Solar roofing system and method of installing the same

Abstract

A solar roofing system wherein the solar panels are integrated into the existing roof of a building in a watertight fashion, through the use of a starter trim piece, side step flashing pieces which are installed under each course of shingles such that they overlap to form a barrier along the side; a step flashing cover which seals the step flashing with the left and right sides of the solar panels, a Z-cleat that is fastened and sealed to the top of each solar panel, and a hood flashing which attaches to the Z-cleat and provides a sealed, watertight transition to the regular roofing material. The solar roofing system is watertight, and integrated with the actual roof, such that it does not need to be replaced when the roofing is replaced.

1 . A solar roof assembly, comprising:
 a panel comprising at least one solar energy collector unit; and   a plurality of trim elements to attach the panel to a support surface, wherein the plurality of trim elements permit water-tight integration of the panel with an asphalt-shingled roof, such that the solar roof assembly does not require removal or replacement when the asphalt-shingled roof is replaced.   
     
     
         2 . A solar roof assembly for installation on a support surface, comprising:
 at least one panel, said panel having a main body with a solar energy collector unit thereon, two upwardly directed flanges on opposing lateral sides of the main body, and a top edge;   a cleat having a bottom surface, a top surface and a wall therebetween, said bottom surface affixed to the main body between the two upwardly directed flanges, near the top edge of the panel; and   a hood, which has a bend along its length which is generally aligned with the top edge of the at least one panel, said hood having an upper portion above the bend which is fastened to the support surface, and a lower portion below the bend extending from the support surface past the top edge of the at least one panel and affixed to the top surface of the cleat.   
     
     
         3 . The solar roof assembly of  claim 2 , further comprising:
 electrical wiring components electrically connected to the solar energy collecting unit;   wherein the electrical wiring components are enclosed between the main body of the panel, the cleat and the hood.   
     
     
         4 . The solar roof assembly of  claim 3 , wherein a row of shingles is installed over the upper portion of the hood, to provide a watertight transition from the support surface to the solar roof assembly. 
     
     
         5 . The solar roof assembly of  claim 4 , further comprising a first panel and a second panel, wherein the first and second panels are placed adjacent to one another along their lateral sides. 
     
     
         6 . The solar roof assembly of  claim 5 , wherein the panels have interlocking features on adjacent upwardly directed flanges. 
     
     
         7 . The solar roof assembly of  claim 6 , wherein the interlocking features comprise an upwardly directed flange having a protrusion on the first panel and the adjacent upwardly directed flange on the second panel being a generally U-shaped flange with an interiorly wrapped lip, wherein the U-shaped flange fits over the upwardly directed flange with the protrusion, and the interiorly wrapped lip engages the protrusion. 
     
     
         8 . The solar roof assembly of  claim 7 , further comprising:
 clips to secure each panel to the support structure, said clips comprising a base which is attached to the support structure and a hook which fits over the upwardly directed flange.   
     
     
         9 . The solar roof assembly of  claim 8 , wherein the first panel is secured to the support structure using clips along each lateral side, and the U-shaped flange of the second panel fits over the upwardly directed flange of the first panel and the clips, and the second panel is secured to the support surface using clips along the lateral side which is not adjacent to the first panel. 
     
     
         10 . The solar roof assembly of  claim 2 , wherein a foam backing and an underlayment are attached to the support surface beneath the panels. 
     
     
         11 . The solar roof assembly of  claim 2 , for application to a support surface with a covering of flexible shingles, further comprising:
 A panel assembly, comprising the at least one panel, said panel assembly having a first side with a first upwardly directed flange thereon, a second side with a second upwardly directed flange thereon, and a bottom;   A first slit in the covering of flexible shingles adjacent to the first side of the panel assembly and a second slit in the covering of flexible shingles adjacent to the second side of the panel assembly;   a starter trim piece, having a cleat for the attachment of the bottom of the panel assembly;   a first plurality of side step flashing pieces, wherein each side step flashing piece comprises an L-shaped piece with a first leg which fits under the shingles adjacent to the first side of the panel assembly and a second leg which extends through the first slit and is adjacent to the first upwardly directed flange, and wherein the side step flashing pieces are overlapping along the first side of the panel assembly;   a second plurality of side step flashing pieces, wherein each side step flashing piece comprises an L-shaped piece with a first leg which fits under the shingles adjacent to the second side of the panel assembly and a second leg which extends through the second slit and is adjacent to the second upwardly directed flange, and wherein the side step flashing pieces are overlapping along the second side of the panel assembly;   a first side step flashing cap, having an inverted “u” shape which fits over the first plurality of overlapping side step flashing pieces and the adjacent first upwardly directed flange; and   a second side step flashing cap, having an inverted “u” shape which fits over the second plurality of overlapping side step flashing pieces and the adjacent second upwardly directed flange.   
     
