 1 52
Prosecution-Amendment 2015-06-08 1 3
Prosecution-Amendment 2015-06-10 5 268
Amendment 2015-09-10 6 189
Final Fee 2016-04-01 2 95
Fees 2016-11-07 1 33