Stabilizing apparatuses for use with anchors and horizontal supports for solar modules used within a solar racking system and related methods

Abstract

The present subject matter relates to stabilizing apparatuses for use with anchors and horizontal supports for solar modules used within a solar racking systems and related methods. In particular, the present subject matter relates to stabilizing apparatuses and horizontal supports that can be used in structure systems to provide for integration of solar panels or use of insulated roofing panels for non-solar applications to form a roofing system for a building or other structure.

Description

[0001] DESCRIPTION

[0002] STABILIZING APPARATUSES FOR USE WITH ANCHORS AND HORIZONTAL SUPPORTS FOR SOLAR MODULES USED WITHIN A SOLAR RACKING SYSTEM AND

[0003] RELATED METHODS

[0004] RELATED APPLICATION

[0005] The present application and presently disclosed subject matter claims the benefit of U.S. Provisional Patent Application Serial. No. 63 / 504,609, filed May 26, 2023, the disclosure of which is incorporated herein by reference in its entirety.

[0006] TECHNICAL FIELD

[0007] The present subject matter relates to stabilizing apparatuses for use with anchors and horizontal supports for solar modules used within a solar racking systems and related methods. In particular, the present subject matter relates to stabilizing apparatuses and horizontal supports that can be used in structure systems to provide for integration of solar panels or use of insulated roofing panels for non-solar applications to form a roofing system for a building or other structure.

[0008] BACKGROUND

[0009] There has been an increasing demand of utilizing solar energy as a clean alternative for individual homes. Solar modules are of particular interest and are widely utilized and installed in a solar rack that resides on top of the existing roof of a house or other building. Generally, each of the solar modules can be arranged in an array and held between vertical rails in a racking system secured onto an existing roof. These solar racking system installations are typically not watertight as racks are affixed upon an existing roof. In these racking systems, rainwater leakage can become a problem. The rainwater seeps down through joints between the frame of the solar module and the vertical rail of the racking system and onto the roof. Such leakage as well as other issues encountered when mounting the racking system on the roof make such racking system installations less desirable, even when weighed against the benefits of solar power.

[0010] While there are existing racking structures that offer “watertight” solutions, they are not very durable, expensive to produce and construct, and complicated to install and assemble. For example, certain leading alternatives rely on wooden rafters or girders which can lead to rot and degradation of the structural integrity of the roof below the racking system. Racking systems are complicated and contain a multitude of parts which makes assembly complicated and makes user error more likely during installation. Existing watertight solutions rely on exposed commercial / roofing seam tape or ethylene propylene diene monomer rubber (EPDM) gaskets that are exposed to the sun and other elements which results in degradation over time and a typical maximum lifespan of around three (3) years before replacement is needed. Racking structures that do not rely on the seam tape or EPDM gaskets to create a watertight seal have purlin caps that protrude from between the solar panels or insulated metal plates that create water dams which cause water to pool leading to mold and waste buildups that can degrade and break the watertight seal over time and obstruct the energy collection of the solar panels.

[0011] To combat such issues that arise with solar module array installations that are secured to existing roofs, the construction industry stands to gain by integrating solar modules into roof assemblies in new construction or when replacing a roof on an existing structure. For such solar roof assembly installation, though, there are few options available for a fully integrated roofing system that include the structural member required and there are no options that offer reliable, lasting, watertight protection.

[0012] Additionally, for racking systems that form a roof of a structure, depending on the materials and components used, the post and frames that are used to support the racking structures can create opportunity for instability and provide less flexibility for forming and resetting the racking, or roof, structure. When installation the post and frames used to support the raking structures, helical anchors are sometimes used to anchor the base to the surface on which the racking structure stands, such as the ground. Due to the natural of the helical anchors and the terrain in which they may be used, the mounting plates used on the exposed ends of the helical anchors can be slightly screwed in one direction or another so that the mounting plates are not level. This issue, in turn, can lead to the post base and thus the post being not level.

[0013] As such, in general construction and solar installation, a need exists to create an easy to assemble, long lasting, watertight roof assembly that reduces the number of steps required, reduces labor costs, and simplifies the process of both general roof construction as well as providing level mounting plates for attachment of posts, post bases, or columns used on structures of all types. SUMMARY

[0014] The present subject matter relates to stabilizing apparatuses for use with anchors and horizontal supports for solar modules used within a solar racking systems and related methods. In particular, the present subject matter relates to stabilizing apparatuses that can be used to provide a level securement to posts, post bases, or columns used on structures of all types as well as horizontal supports that extend underneath the bottom side of the solar modules and use set screws to clamp to pressure a gasket and make sure we get a water tight seal on the infinity rack roof. Methods related to the manufacture and assembly of the posts and frame components for supporting roofing systems disclosed herein are also provided.

[0015] Thus, it is an object of the presently disclosed subject matter to provide stabilizing apparatuses for use with helical anchors for all types of structures and horizontal supports for solar modules used within a solar racking systems and related methods. While one or more objects of the presently disclosed subject matter having been stated hereinabove, and which is achieved in whole or in part by the presently disclosed subject matter, other objects will become evident as the description proceeds when taken in connection with the accompanying drawings as best described hereinbelow.

[0016] BRIEF DESCRIPTION OF THE DRAWINGS

[0017] A full and enabling disclosure of the present subject matter including the best mode thereof to one of ordinary skill in the art is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:

[0018] Figures 1A illustrates a perspective view of an embodiment of a structure system that includes embodiments of solar panels as an outer surface of the roof according to the present subject matter;

[0019] Figure IB illustrates a perspective view of another embodiment of a structure system that includes embodiments of solar panels as an outer surface of the roof according to the present subject matter;

[0020] Figure 2 illustrates a perspective view of an example embodiment of a base building structure according to the present subject matter on which an embodiment of a roofing system can be installed; Figure 3 A and 3B illustrates a perspective view of portions of the base building structure according to Figure IB with embodiments of post beams and frame beams as well as brackets of a roofing system according to the present subject matter being installed;

[0021] Figure 4A illustrates a side plan view showing a portion of a post beam and post base that form a column of the base building structure according to Figure IB according to the present subject matter;

[0022] Figure 4B illustrates side, cross-sectional, and top views of a post base that facilitates the formation of a column of the building structure according to Figure IB according to the present subject matter;

[0023] Figures 4C and 4D illustrate side and cross-sectional views of a post beam that facilitates the formation of a column of the building structure according to Figure IB according to the present subject matter;

[0024] Figures 4E and 4F illustrate side and cross-sectional views of a frame beam that facilitates the formation of a column of the building structure according to Figure IB according to the present subject matter;

[0025] Figure 5A illustrates side, cross-sectional, and top views of a T frame that facilitates the formation of a column of the building structure for holding frame beams according to Figure IB according to the present subject matter;

[0026] Figures 5B and 5C illustrates side, cross-sectional, and top views of a T bracket that is securable to a column to facilitate support of frame beams of the building structure according to Figure IB according to the present subject matter;

[0027] Figure 6A illustrates a side plan view showing a portion of a brace bracket that is securable to a column to facilitate support of frame beams of the base building structure according to Figure IB according to the present subject matter;

[0028] Figures 6B illustrates side, cross-sectional, and top views of a right side brace bracket according to Figure 6A according to the present subject matter;

[0029] Figures 6C illustrates side, cross-sectional, and top views of a left side brace bracket according to Figure 6A according to the present subject matter; Figures 7A and 7B illustrates side, cross-sectional, and top views of a L bracket that is securable to a column to facilitate support of frame beams of the building structure according to Figure IB according to the present subject matter;

[0030] Figure 8A illustrates a side plan view showing a portion of a frame beam, rafter beam, and U-bracket used to secure the frame beam and rafter beam together according to Figure IB according to the present subject matter;

[0031] Figure 8B illustrates cross-sectional view of a frame beam according to Figure IB according to the present subject matter;

[0032] Figure 8C illustrates side, cross-sectional, and top views of a U-bracket that is securable to a frame beam to facilitate securement and support of a rafter beam of the building structure according to Figure IB according to the present subject matter;

[0033] Figures 9A and 9B illustrate perspective views of portions of the base building structure according to Figure IB showing installation of wires into wire troughs according to the present subject matter;

[0034] Figure 10A illustrates a cross-sectional view of a portion of an embodiment of the roofing system according to present subject matter showing the solar modules laid side-by-side with a seal secured between the solar modules;

[0035] Figure 10B illustrates a cross-sectional view of a portion of an embodiment of the roofing system according to present subject matter showing the solar modules laid side-by-side as shown in Figure 10A and secured between the gaskets of the roofing system; and

[0036] Figure IOC illustrates an end side plan view of an embodiment of the gaskets as shown in Figure 10B used in conjunction with roofing panels or solar panels of the roofing system according to the present subject matter;

[0037] Figures 11 A, 11B, and 11C illustrate perspective views of portions of the base building structure according to Figure IB showing installation of gaskets on the support beams of the roofing system according to the present subject matter;

[0038] Figures 12A, 12B, and 12C illustrate perspective views of portions of the base building structure according to Figure IB showing installation of solar panels / roofing panels on the support beams of the roofing system according to the present subject matter; Figures 13A and 13B illustrate perspective views of portions of the base building structure according to Figure IB showing installation of top caps over the solar panel s / roofing panels and secured on the support beams of the roofing system according to the present subject matter;

[0039] Figures 14A and 14B illustrate perspective views of portions of the base building structure according to Figure IB showing installation of top caps over the solar panels / roofing panels and secured on the support beams of the roofing system according to the present subject matter;

[0040] Figure 15A illustrates a cross-sectional view of another embodiment of a support beam of a roofing system that includes embodiments of gaskets, end fins, a wire trough, and a top cap according to the present subject matter;

[0041] Figure 15B illustrates a cross-sectional view of another embodiment of a support beam of a roofing system that includes embodiments of a wire trough and a top cap according to the present subject matter;

[0042] Figure 16 illustrates side, cross-sectional, and top views of a wall bracket that is securable to a post beam to facilitate securement to a wall of another structure according to the present subject matter;

[0043] Figure 17 illustrates a side plan view of an embodiment of an edge strip according to the present subject matter;

[0044] Figures 18A and 18B illustrates a perspective view and a side plan view, respectively, of a helical anchor that can be capped on an end proximate to a surface on which a structure is being installed by a stabilizing apparatus according to the present subject matter;

[0045] Figure 19A illustrate a side plan view of an embodiment of a head device of a stabilizing apparatus according to the present subject matter;