     
         12 . The solar roof assembly of  claim 2 , for application to a support surface, further comprising:
 a panel assembly, comprising the at least one panel, said panel assembly having a first side with a first upwardly directed flange thereon, a second side with a second upwardly directed flange thereon, and a bottom;   a starter trim piece, having a cleat for the attachment of the panel assembly and a cleat for attachment to a row of shingles;   a first lineal side channel, comprising a two-layered back section with an opening along the bottom thereof which fits over the first upwardly directed flange of the panel assembly, a bottom leg which lies generally flush with the support surface, and a top leg which extends generally parallel with the bottom leg and is at a level sufficient to allow adjacent shingles to be installed under the top leg; and   A second lineal side channel, comprising a two-layered back section with an opening along the bottom thereof which fits over the second upwardly directed flange of the panel assembly, a bottom leg which lies generally flush with the support surface, and a top leg which extends generally parallel with the bottom leg and is at a level sufficient to allow adjacent shingles to be installed under the top leg.   
     
     
         13 . A kit for installing a solar roof assembly, comprising:
 a plurality of panels, each having a main body with a solar energy collecting unit thereon and two upwardly directed flanges extending therefrom, wherein each of the plurality of panels has features to interlock with adjacent panels;   a starter trim piece, having a cleat for the attachment of panels;   a cleat for the top of each panel;   a hood; and   electrical wiring components to link the solar collecting unit to an electrical grid.   
     
     
         14 . The kit for installing a solar roof assembly of  claim 13 , further comprising:
 a plurality of side step flashing pieces; and   two side step flashing caps which fit over the side step flashing pieces and the upwardly directed flange of the panels on the lateral edges of the solar roof assembly.   
     
     
         15 . The kit for installing a solar roof assembly of  claim 13 , further comprising:
 two lineal side channels;   a foam backing layer; and   an underlayment for layering between the foam backing and the panels.   
     
     
         16 . A method of installing a solar roof assembly on a support surface, comprising the steps of:
 positioning at least one panel on the support surface, the at least one panel having a main body with a solar energy collecting unit thereon and two upwardly-directed flanges extending therefrom on opposing lateral sides of the main body, and a top edge;   fastening a cleat having a bottom surface, top surface and a wall therebetween, to the main body near the top edge thereof, so that the bottom surface is securely attached to the main body between the upwardly directed flanges, above the solar energy collecting unit;   electrically connecting electrical connectors for the solar energy collecting units and feeding the electrical connectors through the support surface above the cleats;   attaching an upper portion of a hood to the support surface above the top edge of the at least one panel; and   affixing a lower portion of the hood to the top surface of the cleat and the upwardly directed flanges.   
     
     
         17 . The method of installing a solar roof assembly of  claim 16 , wherein there are at least three panels, further comprising the steps of:
 Fastening a starter trim piece to the support surface, the starter trim piece having a cleat for connection of the panels   installing a starter panel on the starter trim piece;   installing at least one intermediate panel adjacent to the starter panel;   installing an end panel adjacent to the at least one intermediate panel, wherein the starter panel, intermediate panel and end panel have interlocking features as between the panels.   
     
     
         18 . The method of installing a solar roof assembly of  claim 16  on a support surface having a covering of flexible shingles, further comprising the steps of:
 slitting the shingles along each side of an installation site for the panels; and 
 inserting a plurality of side step flashing pieces having an L-shaped cross section with a first leg and a second leg along the slit, with the first leg of each of the plurality of side step flashing pieces under a row of shingles and the second leg of each of the plurality of side step flashing pieces positioned adjacent to the upwardly directed flanges on the outer sides of the at least one panel; and 
 installing a side step flashing cap over the second legs and the upwardly directed flange. 
 
     
     
         19 . The method of installing a solar roof assembly of  claim 16 , further comprising the steps of:
 laying one row of metal shingles;   installing a starter trim piece above the row of metal shingles; and   installing a first and second lineal side channel along the upwardly directed flanges of the at least one panel that are adjacent to the support surface.   
     
     
         20 . A solar roof assembly, comprising:
 a plurality of panels laid side-by-side on a support surface, each panel comprising a main body with a solar energy collecting unit and two upwardly directed flanges wherein the flanges that are adjacent to another flange when the panels are laid side-by-side are adapted to interconnect with the flange of the adjacent panel in a water-tight fashion;   a plurality of trim, flashing and cap elements to seal the bottom and the sides of the plurality of panels in a water-tight fashion;   a cleat, installed between the upwardly directed flanges of each panel, having a bottom surface affixed to the main body, a top surface, and a wall therebetween; and   a hood, having a top portion which is attached to the support surface above the panels, and a its bottom side which is attached to the top surfaces of the cleats and upwardly directed flanges, said hood having a row of shingles installed over the top portion to provide a water-tight seal.