# US 2021/0239365 A1 · Purlin construction and clip for flat panel roof structures

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- Number: US 2021/0239365 A1
- Document ID: US20210239365A1
- Status: Published application
- Kind: A1
- Application number: 17/168,456
- Filed: 2021-02-05
- Published: 2021-08-05
- Earliest claimed: 2020-02-05
- Inventors: John Powers, III
- Web page: https://patentgrep.com/patent/US20210239365A1

## CPC

- F24S 25/634: Clamps; Clips
- F24S 25/12: using posts in combination with upper profiles
- F24S 25/13: Profile arrangements, e.g. trusses (F24S25/12 takes precedence)
- F24S 25/15: using bent plates; using assemblies of plates
- F24S 25/33: forming substantially planar assemblies, e.g. of coplanar or stacked profiles
- F24S 25/35: by means of profiles with a cross-section defining separate supporting portions for adjacent modules
- H02S 20/24: specially adapted for flat roofs
- H02S 30/00: Structural details of PV modules other than those related to light conversion (semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H10F10/00, H10F19/00, of organic PV modules H10K30/00)
- H02S 30/10: Frame structures
- F24S 2025/6003: {by clamping}
- Y02B 10/10: Photovoltaic [PV]
- Y02B 10/20: Solar thermal
- Y02E 10/47: Mountings or tracking
- Y02E 10/50: Photovoltaic [PV] energy
- F24S: SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS (for producing mechanical power from solar energy F03G6/00)
- H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00)
- Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Solar panels are coupled to elongated purlins by solar panel clamps. A single strip of sheet metal is folded to form a first mounting portion, a second mounting portion opposed to the first mounting portion, and a first section of an upright wall extending perpendicularly therebetween. A first and second mounting shelves extend perpendicularly from the first section of the upright wall. A second section of the upright wall extends perpendicularly from between the first and second mounting shelves. A plurality of solar panel clamps affix the plurality of solar panels to the mounting shelves of the elongated purlins.

## Claims

### Claim 1

Solar panels coupled to elongated purlins by solar panel clamps comprising:
a single strip of sheet metal folded to comprise:
a first mounting portion;
a second mounting portion opposed to the first mounting portion;
a first section of an upright wall extending perpendicularly from between the first mounting portion and the second mounting portion;
a first mounting shelf extending perpendicularly from the first section of the upright wall parallel to and in an overlying position with the first mounting portion;
a second mounting shelf extending perpendicularly from the first section of the upright wall opposing the first mounting shelf and parallel to and in an overlying position with the second mounting portion; and
a second section of the upright wall extending perpendicularly from between the first mounting shelf and the second mounting shelf;
a plurality of solar panels, each solar panel including a generally rectangular frame with an inwardly extending horizontal leg supporting solar sensors, each of the plurality of solar panels carried by one of the first mounting shelf and the second mounting shelf; and
a plurality of solar panel clamps affixing the plurality of solar panels to the mounting shelves of the elongated purlins.

### Claim 2 (depends on 1)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 1 wherein each of the solar panel clamps further comprising:
an attachment plate fastened to the upright wall of one of the plurality of purlins, the attachment plate including a surface for engagement with the purlin and an edge generally perpendicular thereto;
a U-shaped element having a closed end and an open end, coupled to the attachment plate; and
wherein the open end receives one of the first mounting shelf and the second mounting shelf therein along with the inwardly extending horizontal leg of the frame of one of the plurality of solar panels.

### Claim 3 (depends on 2)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 2 wherein the U-shaped element includes a first portion and a second portion joined at the closed end and terminating at a first edge and a second edge, respectively, and wherein the first edge of the first portion of the U-shaped member forms a juncture with the edge of the attachment plate with the first portion perpendicular to the surface of the attachment plate.

### Claim 4 (depends on 3)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 3 wherein the U-shaped element and the attachment plate are formed of a single piece of material and wherein the juncture of the first edge of the first portion and the edge of the plate is a bend in the single piece of material.