[0046] Figure 19B illustrate a side plan view of a portion of an embodiment of a mounting assembly of a stabilizing apparatus according to the present subject matter;

[0047] Figure 19C illustrate a side plan view of an embodiment of a stabilizing apparatus with the head device according to Figure 19A engaged by the portion of the mounting assembly shown in Figure 19B according to the present subject matter;

[0048] Figure 19D illustrate a side plan view of an embodiment of a mounting assembly of a stabilizing apparatus according to the present subject matter; Figure 19E illustrate a side plan view of an embodiment of a stabilizing apparatus with the head piece according to Figure 19A engaged by the mounting assembly shown in Figure 19D according to the present subject matter;

[0049] Figure 19F illustrate a bottom plan view of the embodiment of the head device of a stabilizing apparatus according to Figure 19A;

[0050] Figure 20A illustrate a side plan view of an embodiment of a head piece of a stabilizing apparatus according to the present subject matter;

[0051] Figure 20B illustrate a side plan view of a portion of an embodiment of a mounting assembly of a stabilizing apparatus according to the present subject matter;

[0052] Figure 20C illustrate a side plan view of an embodiment of a stabilizing apparatus with the head piece according to Figure 20A engaged by the portion of the mounting assembly shown in Figure 20B according to the present subject matter;

[0053] Figure 20D illustrate a side plan view of an embodiment of a mounting assembly of a stabilizing apparatus according to the present subject matter;

[0054] Figure 20E illustrate a side plan view of an embodiment of a stabilizing apparatus with the head piece according to Figure 20A engaged by the mounting assembly shown in Figure 20D according to the present subject matter;

[0055] Figures 21A-21C illustrate top plan views of an embodiment of mounting plate of the mounting assembly of the stabilizing apparatus and an embodiment of a post base of a post or column that is secured to the mounting plate for proper placement and origination of the post or column supported by the post base according to the present subject matter;

[0056] Figure 22 illustrates a side plan view of solar modules in side-by-side placement having an embodiment of an adhesive gasket secured between the side walls of the solar modules and an embodiment of a horizontal support secured beneath the solar modules according to the present subject matter;

[0057] Figure 23A illustrates a side plan view of an embodiment of a horizontal support according to the present subject matter;

[0058] Figure 23B illustrates a side plan view of the embodiment of the horizontal support according to the Figure 23A being secured beneath frame portions of solar modules according to the present subject matter; Figure 24 illustrates a bottom perspective view of the embodiment of the horizontal support according to the Figure 23A being secured beneath the frame portions of the solar modules according to the present subject matter;

[0059] Figure 25 illustrates a top perspective view of the embodiment of the horizontal support according to the Figure 23A being secured beneath the frame portions of the solar modules according to the present subject matter;

[0060] Figure 26 illustrates a top perspective view of an embodiment of a horizontal according to the present subject matter;

[0061] Figure 27 illustrates a top perspective view of another embodiment of a horizontal according to the present subject matter;

[0062] Figures 28A and 28B illustrate side plan views of an embodiment of a horizontal support for providing support to and capping an end frame of a solar module according to the present subject matter;

[0063] Figure 29A illustrates a front plan view of another embodiment of a horizontal support according to the present subject matter;

[0064] Figure 29B illustrates a front plan view of a further embodiment of a horizontal support according to the present subject matter;

[0065] Figure 30 illustrates a front perspective view of the embodiment of the horizontal support according to Figure 29 A;

[0066] Figure 31 illustrates a top side perspective view of the embodiment of the horizontal support according to Figure 29 A;

[0067] Figure 32 illustrates side plan views of an embodiment of a V-gasket that fits on the frame spacer post according to the embodiment of the horizontal support in Figure 29A; and

[0068] Figure 33 illustrates a side plan view of another embodiment of a horizontal support for providing support to and capping an end frame of a solar module according to the present subject matter.

[0069] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the present subject matter. DETAILED DESCRIPTION

[0070] Reference now will be made to the embodiments of the present subject matter, one or more examples of which are set forth below. Each example is provided by way of an explanation of the present subject matter, not as a limitation. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present subject matter without departing from the scope or spirit of the present subject matter. For instance, features illustrated or described as one embodiment can be used on another embodiment to yield still a further embodiment. Thus, it is intended that the present subj ect matter cover such modifications and variations as come within the scope of the appended claims and their equivalents. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only, and is not intended as limiting the broader aspects of the present subject matter, which broader aspects are embodied in exemplary constructions.

[0071] Although the terms first, second, right, left, front, rear, back, etc. may be used herein to describe various features, elements, components, regions, layers and / or sections, these features, elements, components, regions, layers and / or sections should not be limited by these terms. These terms are only used to distinguish one feature, element, component, region, layer or section from another feature, element, component, region, layer, or section. Thus, a first feature, element, component, region, layer, or section discussed below could be termed a second feature, element, component, region, layer, or section without departing from the teachings of the disclosure herein.

[0072] Similarly, when a component, layer or coating is being described in the present disclosure as "on" or "over" another component, layer, or substrate, it is to be understood that the components or layers can either be directly contacting each other or have another component, layer or feature between the components or layers, unless expressly stated to the contrary. Thus, these terms are simply describing the relative position of the components or layers to each other and do not necessarily mean “on top of’ since the relative position above or below depends upon the orientation of the device to the viewer.

[0073] Embodiments of the subject matter of the disclosure are described herein with reference to schematic illustrations of embodiments that may be idealized. As such, variations from the shapes and / or positions of features, elements, or components within the illustrations as a result of, for example but not limited to, user preferences, manufacturing techniques and / or tolerances are expected. Shapes, sizes and / or positions of features, elements or components illustrated in the figures may also be magnified, minimized, exaggerated, shifted, or simplified to facilitate explanation of the subject matter disclosed herein. Thus, the features, elements or components illustrated in the figures are schematic in nature and their shapes and / or positions are not intended to illustrate the precise configuration of the subject matter and are not intended to limit the scope of the subject matter disclosed herein.

[0074] As used herein, the term "solar modules" and “solar panels” are generally used interchangeably and refer to a single photovoltaic panel that is an assembly of connected solar cells. The solar cells absorb sunlight as a source of energy to generate electricity. An array of solar modules can be used to collect and supply power to a variety of structures and / or apparatuses.

[0075] As used herein, the term "roofing panels" is used broadly to mean any type of roofing panel and can include, but is not limited to solar modules, or solar panels, insulated roofing panels that do not include solar cells, or other roofing panels.

[0076] As used herein, the term a "plurality" means two or more.

[0077] As used herein, the terms such as “include,” “including,” “contain,” “containing,” “having,” and the like mean “comprising.” The present disclosure also contemplates other embodiments “comprising,” “consisting of,” and “consisting essentially of,” the embodiments or elements presented herein, whether explicitly set forth or not.

[0078] As used herein, the term “a,” “an,” “the” and similar terms used in the context of the disclosure (especially in the context of the claims) are to be construed to cover both the singular and plural unless otherwise indicated herein or clearly contradicted by the context. In addition, “a,” “an,” or “the” means “one or more” unless otherwise specified.

[0079] As used herein, the term “or” can be conjunctive or disjunctive.

[0080] As used herein, the term “substantially” means to a great or significant extent, but not completely.

[0081] As used herein, the term “about” or “approximately” as applied to one or more values of interest, refers to a value that is similar to a stated reference value, or within an acceptable error range for the particular value as determined by one of ordinary skill in the art, which will depend in part on how the value is measured or determined, such as the limitations of the measurement system. In one aspect, the term “about” refers to any values, including both integers and fractional components that are within a variation of up to ± 10% of the value modified by the term “about.” Alternatively, “about” can mean within 3 or more standard deviations, per the practice in the art. Alternatively, such as with respect to biological systems or processes, the term “about” can mean within an order of magnitude, in some embodiments within 5-fold, and in some embodiments within 2-fold, of a value. As used herein, the symbol means “about” or “approximately.”

[0082] As used herein, the term “majority” means more than 50%. For example, a majority of a surface means more than 50% of the surface.

[0083] All ranges disclosed herein include both end points as discrete values as well as all integers and fractions specified within the range. For example, a range of 0.1-2.0 includes 0.1, 0.2, 0.3, 0.4 . . . 2.0. If the end points are modified by the term “about,” the range specified is expanded by a variation of up to ±10% of any value within the range or within 3 or more standard deviations, including the end points. Thus, it is to be understood that the ranges and limits mentioned herein include all ranges located within the prescribed limits (i.e., subranges). For instance, a range from about 100 to about 200 also includes ranges from 110 to 150, 170 to 190, 153 to 162, and 145.3 to 149.6. Further, a limit of up to about 7 also includes a limit of up to about 5, up to 3, and up to about 4.5, as well as ranges within the limit, such as from about 1 to about 5, and from about 3.2 to about 6.5 as examples.

[0084] The present disclosure relates to a structure system for forming a structure with a roof that can include solar modules and / or insulated roofing panels, i.e., weatherproof roofing panel, which in some embodiments can be insulated metal plates, that form the majority of the outer surface of the roof. The structure system can include a frame structure that can include post beams and post bases that can form columns and frame beams and include a roofing system that includes rafter beams and panels, such as solar modules and / or insulated roofing panels. For example, the structure system can include roofing systems, roofing systems with integrated solar racking systems, roofing systems components, and related methods as disclosed and taught in U.S. Provisional Patent Application Serial No. 63 / 150,569, filed February 17, 2021, and PCT International Patent Application No. PCT / US2022 / 016881, filed February 17, 2022, and published as International Patent Publication No. WO 2022 / 178189, the disclosure of these documents being incorporated herein by reference in their entireties. The present disclosure also relates to stabilizing apparatuses that are provided that can be used to provide a level surface to which a structure, such as the assembled structure systems described herein can be secured. Additionally, the present disclosure relates to horizontal supports that are provided for engaging frame side ends of solar modules. For example, the horizontal supports can be used to hold adjacent sides of two solar modules or to cap a side end of a solar module along a horizontal edge.

[0085] The structure system as disclosed herein can comprise a frame system and a roofing system. The frame system can comprise a plurality of post beams and a plurality of frame beams. Each of the post beams can comprise an extruded aluminum structural beam. Each of the post beams of the plurality of post beams can have two parallel post slots along at least a first side wall of the post beam. The frame system can also include a plurality of post bases corresponding to the plurality of post beams. Each of the post bases can comprise four side walls with an aperture formed at a top of the post base for receiving a corresponding post beam of the plurality of post beams. The post base can include a base shelf extending from at least one of the four walls of the post base configured to support a bottom end of the corresponding post beam. Further, post bases can further comprise two base slots that can be aligned with the post slots in the first side wall of the four side walls of the post beam. The frame system of the structure system can also comprise a plurality of frame beams. Each of the frame beams can comprise an extruded aluminum structural beam. Each of the frame beams of the plurality of frame beams can have two parallel frame slots along at least a first side wall and a second side wall of frame beam. The frame system can also comprise a plurality of T-frames. Each T-frame can be configured to extend upward from a top end of a corresponding post beam of the plurality of post beams. Each T-frame can have a post receiving aperture for receiving the top end of the corresponding post beam and a frame beam groove positioned above the post receiving aperture for receiving one or more frame beams of the plurality of frame beams. Additionally, the frame system can comprise a plurality of brackets for securing corresponding post beams of the plurality of post beams and corresponding frame beams of the plurality of frame beams together.

[0086] The roofing system of the structure system can be secured to and can reside above the frame structure. The roofing system can comprise a plurality of rafter beams. Each of the rafter beams can comprise an extruded aluminum structural beam. The roofing system can also comprise roofing panels comprising at least one of an insulated roofing panel or a solar module. Additionally, the roofing system can comprise a plurality of top caps corresponding to the number of the structural beams. The top caps can be configured to secure the roofing panels in place on the structural beams. Further, the roofing system can comprise gaskets for sealing the roofing panels and end fins attachable to at least one of the structural beams or the top caps to enclose end edges of the roofing system. The roofing system can also comprise one or more interior gutters built into each of the structural beams to drain any water that leaks between the gaskets and the roofing panels.

[0087] In some embodiments where solar modules are used as roofing panels, the roofing system can comprise wire troughs configured to accommodate wiring for solar modules used as roofing panels. Each of the wire troughs can be attached to a side of a structural beam. Additionally, in such embodiments, the one or more structural beams can further comprise a bonding rail. The bonding rail, or bonding jumper rail, can be used for clipping standard UL listed bonding jumpers between a solar module and a beam. Additionally, in some embodiments, the bonding rail can also be used to clip optimizers / microinverters in the same way these devices clip to a solar module frame.

[0088] In some embodiments, the structural beams can comprise one or more T-bolt slots therein. The T-bolt slots, for example, can be used for attaching wire troughs and attaching insulation covers and other accessory attachment as well as for securing bolts to the respective structural beam for securement of structural attachment brackets for securing the respective structural beam to a building structure being roofed. Each of the structural beams can also comprise a threaded channel on a top portion of the respective structural beam for securing a top cap to the respective structural beam.

[0089] The roofing system disclosed herein is not only novel to the solar industry, but also to the general construction industry as well. The roofing system allows for a less expensive and more durable alternative for the general construction industry for new buildings, modular or prefabricated homes, and kit construction, such as for homes and outbuildings. The roofing system disclosed herein can be considered “kit-like” in that it can come partially pre-assembled and can include easy to assemble components. It can also increase the accessibility of building integrated photovoltaics (“BIPV”) for a number of building types, reducing both a cost and complication barrier to installation.

[0090] In roofing and general construction, the use of the structural beams of the roofing system disclosed herein can allow for large unsupported spans while creating a roofing system with a far superior lifespan compared to traditional roofing methods. The weatherproof roofing panels, which can comprise insulated metal plates, can be sandwiched into the beam system between the structural beams and the top caps. As stated above, this beam system can incorporate an internal backup gutter system to facilitate the removal of moisture from the roofing system. Thus, whether or not solar photovoltaic solar modules are integrated therein, the roofing system disclosed herein will create a durable, sound roofing structure for a variety of structure types.

[0091] Thus, the present disclosure provides a roofing system that uses structural beams and top caps that can secure and hold multiple types of solar modules and insulated weatherproof roofing panels in a watertight, shingle-like assembly using roofing panel gaskets in a racking system, thereby providing a racking system that is integrated into the roofing structure of a building. The entire roofing system is designed to meet the typical structural requirements of a roof and / or solar array with a unique design, as explained further below with reference to the figures, which provides an all-in-one solution with long-term structural and watertight fortitude.

[0092] A building structure, generally, BS, is provided as shown in Figures 1A andlB that includes a structure system, generally designated 10, that can incorporate roofing panels that can be either solar modules or insulated roofing panels. The structure system can include a frame system 10A and a roofing system 10B. Thus, a structure system 10 can be provided that operate as a regular roofing structure or a roofing structure that operates as both a roof and an integrated solar rack. The building structure BS is used herein simply for illustrative purposes only. It is noted that the structure system 10 can be used on any type of building and can include an array of roofing styles.

[0093] Referring to Figures 1A-15B, the structure system 10 is provided that can comprise a frame system 10A and a roofing system 10B that can include an array of components. The frame system 10A can include a plurality of post beams 100 as shown in Figures 1A-2, 4A, and 4C-4E and a plurality of frame beams 120 as shown in Figures 1A-2 and 4F-4H. Each of the post beams 100 can comprise an extruded aluminum structural beam. Each of the post beams 100 of the plurality of post beams 100 can have two parallel post slots 102 along at least a first side wall 100A of the post beam 100. Each slot 102 can be a T-bolt slot. The frame system 10A can also include a plurality of post bases 130 as shown in Figures 1 A-2 and 4B corresponding to the plurality of post beams 100. The frame system 10A of the structure system 10 can also comprise a plurality of frame beams 120. Each of the frame beams 120 can also comprise an extruded aluminum structural beam. Each of the frame beams 120 of the plurality of frame beams 120 can have two parallel frame slots 122 along at least a first side wall 120A and a second side wall 120B of frame beam 120 as shown in Figures 4F-4H. Each slot 122 can be a T-bolt slot. The frame system 10A can also comprise a plurality of T-frames 140 as shown in Figures 1A-2 and 5A. Each T-frame 140 can be configured to extend upward from a top end 101A of a corresponding post beam 100 of the plurality of post beams 100. Each T-frame 140 can have a post receiving aperture 142 for receiving the top end 101A of the corresponding post beam 100 and a frame beam groove 144 positioned above the post receiving aperture 142 for receiving one or more frame beams 120 of the plurality of frame beams 120. Additionally, the frame system 10A can comprise a plurality of brackets 150, 160, 170, 180 as shown in Figures 3A-8C for securing corresponding post beams 100 of the plurality of post beams 100 and corresponding frame beams 120 of the plurality of frame beams 120 together.

[0094] Referring to Figures 4A and 4B, each of the post bases 130 can comprise four side walls 130A, 130B, 130C, 130D with an aperture 132 formed at a top 131A of the post base as shown in Figures 1A-2 and 4F for receiving a bottom end 101B of a corresponding post beam 100 of the plurality of post beams 100. The post base 130 can include a base shelf 134 extending from at least one of the four walls 130A, 130B, 130C, 130D of the post base 130 configured to support the bottom end 101B of the corresponding post beam 100. For example, as shown in Figure 4B, in some embodiments, the post base 130 can include two shelves 134 on opposing first wall 130A and second wall 130B. Further, post bases 130 can further comprise two base slots 136 that can be in at least side wall 130A of the post base 130 that can be aligned with the post slots 102 in the first side wall 100A of the four side walls 100A, 100B, 100C, 100D of the post beam 100. The slots 136 can be elongated apertures that can receive bolts, such as T-bolts that have been slid into the slots 102 of the post beams 100. For example, in some embodiments, two base slots 136 can be in first side wall 130A of the post base 130 that can be aligned with the post slots 102 in the first side wall 100A of the post beam 100 and two base slots 136 can be in second side wall 130B of the post base 130 that can be aligned with the post slots 102 in the second side wall 100B of the post beam 100.

[0095] Additionally, each post base 130 of the plurality of post bas post bases 130 can comprise a bottom wall 131B that includes a first aperture 138A therein configured for receiving direct current (DC) wiring and a second aperture 138B therein configured for receiving alternating current (AC) wiring. Additionally, each post base of the plurality of post bases 130 can comprise a pair of securement slots 135 in the bottom wall for securing the post base to a surface.

[0096] Referring to Figures 1A-2, 4A, and 4C-4E, the post beams 100 of the frame system 10A can fit in and be secured to the post base 130 to form posts P of the building structure BS in the structure system 10. As stated above, each of the post beams 100 of the plurality of post beams 100 can have two parallel post slots 102 along at least a first side wall 100A of the post beam 100. For example, as stated above, each of the post beams 100 can also comprise two parallel post slots 102 along a second side wall 100B of the post beam 100 opposite the first side wall 100A of the post beam 100. In some embodiments, the post slots 102 in the plurality of post beams 100 can comprise T-bolt slots configured to receive T-bolts for facilitating the securement of the plurality of post beams 100, the plurality of post bases 130, the plurality of frame beams 120, the plurality of T-frames 140 and plurality of brackets into a desired structure. In some embodiments, each of the post beams 100 can comprise a first channel 104 configured for receiving direct current (DC) wiring and a second channel 106 configured for receiving alternating current (AC) wiring. As shown, in some embodiments, each of the first and second channels 104, 106 of the post beams 100 can comprise an enclosed channel with a cavity that is open on the top and bottom ends 101A, 101B of the respective post beam 100. The first and second channels 104, 106 of the post beams 100 can have a dividing wall 105 between the first and second channels 104, 106. The first and second apertures 138A, 138B of the post base 130 and the first and second channels 104, 106 of the post beams 100 can be of a size to receive one inch conduit for bringing the AC and DC wiring into the post P.

[0097] In some embodiments, the post beams 100 can comprise two structural beams secured together to form a post beam 100’ as shown in Figure 4D. Thus, each of the extruded aluminum structural beam of the post beams 100’ can actually comprise two structural beams 108’ and 112’ secured to each other to form the respective post beam 100’. The post beam 100’ can operate generally the same the post beam 100 that is of a unitary structural beam construction shown in Figure 4C. The post beam 100’ shown in Figure 4D can comprise two parallel post slots 102’ along a first and second side wall 100A’, 100B’ of the post beam 100’. Each of the post beams 100’ can comprise a first channel 104’ and a second channel 106’ that can comprise an enclosed channel with a cavity that is open on the top and bottom ends 101A’, 101B’ of the respective post beam 100’. In some embodiments, each of the two structural beams 108’ and 112’ can have a front side wall forming a side wall 100C’ or 100D’ of the post beam 100’. Each of the two structural beams 108’ and 112’ can also have a back side wall 116’ and 118’ of the respective structural beam 108’ and 112’. The back side walls 116’ and 118’ can each have a rail 110A’ and 114A’ and slot HOB’ and 114B’ that extend from a first end to a second end of the respective structural beam 108’ and 112’ on the back side wall 116’ and 118’. Additionally, each of the two structural beams 108’ and 110’ can have first and second side walls each having a post slot 102’ therein. In this manner, the rail 110A’ and the slot HOB’ of a first structural beam 108’ is configured to engage a slot 114B’ and a rail 114A’ of a second structural beam 112’ to form a post beam 100’ that comprises the two parallel post slot 102’ along the first side wall 100A’ of the post beam 100’ and two parallel post slots 102’ along a second side wall 100B’ opposite the first side wall 100A’ of the post beam 100’.