### Claim 5 (depends on 3)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 3 wherein the juncture of the first edge of the first portion and the edge of the plate is a weld.

### Claim 6

Solar panels coupled to elongated purlins by solar panel clamps comprising:
elongated purlins incorporated into a roof structure, each purlin including a single strip of sheet metal folded to comprise:
a first mounting portion having an inner edge;
a first portion of an upright wall extending perpendicularly from the inner edge of the first mounting portion;
a first mounting shelf includes a first portion extending perpendicularly from the first portion of the upright wall parallel to and in an overlying position with the first mounting portion and a second portion of the first mounting shelf bent back overlying the first portion of the first mounting shelf;
an upper upright portion includes a first portion extending from and perpendicular to the second portion of the first mounting shelf and a second portion of the upper upright portion bent back overlying the first portion of the upper upright portion;
a second mounting shelf includes a first portion extending perpendicularly from the second portion of the upper upright portion diametrically opposed to the first mounting shelf and a second portion bent back overlying the first portion of the second mounting shelf;
a second portion of the upright wall extending perpendicularly from the second portion of the second mounting shelf a distance equal to the length of the first portion of the upright wall in parallel abutting engagement therewith; and
a second mounting portion extending perpendicularly from the second portion of the upright in a direction opposed to and in a plane with the first mounting portion;
a plurality of solar panels, each solar panel including a generally rectangular frame with an inwardly extending horizontal leg supporting solar sensors, each of the plurality of solar panels carried by one of the first mounting shelf and the second mounting shelf; and
a plurality of solar panel clamps affixing the plurality of solar panels to the mounting shelves of the elongated purlins.

### Claim 7 (depends on 6)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 6 wherein each of the solar panel clamps further comprising:
an attachment plate fastened to the upright wall of one of the plurality of purlins, the attachment plate including a surface for engagement with the purlin and an edge generally perpendicular thereto;
a U-shaped element having a closed end and an open end, coupled to the attachment plate; and
wherein the open end receives one of the first mounting shelf and the second mounting shelf therein along with a portion of the frame of one of the plurality of solar panels.

### Claim 8 (depends on 7)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 7 wherein the U-shaped element includes a first portion and a second portion joined at the closed end and terminating at a first edge and a second edge, respectively, and wherein the first edge of the first portion of the U-shaped member forms a juncture with the edge of the attachment plate with the first portion perpendicular to the surface of the attachment plate.

### Claim 9 (depends on 8)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 8 wherein the U-shaped element and the attachment plate are formed of a single piece of material and wherein the juncture of the first edge of the first portion and the edge of the plate is a bend in the single piece of material.

### Claim 10 (depends on 8)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 8 wherein the juncture of the first edge of the first portion and the edge of the plate is a weld.

### Claim 11 (depends on 6)

Solar panels coupled to elongated purlins by solar panel clamps as claimed in claim 6 further comprising:
a first lip formed perpendicularly at an outer edge of the first mounting portion and parallel to and opposite the first portion of the upright wall; and
a second lip formed perpendicularly at an outer edge of the second mounting portion and parallel to and opposite the second portion of the upright wall.

### Claim 12

A solar panel clamp for use in affixing solar panels in the channels of elongated purlins comprising:
an attachment plate configured to be fastened to a purlin, the attachment plate including a surface for engagement with the purlin and an edge generally perpendicular thereto;
a U-shaped element having a closed end and an open end, the U-shaped element including a first portion and a second portion joined at the closed end and terminating at an first edge and a second edge, respectively; and
wherein the first edge of the first portion of the U-shaped member forms a juncture with the edge of the attachment plate with the first portion perpendicular to the surface of the attachment plate.

### Claim 13 (depends on 12)

The solar panel clamp as claimed in claim 12 wherein the U-shaped element and the attachment plate are formed of a single piece of material and wherein the juncture of the first edge of the first portion and the edge of the plate is a bend in the single piece of material.

### Claim 14 (depends on 12)

The solar panel clamp as claimed in claim 12 wherein the juncture of the first edge of the first portion and the edge of the plate is a weld.