[0098] Referring to Figures 1A-2 and 4F-4H, the frame beams 120 of the frame system 10A can form girders G of the building structure BS in the structure system 10. As stated above, each of the frame beams 120 of the plurality of frame beams 120 can also have two parallel frame slots 122 along at least a first side wall 120A of the frame beams 120. For example, as stated above, each of the frame beams 120 can also comprise two parallel frame slots 122 along a second side wall 120B of the frame beams 120 opposite the first side wall 120A of the frame beams 120. In some embodiments, the frame slots 122 in the plurality of frame beams 120 can comprise T-bolt slots configured to receive T-bolts for facilitating the securement of the plurality of post beams 100, the plurality of post bases 130, the plurality of frame beams 120, the plurality of T-frames 140 and plurality of brackets into a desired structure. In some embodiments, each of the frame beams 120 can comprise a first channel 124 and a second channel 126. As shown, in some embodiments, each of the first and second channels 124, 126 of the frame beams 120 can comprise an enclosed channel with a cavity that is open on the top and bottom ends 121A, 121B of the respective frame beams 120. The first and second channels 124, 126 of the frame beam 120 can have a dividing wall 125 between the first and second channels 124, 126.

[0099] Similarly, in some embodiments, the frame beams 120 can comprise two structural beams secured together to form a frame beam 120’ as shown in Figure 4G. Thus, each of the extruded aluminum structural beam of the frame beam 120’ can comprise two structural beams 128’ and 129’ secured to each other to form the respective frame beam 120’. The post beam 100’ can operate generally the same the post beam 100 that is of a unitary structural beam construction shown in Figure 4C. The frame beam 120’ shown in Figure 4D can comprise two parallel frame slots 122’ along a first and second side wall 120A’, 120B’ of the frame beam 120’. Each of the frame beam 120’ can comprise a first channel 124’ and a second channel 126’ that can comprise an enclosed channel with a cavity that is open on the top and bottom ends 121A’, 121B’ of the respective frame beam 120’. In some embodiments, each of the two structural beams 128’ and 129’ can have a front side wall forming a side wall 120C’ or 120D’ of the frame beam 120’. Each of the two structural beams 128’ and 129’ can also have a back side wall 128C’ and 129C’ of the respective structural beam 128’ and 129’. The back side walls 128’ and 129’ can each have a rail 128A’ and 129A’ and slot 128B’ and 129B’ that extend from a first end to a second end of the respective structural beam 128’ and 129’ on the back side wall 128C’ and 129C’. Additionally, each of the two structural beams 128’ and 129’ can have first and second side walls each having a frame slot 122’ therein. In this manner, the rail 128A’ and the slot 128B’ of a first structural beam 128’ is configured to engage a slot 129B’ and a rail 129A’ of a second structural beam 129’ to form a frame beam 120’ that comprises the two parallel frame slot 122’ along the first side wall 120A’ of the frame beam 120’ and two parallel post slots 122’ along a second side wall 120B’ opposite the first side wall 120A’ of the frame beam 120’.

[0100] As stated above, each T-frame 140 of the plurality of T-frames 140 can have a post receiving aperture 142 for receiving the top end 101A of a corresponding post beam 100 and a frame beam groove 144 positioned above the post receiving aperture 142 for receiving one or more frame beams 120 of the plurality of frame beams 120. Referring to Figure 5A, each T-frame 140 of the plurality of T-frames 140 can comprise a post sleeve 146 in which the post receiving aperture 142 resides. The post sleeve 146 can comprise four side walls 146A, 146B, 146C, 146D with a first side wall 146A of the four side walls having two parallel slots 148 therein. The two parallel slots 148 of the post sleeve 146 can be aligned with the post slots 102 in the first side wall 100A of the four side walls 100A, 100B, 100C, 100D of the respective post beam 100 to secure the T- frame 140 to a respective post beam 100 of the plurality of post beams 100. As above, in some embodiments, a second side wall 146A of the four side walls 146A, 146B, 146C, 146D of the post sleeve 146 can have two parallel slots 148 therein can be aligned with the post slots 102 in the second side wall 100B of the respective post beam 100 to secure the T-frame 140 to a respective post beam 100. The slots 148 can be apertures for receiving portions of T-bolts inserted in the post slots 102 of the post beams 100.

[0101] As shown in Figure 5A, the frame beam groove 144 can extend above the post sleeve 146 of each T-frame 140. The frame beam groove 144 in the T-frame 140 can comprise a bottom groove wall 144A as well as a first side wall 144B and a second side wall 144C extending upward from opposing sides of the bottom groove wall 144A. The bottom groove wall 144A of the frame beam groove 144 can comprise at least two parallel slots 148A therein that can be aligned with the frame slots 122 in the first side wall 120A of a frame beam 120 to secure the T-frame 140 to a respective frame beam 120 of the plurality of frame beams 120. The slots 148A can be apertures for receiving portions of T-bolts inserted in the frame slots 122 of the frame beams 120. In some embodiments as shown, the bottom groove wall 144A of the frame beam groove 144 can comprise a first bottom groove 144A1 wall that can extend from a top of the post sleeve 146 perpendicular to the first wall 146A of the four walls of the post sleeve 140 and a second bottom groove wall 144Ai that extends from a top of the post sleeve 146 perpendicular to the second wall 146B of the four walls of the post sleeve 146. The first bottom groove wall 144A1 can have two parallel slots 148A therein that can be aligned with frame slots 122 in the first side wall 120A of one or more frame beams 120 to secure the T-frame 140 to one or more respective frame beams 120. Similarly, the second bottom groove wall 144Az can have two parallel slots 148A therein that can be aligned with frame slots 122 in the first side wall 120A of one or more frame beams 120B to secure the T- frame 140 to the one or more respective frame beams 120. In some embodiments, the first and second sidewalls 144B, 144C of the frame beam groove 144 of the T-frame 140 can be contiguous with a third wall 146C and fourth wall 146D of the four walls of the post sleeve 146 of the T-frame 140 as seen in Figure 5A. T-frame 140 can have a cut out on one side for mounting of a NS brace bracket 160 (described below) where the NS brace bracket 160 lines up on a central post beam 100

[0102] As stated above, a plurality of different brackets 150, 160, 170 for securing corresponding post beams 100 of the plurality of post beams 100 and corresponding frame beams 120 of the plurality of frame beams 120 together. Shown in Figures 5B-7C, NS T-brackets 150, NS Left (L) and Right (R) brace brackets 160, and L-brackets 170 are provided. As shown in Figures 5B and 5C, a NS T-bracket 150 is provided that can comprise a bracket body 152 with one or more flanges 156 extending from the bracket body 152. The bracket body 152 can extend in a first plane and the first flange 156 can extend from the bracket body 152 in a second plane perpendicular to the first plane. For the NS T-bracket 150, the more or more flanges 156 can be a first flange 156A and a second flange 156B to support two different frame beams 120 on either side of a post beam 100. For example, as shown in Figures 5B and 5C, a NS T-bracket 150 is provided that can comprise a bracket body 152 with a first flange 156 extending from the bracket body 152. The bracket body 152 can extend in a first plane and the first flange 156 can extend from the bracket body 152 in a second plane perpendicular to the first plane. NS T-bracket 150 can comprise a second flange 156B that extends from the bracket body 152 in the second plane perpendicular to the first plane. Webbing 155 can be provided to provide extra support and strength between bracket body 152 and first and second flanges 156A, 156B. The first flange 156A and second flange 156B can create a space 153 for receiving the post beam 100 therein. The bracket body 152 of the NS T-bracket 150 can comprise two parallel slots 154 therein that can be aligned with post slots 102 in the first side wall 100A of a post beam 100 of the plurality of post beams 100. The first and second flanges 156A, 156B can each have two parallel slots 158 therein that can be aligned with frame slots 122 in the first side wall 120A of two different frame beams 120 of the plurality of frame beams 120 to secure the post beam 100 and frame beams 120 together.

[0103] As shown in Figures 6A-6C, NS right and left brackets 160 are provided. Each bracket 160 can comprise a bracket body 162 with a first flange 166 extending from the bracket body 162. The bracket body 162 can extend in a first plane and the first flange 166 can extend from the bracket body 162 in a second plane perpendicular to the first plane. The bracket body 162 of the NS right or left bracket 160 can comprise two parallel slots 164 therein that can be aligned with post slots 102 in the first side wall 100A of a post beam 100 of the plurality of post beams 100. Similarly, the first flange 166 can have two parallel slots 168 therein that can be aligned with frame slots 122 in the first side wall 120A of a frame beam 120 of the plurality of frame beams 120 to secure the post beam 100 and frame beam 120 together. Webbing 165 can be provided to provide extra support and strength between bracket body 162 and flanges 166. NS Brackets 160 have a left and right configuration for holding the North to South brace (front to back of structure). NS Brackets 160 can be configured to join the side wall of the frame beam 120 to the end of a frame beam 120 turned 90 degrees and perpendicular to the post beam 100.

[0104] As shown in Figures 7A and 7B, L- brackets 170 are provided. Each bracket 170 can comprise a bracket body 172 with a first flange 176 extending from the bracket body 172. The bracket body 172 can extend in a first plane and the first flange 176 can extend from the bracket body 172 in a second plane perpendicular to the first plane. The bracket body 172 of the L-bracket 170 can comprise two parallel slots 174 therein that can be aligned with post slots 102 in the first side wall 100A of a post beam 100 of the plurality of post beams 100. Similarly, the first flange 176 can have two parallel slots 178 therein that can be aligned with frame slots 122 in the first side wall 120A of a frame beam 120 of the plurality of frame beams 120 to secure the post beam 100 and frame beam 120 together.

[0105] Referring to Figures 3A-3B and 8A-8C, a plurality of U brackets 180 can be provided that can be used to secure rafter beams 20 for a roofing system 10B to the frame system 10A formed by the post beams 100 and the frame beams 120. Each U-bracket 180 can comprise a bottom wall 182 having two parallel slots 184 therein that can be aligned with frame slots 122 in the second side wall 120B of a frame beam 120 of the plurality of frame beams 120 for securing the U bracket 180 to the respective frame beam 120. The U bracket 180 can also comprise a first side wall 186A and a second side wall 186B that extend upward from opposing sides of the bottom wall 182 of the U bracket 180. The first and second side walls 186A, 186B and bottom wall 182 can form an open channel 185 for receiving a rafter beam 20 of the plurality of rafter beams 20 for securing the rafter beam 20 to the frame beam 120. The first side wall 186A of the U-bracket 180 can comprise a first curved slot 188A and a second curved slot 188B that can extend through a top end I86A1 of the first side wall 186A of the U-bracket 180 with the first and second slots 188A, 188B curving toward each other at top portions of the first and second curved slots 188A, 188B. Similarly, the second side wall 186B of the U-bracket 180 can comprise a first curved slot 188A and a second curved slot 188B that can extend through a top end I86B1 of the second side wall 186B of the U- bracket 180 with the first and second slots 188A, 188B curving toward each other at top portions of the first and second curved slots 188A, 188B. The shape of the first and second curved slots 188A, 188B of the first and second side walls 186A, 186B help to hold the rafter beam in place. The use of T-bolts in slots of the rafter beam 20 and the shape of the first and second curved slots 188A, 188B make installation much easier, while providing a strong hold between the rafter beam 20 and the U-bracket 180 and frame beam 120. In particular, the first and second curved slots 188A, 188B in the first and second side walls 186A, 186B of the U bracket 180 are transverse to T-bolt slots in the respective rafter beam 20 placed in the channel of the U bracket 180. The U bracket 180 can have an opening therein to receive 3 / 4" conduit that can be run along the top of the framing system under the rafter beams 20 to facilitate wiring.

[0106] Referring to Figure 16, a wall bracket 190 can be provide that is configured to be secured to another structure and to a post beam of the plurality of post beams. The wall bracket 190 has a first side wall that has one or more securement apertures for receiving fasteners for securement to a structure. The wall bracket 190 can comprise second and third side walls that extend from the first side wall. The second and third side walls each can have two parallel slots therein. The parallel slots in the second side wall of the wall bracket 190 can be aligned with the post slots 102 in the first side wall 100A of a post beam 100 of the plurality of post beams 100. Similarly, the parallel slots in the third side wall of the wall bracket 190 can be aligned with post slots 102 along the second side wall 100B of the post beam 100 opposite the first side wall 100A of the post beam 100

[0107] Once a frame structure, or building structure BS, is assembled from the frame system 10A, roofing system 10B of the structure system 10 can be assembled and secured to the frame structure. Referring to Figures 1A, IB, and 9A-15B, the roofing system 10B can include rafter beams 20 and roofing panels 40 that can be manufactured in a variety of sizes to support a range of spans. The roofing system 10B incorporates top caps 50 and gaskets 60 such that the rafter beams 20 receives the top caps 50 with the gaskets 60 securing and holding the roofing panels 40 between the structural beams 20 and the top caps 50. The roofing system 10B with the structural beams 20, the top caps 50, and the gaskets 60 can be used to support roofing panels 40 that can be either solar panels, i.e., solar modules, 42 or insulated roofing panels, i.e., weatherproof roofing panels, 44 to create a completely watertight structure. The gaskets 60 can comprise adhesive flat gaskets that adhere between the modules along the long edge where it does not rest on the structure framing system to make a watertight seal.

[0108] When the roofing system 10B is used as a roofing structure, the insulated panels 44 (as shown in Figure IB) can be sandwiched between the rubber gaskets 60 positioned on the top caps 50 and the beams 20. The rafter beams 20 that can be attached to frame beams 120 as described above and can function as rafters and the insulated roof panels 44 function as sheathing and roofing material. Each of the rafter beams 20 can include an interior gutter 30 that captures any moisture that may get past the gaskets 60 serving as a safety net for the watertight seal. That water would then run through an inside gutter channel 30 within the respective rafter beam 20 and come out the end outside of the underlying structure maintaining its watertight seal.

[0109] When used to create a solar integrated roofing structure, the solar modules 42 can be similarly sandwiched between the rubber gaskets 60 positioned on the top caps 50 and the beams 20. A sealant can be used between the solar modules. For example, a double-sided butyl tape can be placed in between the overlap to seal the overlapping solar modules 42 to along the overlap. Unlike conventional solar racking structures commonly used, this tape is not exposed to the elements and therefore does not have a limited lifespan. The same or similar sealants can be used between insulated roofing panels 44. The solar modules 42 can then be bonded to the bonding rail on the beam using a bonding jumper to create an obvious visible bond between the solar modules 42 and the respective rafter beam 20. This bonding is required in a solar installation due to the electrical components. A wire trough 70 can be slid into the respective rafter beam 20 for wire management and / or micro-inverter / optimizer mounting to hide and protect wiring in between the solar modules 42. This application contains the same gutter structure 30 as the roofing structure using insulated roofing panels applications.

[0110] An exemplary embodiment of the roofing system 10B as shown in Figures 1A, IB, and 9A-15B will now be described in more detail. The roofing system 10B can comprise two or more, or a plurality of, rafter beams 20 with each of the rafter beams 20 comprising an extruded structural beam. The rafter beams 20 can comprise a metal. For example, the structural beams 20 can comprise extruded aluminum. As shown in Figures 15A-15B, each rafter beam 20 can comprise a top wall 22A and a bottom wall 22B and two opposing side walls 22C, 22D. The rafter beam 20 can comes in various dimensions depending on the building structure with which it will be used. For example, for standard solar mounting applications with maximum span of about 6 feet, the cross-sectional dimensions of the beam 20 can be about 3.5 inches in width WB by about 3 inches in height HB. For spans up to about 12 feet, the cross-sectional dimensions of the beam 20 can be about 3.5 inches in width WB by about 6 inches in height HB. For spans up to about 16 feet, the cross-sectional dimensions of the beam 20 can be about 3.5 inches in width WB by about 8 inches in height HB. For spans up to about 18 feet, the cross-sectional dimensions of the beam 20 can be about 3.5 inches in width WB by about 10 inches in height HB. The thickness of the top wall 22A, the bottom wall 22B, and two opposing side walls 22C, 22D may vary as well, depending on the length of the span of the rafter beam 20. Additionally, the rafter beam 20 can include reinforcement support tabs 38, 38A within an interior of the rafter beam 20 that can be provided at different angles to provide increased structural integrity and support to the rafter beam 20 to help withstand the different types of stresses and forces placed on the beams 20. For example, as shown in Figure 15 A, the support tabs 38 within the interior of the rafter beam 20 can include support tabs 38 that run at acute angles to the walls 22A, 22B, 22C and 22D of the rafter beam 20 as well as support tabs 38 that are about perpendicular, or normal, to the respective walls 22A, 22B, 22C and 22D of the rafter beam 20 from which they extend to provide increased structural integrity and support to the rafter beam 20. In some embodiments, as shown in Figure 15B, the support tabs 38A within the interior of the rafter beam 20 may include only support tabs 38 that are about perpendicular, or normal, to the respective walls 22A, 22B, 22C and 22D of the rafter beam 20 from which they extend to provide increased structural integrity and support to the rafter beam 20.

[0111] T-bolt slots 24 can be formed in at least one of the side walls 22C, 22D of each extruded beam 20 of receiving accessory attachments. For example, the T-bolt slots 24 can be used for attaching a wire trough 70 and / or for inserting bolts 82 into the respective rafter beam 20 for attachment of structural attachment brackets 80 for securing the respective structural beam to a building structure BS being roofed. In some embodiments, brackets having a T-shaped engagement can be slid into the T-bolt slots 24 for securing the respective structural beam to a building structure BS being roofed. The T-bolt slots 24 in each of the structural beams 20 can be formed in the respective rafter beam 20 during extrusion of the respective rafter beam 20. Additionally, the T-bolt slot channels 24 positioned proximate to the bottom 22B of the structural beams 20 can be used to install a bottom cap (not shown). This makes it easy to insulate the spaces between the structural beams 20 for a higher R-Value when used in general construction or building integrated photo-voltaics (“BIPV”) applications and it is enclosed with a covering.

[0112] Each rafter beam 20 can also comprise channel walls 26 that can extend upward from the top wall 22A of the extruded beam 20. The channel walls 26 can form a threaded channel 28 for securing a respective top cap 50 to the respective rafter beam 20. The threaded channel 28 on the top portion, i.e., the top wall 22A of the respective rafter beam 20 can be formed as an integral part of the respective rafter beam 20 during the extrusion process.

[0113] Additionally, as shown in Figures 15A and 15B, each rafter beam 20 can comprise gasket channel walls 32 extending upward from the top wall 22A of the extruded beam 20. The gasket channel walls 32 form one or more gasket attachment channels 34A, 34B for securing gaskets 60 to the extruded beam 20. Thereby, each rafter beam 20 can be used to secure a bottom gasket 60B of the gaskets 60 such that the bottom gasket 60B can form a seal between the roofing panels 40 and the respective rafter beam 20 when the components are installed in the roofing system 10. As in the embodiment shown in Figures 15A and 15B, the rafter beam 20 can have a first gasket attachment channel 34A on a first side of the top wall 22A of the rafter beam 20 and a second gasket attachment channel 34B on a second side of the top wall 22A of the rafter beam 20 to accommodate bottom gaskets 60B for securement of roofing panels 40 on either side of the rafter beam 20. Depending on where the rafter beam 20 is used in the roofing system 10, for example, if the rafter beam 20 is a beam that forms an end edge of the roofing system 10, the gasket attachment channel 34A, 34B that forms the outer gasket attachment channel can be used for securing one of the end fins 18 to the respective rafter beam 20. Each of the gasket attachment channels 34A, 34B of the respective rafter beam 20 can be formed as an integral part of the respective rafter beam 20 during the extrusion process. As shown in Figures 15A and 15B, the gasket channel walls 32 can have lips 32A that extend farther inward into the channel than the base of the gasket channel walls 32 such that the base of the respective gasket attachment channel 34A, 34B is wider than its entrance. This configuration of the gasket attachment channels 34A, 34B create a holding mechanism for securing bottom gaskets 60B or end fins 18 to the rafter beam 20 with an easy-to- use sliding engagement. Each rafter beam 20 can also comprise one or more interior gutters 30 built into the rafter beam 20 to drain any water that may leak between the gaskets 60 and the roofing panels 40 of the roofing system 10B. In particular, the interior gutters 30 can be formed along the top wall 22A of the extruded beam 20. In some embodiments, for example, two interior gutters 30 can be formed on either side of the threaded channel 28 between channel walls 26 that form the threaded channel 28 extending upward from the top wall 22A and gasket channel walls 32 that form one or more gasket attachment channels 34A, 34B also extending upward from the top wall 22A. The channel walls 26 of the thread channel 28 and the channel walls 32 of the gasket attachment channels 34A, 34B on rafter beam 20 with either a gasket 60 or an end fin 12 therein can thereby forms side walls of the one or more interior gutters 30.

[0114] As disclosed above for embodiments of the roofing system 10B that are a solar integrated roofing structure, the roofing system 10B can also comprise wire troughs 70 configured to accommodate wiring for solar modules 42 used as roofing panels. Each wire trough, or wire trough attachment, 70 can be attached to a side wall 22C, 22D of the rafter beam 20. As explained above, in some embodiments, a wire trough attachment 70 can be configured to engage a T-bolt slot 24 in a side wall 22C, 22D of rafter beam 20. The wire trough 70 is configured to accommodate wiring for solar modules 42 used as roofing panels 40 in conjunction with the rafter beam 20 to form the roofing system 10. For example, referring to Figures 15A and 15B, the wire trough 70 can be slid into a T-bolt slot 24 formed in the rafter beam 20. In such embodiments, each wire trough 70 can include a T-shaped base 72 that is configured to fit into one of the T-bolt slots 34 formed in a side wall 22C, 22D of the rafter beam 20 to firmly hold the respective wire trough 70 in place on the rafter beam 20. Each wire trough 70 can also comprise a trough body 74 that extends out from the T-shaped base 72. In some embodiments, the body 74 of the wire trough 70 can form the cavity of the trough between a wall 76 of the body 74 of the wire trough 70 and the side wall 22C, 22D of rafter beam 20 to which the wire trough 70 is secured.

[0115] Each rafter beam 20 can also comprise a bonding rail 78 as shown in Figures 15A and 15B, for example. The bonding rail 78 can extend outward from one of the side walls 22C, 22D of the extruded beam 20 above a T-bolt slot 24 in a side wall 22C, 22D of rafter beam 20. In some embodiments, the bonding rail 78 can be formed as an integral part of the extruded beam 20 during the extrusion process. For example, the bonding rail 78 can be on a side of a side wall 22C, 22D of rafter beam 20 to which the wire trough 70 is attached. In this manner, a standard UL listed bonding jumper can be attached or clipped to the bonding rail 78 between solar module 42 and rafter beam 20. Similarly, optimizers and / or microinverters can be attached or clipped to the bonding rail 78 in same way with the wire trough 70 hiding the wiring and microinverters and / or optimizers.

[0116] The roofing system 10B can comprise roofing panels 40 as shown in Figures 10B-10B and 12A-14B. The roofing panels 40 can comprise at least one of insulated roofing panels 44 or solar modules 42. When the roofing panels 40 comprise solar modules 42, the structural beams 20, the top caps 50 and the gaskets 60 form an integrated solar racking system that forms a roof of a structure.

[0117] The roofing system 10B can also comprise top caps 50 corresponding to the number of the one or more structural beams as shown in Figures 10A and 13A-15B. The top caps 50 can comprise a metal. For example, the top caps 50 can comprise extruded aluminum. The top caps 50 can be configured to secure the roofing panels 40 in place on the structural beams 20. The top caps 50 can have one or more gasket attachment channels 58A, 58B for securing top gaskets 60A of the gaskets 60 for forming a seal between the roofing panels 40 and the respective top cap 50.

[0118] In some embodiments, each top cap 50 can comprise a top portion 52 that includes a first flange 52A extending in a first direction Di and a second flange 52B extending in an opposing second direction D2 with a securement indention 52C between the first and second flange 52A, 52B for receiving a fastener therein to engage the threaded channel 28 of the rafter beam 20. Each top cap 50 can comprise a securement positioning channel 54 that extends from a bottom portion 56 of the top cap 50.

[0119] The securement positioning channel 54 can align with the securement indention 52C between the first and second flanges 52A, 52B and can have securement channel walls 54A, 54B that extend from the bottom portion 56 of the top cap 50 to form the securement positioning channel 54. In some embodiments, the securement channel walls 54A, 54B can be separated by a distance such that the securement positioning channel 54 has an inner width IWsc as measured from the inner surfaces of the securement channel walls 54A, 54B that is slight wider than the outer width OWTC of the threaded channel 28 as measured from the outer surfaces of the channel walls 26 of the threaded channel 28. Thus, when the top cap 50 is placed on the rafter beam 20 to be secured thereto, the securement positioning channel 54 of the top cap 50 is placed over the threaded channel 28 of the rafter beam 20 such that channel walls 26 of the thread channel 28 fit within the securement channel walls 54A, 54B to align the securement indention 52C with the thread channel 28 for inserting one or more fasteners through pre-drilled holes (not shown) in the securement indention 52C and into the thread channel 28. Additionally, the fitting of the securement channel walls 54A, 54B of the securement positioning channel 54 of the top cap 50 over the channel walls 26 of the thread channel 28 of the rafter beam 20 can also align the gasket attachment channels 58A, 58B for securing top gaskets 60A of the gaskets 60 to the top cap 50 with the gasket attachment channels 34A, 34B of the rafter beam 20 for securing bottom gaskets 60B of the gaskets 60 to the rafter beam 20. This alignment of the top gasket attachment channels 58A, 58B with bottom gasket attachment channels 34A, 34B of the rafter beam 20 ensure proper securement and sealing of the roofing panels 40 and the roofing system 10B that forms a roofing structure for a building structure BS.

[0120] To form the top gasket attachment channels 58A, 58B, each top cap 50 can comprise top gasket channel walls 57 extending downward from the bottom portion 56 of the top cap 50. The top gasket channel walls 57 can be positioned on the first and second flange 52A, 52B of the top cap 50 forming top gasket attachment channels 58A, 58B on both sides of the top cap 50 to align with the gasket attachment channels 34A, 34B of the rafter beam 20 when the top cap 50 is secured thereto. In particular, as in the embodiments shown in Figures 15A and 15B, the top cap 50 can have a first top gasket attachment channel 58 A on the first flange 52 A of the rafter beam 20 and a second top gasket attachment channel 58B on the second flange 52B of the top cap 50 to accommodate top gaskets 60A for securement of roofing panels 40 on either side of the top cap 50. Depending on where the top cap 50 is used in the roofing system 10, for example, if the top cap 50 is a beam that forms an end edge of the roofing system 10, the outer top gasket attachment channel 58A, 58B can be used for securing the end fin 16 to the respective top cap 50. Each of the top gasket attachment channels 58A, 58B of the respective top cap 50 can be formed as an integral part of the respective top cap 50 during the extrusion process. As shown in Figures 15A and 15B, the top gasket channel walls 57 can have lips 57A that extend farther inward into the channel than the base of the top gasket channel walls 57 such that the base of the respective top gasket attachment channel 58A, 58B is wider than an entrance of the respective top gasket attachment channel 58A, 58B. As with the gasket channels of the rafter beam 20, these configurations of the top gasket attachment channels 58A, 58B create a holding mechanism for securing top gaskets 60A or end fins 16 to the top cap 50 with an easy-to-use sliding engagement.

[0121] The roofing system 10B can further comprise roofing panel gaskets 60 for sealing the roofing panels as shown in Figures 10B-11C and 13A-15B. The gaskets 60 can comprise stepped gaskets when using shorter roof panels that overlap or a flat gasket (discussed below). The gaskets 60 can comprise a rubber. For example, the gaskets 60 can comprise a synthetic rubber. In some embodiments, the gaskets 60 can comprise an ethylene propylene diene monomer rubber (EPDM) that can provide a seal between the gaskets 60 and the roofing panels 40 and be sturdy enough to support the roofing panels 40 between the structural beams 20 and the top caps 50 and generally be expected to last the life of the roof structure. For example, the gaskets 60 can be top gaskets 60A or bottom gaskets 60B depending on how the gaskets 60 are oriented and which of the gasket attachment channels 34A, 34B, 58A, 58B the gaskets 60 engage.

[0122] Referring to Figures 5A and 5B, the roofing panel gasket 60 can comprise a longitudinal base 62 having a first side 62A and a second side 62B running the length of the base 62. An engagement rail 64 can extend outward from the first side 62A of the base 62. The engagement rail 64 can be configured to attachably engage a respective gasket attachment channel 34A, 34B, 58A, 58B in either a rafter beam 20 or a top cap 50 of a roofing system 10. For example, in some embodiments, the engagement rail 64 can comprise a rail track 64A that can be inserted into a base of a gasket attachment channel 34A, 34B, 58A, 58B and a stem 64B that extends between the longitudinal base 62 and the rail track 64A. The rail track 64A can be larger in width than at least a lower portion of the stem 64B such the rail track 64A can slidably fit within a base of a gasket attachment channel 34A, 34B, 58A, 58B while the lower portion of the stem 64B can slidably fit between the respective lips 32A, 57A of the gasket channel walls 32, 57 of the respective gasket attachment channels 34A, 34B, 58A, 58B.

[0123] Each roofing panel gasket 60 can comprise a sealing body 66 that can extend upward from the second side 62B of the longitudinal base 62. The sealing body can comprise a flat surface to form a flat gasket. The gaskets 60 can comprise adhesive flat gaskets that adhere between the modules along the long edge where it does not rest on the structure framing system to make a watertight seal. The roofing system 10B can comprise end fins 16, 18 attachable to the structural beams 20 and the top caps 50 to enclose end edges 12, 14 of the roofing system 10B as shown in Figures IB and 10. The end fins 16, 18 can overlap to form a seal at the end edges 12, 14. In some embodiments, the end fins 16, 18 can comprise a metal. In some embodiments, the end fins 16, 18 can comprise a plastic. For example, in some embodiments, the end fins 16, 18 can comprise a hard plastic or metal that can provide a seal at end edges 12, 14 of the roofing system 10B and be sturdy enough to generally be expected to last the life of the roofing system 10.

[0124] In some embodiments as shown in Figures 10A-10C, the roofing panels, such as solar modules or insulated roofing panels, can be secured side-by-side instead of stepped. For example, Figure 10A shows two solar modules 42 that can be placed on a gasket in a structural beam beside each other in close proximity. A panel seal 90 can be secured between the two solar modules 42 sealing the two solar modules 42 together. The panel seal 90 can comprise a sealer 92A, 92B, such commercial / roofing seam tape or a double-sided butyl tape, and a T-seal 94 that comprises a lateral top that extends over an end portion of the of the top of the two solar modules 42 and a tail that extends between the adjacent ends of the two solar modules 42. In some embodiments, the tape 92A can be placed over the top end portion and a portion of the end of the first solar module 42 and the tape 92B can be placed over the top end portion and a portion of the end of the second solar module 42. The T-seal 94, which can comprise a metal such as aluminum in the form of a T- bracket, can be press fit against the strips of tape 92A, 92B, on the top end portions and portions of the ends of the solar modules 42 to seal the gap between the two solar modules 42. Alternatively, the T-seal 94 can have the tape 92A, 92B, secured beneath the top of the T-seal 94 on either side of the tail of the T-seal 94. The solar modules 42 can be placed in a side-by-side configuration and the T-seal 94 with its tail and the tape 92A, 92B facing downward can be press fit between the two solar modules 42 to secure the T-seal 94 to the top of the end portions and the ends of the two solar modules 42 to seal the gap between the two solar modules 42. While the use of the panel seal 90 where roofing panels are placed side-by-side have been described with reference to solar modules 42, the panel seals 90 can be used with insulated roofing panels or a combination of different roofing panels. The tape 92A, 92B can be positioned on the T-seal 94 in such a way so as to limit the exposure of the tape to the elements once solar modules 42 or roofing panels and panel seal 90 are installed. As shown in Figure 10B, gaskets 60C’ and 60D’ used in sealing the sides of the roofing system where the roofing panels 40 engage the structural beams can comprise a different shape from the stepped gaskets shown in Figures 5A,11A and 11B. The top roofing panel gasket 60C’ and the bottom roofing panel gasket 60D’ can be the same or similar in shape, length, and thickness and can be described with reference to gasket 60’ shown in side profile in Figure 10C. The gasket 60’ can comprise a longitudinal base 62’ having a first side 62A’ and a second side 62B’ running the length of the base 62’. An engagement rail 64’ can extend outward from the first side 62A’ of the base 62’. The engagement rail 64’ can be configured to attachably engage a respective gasket attachment channel 34A, 34B, 58A, 58B in either a rafter beam 20 or a top cap 50 of a roofing system 10. For example, in some embodiments, the engagement rail 64’ can comprise a rail track 64A’ that can be inserted into a base of a gasket attachment channel 34A, 34B, 58A, 58B and a stem 64B that extends between the longitudinal base 62’ and the rail track 64A’. The rail track 64A’ can be larger in width than at least a lower portion of the stem 64B’ such the rail track 64A’ can slidably fit within a base of a gasket attachment channel 34A, 34B, 58A, 58B while the lower portion of the stem 64B’ can slidably fit between the respective lips 32A, 57A of the gasket channel walls 32, 57 of the respective gasket attachment channels 34A, 34B, 58A, 58B.

[0125] Each roofing panel gasket 60’ can also comprise a sealing body 66’ that can extend upward from the second side 62B’ of the longitudinal base 62’. The sealing body 66’ can comprise a flat surface to form a flat gasket as shown Figure 10B (see top and bottom gaskets 60C’, 60D’). As shown in Figure 10C, in some embodiments, the sealing body 66’ can comprise vertical sealing layers 68’. The vertical layers 68’ can each have the stepped longitudinal profile of the sealing body 66’. The vertical layers 68’ can create a better and longer lasting seal between roofing panel gasket 60’ and the roofing panels 40’. In some embodiments, the sealing body 66’ may not employ such vertical sealing layers 68’. In some embodiments, the gaskets 60’ can comprise adhesive flat gaskets that adhere between the modules along the long edge where it does not rest on the structure framing system to make a watertight seal.

[0126] The bottom flat gaskets 60D’, for example, as shown in Figure 10B, can form the bottom seal against the roofing panels such as solar modules 42 and can be slid into the gasket attachment channels 34A, 34B of the top wall 22A of the rafter beam 20 similarly to the gaskets being slid into the gasket attachment channels as shown in Figures 11A-11C. As stated above, the bottom gaskets 60D’ are positioned along the span of the length of the respective structural beams 20 to received roofing panels 40 such as solar modules 42, for example, by inserting engagement rail 64D’ of the respective bottom flat gaskets 60D’ in the gasket channel of the respective structural beam with the flat sealing body 66D’ extending from the base 62D’ and facing outward to engage the solar modules 42 as shown in Figure 10B. The top flat gaskets 60C’ can form the top seal against the roofing panels such as solar modules 42. The top caps 50 may also be prepared by inserting engagement rail 64C’ of top gaskets 60C’ into the gasket attachment channels 58A, 58B of the top caps 50 so that the flat sealing body 66D’ extending from the base 62D’ face outward in preparation of attachment of the top caps 50 to the structural beams 20 over the roofing panels, such as solar modules 42. Since the top and bottom gaskets 60C’, 60D’ are flat, the roofing panels such as solar modules 42 can be positioned side-by-side with a panel seal 90, such a T-seal 94, secured between solar modules 42 and overlapping top and portions of the side-by side solar modules 42.

[0127] The solar modules 42 that can comprise the roofing panels 40 of a building structure can be positioned on one or more bottom flat gaskets 60D’ as shown in Figure 10B. The wiring and optimizers and / or microinverters can be attached to the solar modules 42 to permit the solar modules 42 to operate properly once the system is activated as described above. A panel seal 90, such a T-seal 94, can be secured between solar modules 42 and overlapping top and portions of the side-by side solar modules 42. Top caps, as described above with reference to top caps 50, with one or more top flat gaskets 60C’ as shown in Figure 10B installed thereon can then be placed over the solar modules 42 and secured to the structural beam as described above with the solar modules 42 sandwiched between the top flat gasket 60C’ and the bottom flat gasket 60D’ as shown in Figure 10B. Fasteners can be used to secure the top caps to the structural beams as described above.

[0128] As mentioned above, the present disclosure also relates to stabilizing apparatuses that are provided that can be used to provide a level surface to which a structure can be secured. The stabilizing apparatuses can be secured to anchors, such as helical anchors that are used to firmly hold the structure to the ground or surface. For example, in some embodiments, after the stabilizing apparatuses are secured to helical anchors and the mounting plates of the stabilizing apparatuses are leveled, post bases as described above can be aligned with the mounting plates of the stabilizing apparatuses and secured thereto to hold the post bases securely in level positions.

[0129] Referring to Figures 18A and 18B, a n example of an embodiment of an anchor is provided for stability and support of a structure. For example, in some embodiments, helical anchors HA can be used to provide a stable and rigid foundational support to structures that can be attached thereto. The helical anchors HA can comprise an anchor shaft AS with an angled insertion end that can be inserted into the ground. The anchor shaft AS can have one or more helical blades HB extending transversely therefrom that can help hold the anchor HA in the ground once the anchor HA is driven into the ground through a twisting motion. The anchor shaft AS can have a capping end CE distal from the angled insertion end that can reside at or near the surface of the ground in which the anchor HA has been driven. Once the helical anchor HA has been driven into the ground, a structure can be mounted to the helical anchor HA at the capping end CE of the helical anchors HA. An issue can arise due to the nature of the driving process of the helical anchors HA. Often the capping end CE is not level so that any mounting plate secured to it will also not be leveled. Stabilizing apparatuses 200, 220 as shown in Figures 19A-20E can be used to securely attach to the capping end CE of the helical anchors HA while providing a way to level the mounting plates to which the structures are to be secured.

[0130] Referring to 19A-19F, an embodiment of a stabilizing apparatus, generally 200, can be used for providing level mounting plates to which structures can be secured. The stabilizing apparatus 200 can comprise a head device 202 that can include a head base 204 having a first end 204A and a second end 204B. The first end 204A of the head base 204 can have a receiving cavity 207 therein configured to receive a top, or capping, end CE of a helical anchor HA that is securable in a ground surface. The shape and the size of the cavity 207 can vary and can depend on the shape and size of the capping end CE of the anchor HA. The head base 204 of the head device 202 can comprise an anchor locking threaded aperture 208 that can engage the receiving cavity of the head base 204 for receiving a set screw to secure the head device 202 to the helical anchor HA. The head device 202 of the stabilizing apparatus 200 can comprise a ball 206 connected to the second end 204B of the head base 204. The ball 206 can have a majority of a spherical surface exposed. As shown, the ball 206 can be positioned on the head base 204 so that all of the spherical surface of the ball 206 is exposed except the portion resting on the head base 204. As shown in Figure 19A and 19C, in some embodiments, the ball 206 can be removable from the head base 204 of the head device 202. For example, the ball 206 can have a threaded shaft (not shown) extending from a base of the ball 206. For example, the head base 204 of the head device 202 can comprise a ball receiving threaded aperture (not shown) in the second end of the head base 204 for receiving the threaded shaft of the ball 206. In this manner, the ball 206 can be screwed into the head base 204. In some embodiments, the head base 204 of the head device 202 can also comprise a ball locking threaded aperture 205 on its side proximate to the second end 204B that engages the ball receiving threaded aperture in the second end 204B of the head base 204 for receiving a set screw (not shown) in some such embodiments. Once the threaded shaft of the ball 206 is screwed into the ball receiving threaded aperture (not shown) in the second end 204B of the head base 204, the set screw can be screwed into the ball locking threaded aperture 205 and engage the side of the threaded shaft of the ball 206 to secure the ball 206 to the head base 204.

[0131] Additionally, the stabilizing apparatus 200 can comprise a mounting plate assembly 210 that is configured to engage the ball 206 of the head device 202. For example, the mounting plate assembly 210 can comprise a yoke 212 having a yoke body 212A with a front face 211 and a bottom 213. In some embodiments, the body 212 can have a socket 212B therein that has an opening on the front face 211 and bottom 213 of the yoke body 212A. The socket 212B can have an interior configured to accept the ball 206 of the head device 202. For example, in some embodiments, the socket 212B can have a spherical interior configured to accept the ball 206 of the head device 202. The ball 206 can be inserted into the yoke 212 through the opening on the front face 211 and the bottom 213 of the yoke body 212B as shown in Figure 19C.

[0132] The mounting plate assembly 210 can also comprise a mounting plate 216 that is secured on a top portion 215 of the yoke 212. As shown in Figures 19D, 19E, and 21 A, the mounting plate 216 can have a flat top surface 216A distal from the yoke 212 for securing a base portion of a structure to the mounting plate 216. In some embodiments, the mounting assembly 210 can also comprise a neck 214 extending between the yoke 212 and the mounting plate 216. In some embodiments, the mounting plate 216 of the mounting assembly 210 can be secured directly to the yoke 212.

[0133] When installed, the yoke 212 can be rotate about the ball 206 of the head device 202 after the ball 206 is inserted within the socket 212B of the yoke 212. In particular, the yoke 212 can be rotated about the spherical ball 206 to position the flat top surface 216A of the mounting plate 216 in a level position. The flat top surface 216A of the mounting plate 216 needs to be level so that any base structure of the structures the stabilizing apparatus 200 is securing has a level footing. A rear of the yoke body 212A can have a locking aperture 218 for receiving a fastener, such as a locking bolt or set screw. Upon positioning the flat top surface 216A of the mounting plate 216 in a level position, the locking bolt can be tightened into the locking aperture 218 in the rear of the yoke 212 against the ball 206 of the head device 202 to lock the mounting plate assembly 210 in place. In this manner, regardless of the positioning of the top end CE of the helical anchor HA once the helical anchor HA is inserted into the ground, the stabilizing apparatus 200 can provide a level mounting plate 216 on which a portion of a structure can stand. Thus, the positioning of the top end CE of the helical anchor HA can vary once the helical anchor HA is inserted into the ground, while a stable, level, and flat surface for mounting a portion of a structure can be provided by the stabilizing apparatus 200.

[0134] Referring to 20A-20E, another embodiment of a stabilizing apparatus, generally 220, is provided that can be used for providing a level mounting plate to which structures can be secured. Similar to the embodiment described above, the stabilizing apparatus 220 can comprise a head device 222 that can include a head base 224 having a first end 224A and a second end 224B. The first end 224A of the head base 224 can have a receiving cavity (not shown but can be similar to the embodiment shown in Figure 19F) therein configured to receive a top, or capping, end CE of a helical anchor HA that is securable in a ground surface. The shape and the size of the cavity in the first end 224A of the head base 224 can vary and can depend on the shape and size of the capping end CE of the anchor HA. The head base 224 of the head device 222 can comprise an anchor locking threaded aperture 208 that can engage the receiving cavity of the head base 224 for receiving a set screw to secure the head device 222 to the helical anchor HA. The head device 222 of the stabilizing apparatus 220 can also comprise an integral ball 226 extending from the second end of the head base 224. Thus, the head base 224 and the ball 226 can be secured together so that the head base 224 and the ball 226 of the head device 222 are one single unitary structure. As above, the ball 226 can have a majority of a spherical surface exposed.

[0135] As above, the stabilizing apparatus 220 can comprise a mounting plate assembly 230 that is configured to engage the ball 226 of the head device 222. For example, the mounting plate assembly 230 can comprise a yoke 232 having a yoke body 232A with a front face 231 and a bottom 233. The body 212 can have a socket 232B therein that has an opening on the front face

[0136] 231 and bottom 233 of the yoke body 232A. The socket 232B can have an interior configured to accept the ball 236 of the head device 232. For example, in some embodiments, as above, the socket 232B can have a spherical interior configured to accept the ball 236 of the head device 232. The ball 236 can be inserted into the yoke 232 through the opening on the front face and the bottom of the yoke body 232B as shown in Figure 20C and 20B. The mounting plate assembly 230 can also comprise a mounting plate 236 that is secured on a top portion 235 of the yoke 232. As shown in Figures 20D and 20E, the mounting plate 236 can have a flat top surface 236A distal from the yoke

[0137] 232 for securing a base portion of a structure to the mounting plate 236. In some embodiments, the mounting assembly 230 can also comprise a neck 234 extending between the yoke 232 and the mounting plate 236. As shown, the neck 234 is smaller in this embodiment which can be used with structures that are smaller and may create less torque on stabilizing apparatus 220, for example. In some embodiments, the yoke can be secured directly to the mounting plate without a neck between them.

[0138] As shown in Figures 21A-21C, the mounting plate 216 can have apertures therein for securing bases of structures to the mounting plate and to provide paths for wiring or other portions or components of the structure to pass therethrough. For example, mounting plate 216 of the mounting assembly 210 can comprises securement apertures 216C. Once the stabilizing apparatus 200 is secured on the helical anchor HA and the mounting plate 216 is leveled, a base of a structure can be secured to the mounting plate 216. Referring to the post bases 130 described above for reference and as shown in Figures 21 A and 21C, the securement apertures 135 of the post base 130 can be aligned with the securement apertures 216C so that the securement apertures 135 in the post base 130 and the securement apertures 216C of the mounting plate 216 overlap and the four side walls 130A, 130B, 130C, 130D of the post base 130 are properly aligned for supporting the structure. The aligning of the securement apertures 216C of the mounting plate 216 with the securement apertures 135 in a post base 130 enables securement of a post base 130 to the mounting plate 216. Additionally, the mounting plate 216 can have wiring apertures 216B therein for receiving wiring for the structure to be attached to the mounting plate 216 if needed. For example, the first aperture 138A of the post base 130 configured for receiving direct current (DC) wiring can be aligned with one of the wiring apertures 216B of the mounting plate 216 and a second aperture 138B of the post base 130 configured for receiving alternating current (AC) wiring can be aligned with the other wiring apertures 216B of the mounting plate 216. Thus, the mounting plate 216 also comprises a bottom wall that includes a first aperture 216B therein configured for receiving direct current (DC) wiring and a second aperture 216B therein configured for receiving alternating current (AC) wiring.

[0139] Referring again to Figures 3A and 3B, the present disclosure further relates to horizontal supports, such as horizontal supports 41, for engaging frame side ends of solar modules. As can be seen in Figures 3A and 3B that can extend between rafter beams 20 to provide support to solar modules 42 (other roofing panels 40) along horizontal edges of the solar modules that span between the rafter beams 20. The horizontal supports 41 that span between adjacent rafter beams 20 can provide lateral support to adjacent solar modules 42 That span between the two adjacent rafter beams 20. For example, the horizontal supports 41 can be used to hold adjacent sides of two solar modules or to cap an end of a solar module. Different embodiments of a horizontal support 41 can be provided as shown in Figure 22-33, for example.

[0140] Referring to Figures 22-27, an embodiment of a horizontal support 240 is provided for providing support and securement of two solar modules 42 along adjacent sides of the respective solar modules 42. While reference is made to solar modules 42, the horizontal support 240 can be used other roofing panels as well. Like horizontal support 41, the horizontal support 240 can be positioned between and secured to two adjacent rafter beams and can laterally support two adjacent solar modules 42 as explained below. The horizontal support 240 can comprise a base 242 with a first base side end 243A and a second base side end 243B. The base 242 of the horizontal support 240 can also have a front end 247A and a rear end 247B. The front end 247A and rear end 247B of each horizontal support 240 can be secured to rafter beams to support the horizontal support 240. The horizontal support 240 can also comprise a first securement arm 244A that extends upward from the first end 243A of the base 242 and a second securement arm 244B that extends upward from the second end 243B of the base 242. Each of the first and second securement arms 244A, 244B can comprise a plurality of securement apertures 249A, 249B. In some embodiments, the securement apertures 249A, 249B can extend about parallel to the base 242 of the horizontal support 240. Further, the horizontal support 240 can comprise a plurality of set screws 250 for engaging the respective plurality of securement apertures 249A, 249B of the first and second securement arms 244A, 244B. Each of the plurality of set screws 250 can have a length that is long enough to at least extend from the respective first and second securement arms 244A, 244B to a position where the set screws 250 can apply pressure against a frame side end 42A or 42B of a solar module 42 placed in the horizontal support base 242 between the first and second securement arms 244A, 244B.

[0141] In some embodiments, a frame spacer 245 can be provided that can extend upward from the base 242 between the first and second securement arms 244A, 244B to form first and second cavities 246A, 246B for reception of portions of the respective frame side ends 42A, 42B of the solar modules 42 that are positioned side by side. The frame spacer 245 can be aligned with a gasket 96 placed between to the frame side ends 42A, 42B of the solar modules 42 that are adjacent one another. The frame spacer 245 can also have a width that is less than a width of the uncompressed gasket 96. The first and second cavities 246A, 246B can be configured to receive a laterally extending bottom of the respective frame side end 42A, 42B of the solar module 42. The set screws 250 as shown in Figures 22 and 25 can be tightened to press against the frame side ends 42A, 42B of the two solar modules 42 clamping the frame side ends 42A, 42B and the gasket 96 together and compressing the gasket 96 between the two frame side ends 42A, 42B of the solar modules 42.

[0142] In some embodiments as shown in Figures 22, 23 A, and 23B, each of the first and second securement arms 244A, 244B can comprise a respective wire channel 248A, 248B on an end distal to the base 242. The wire channels 248A, 248B can face inward toward the respective frame side end 42A, 42B of the solar module 42 when the horizontal support 240 is placed around the frame side ends 42A, 42B of adjacent solar modules 42. Thus, for example, the wire channels 248A, 248B can have an opening facing inward toward the respective first and second cavities 246A, 246B. The wiring channels 248A, 248B can direct the wires placed therein to wire troughs or other larger conduits for directing the wires as needed with a racking structure.

[0143] As stated above, the horizontal supports can be used to cap an end of a solar module also. Referring to Figures 28A and 28B, an embodiment of a horizontal support 260 can be provided for supporting and capping an end frame 42A of a solar module 42. The horizontal support 260 can comprise a base 252 with a first end 253A and a second end 253B that is distal from the first end 253A. The horizontal support 260 can also comprise a securement arm 254A that extends upward from the first end of the base 252. As with the securement arms described above, the securement arm 254A can comprise a plurality of securement apertures 259 in the side. In some embodiments, the securement apertures 259 can extend through the securement arm 254A in a manner that the axes of the securement apertures 259 extend about parallel to the base 252. The base 252 of the horizontal support 260 can also have a front end and a rear end. Similar to the horizontal support 240, the front end and rear end of each horizontal support 260 can be secured to rafter beams to support the horizontal support 260.

[0144] Additionally, the horizontal support 260 can comprise an abutment arm 254B extending upward from the second end 253B configured to abut against a frame side end 42A of a solar module 42 placed in the horizontal support 260. In particular, the base 252, the securement arm 254A, and the abutment arm 254B can form a receiving cavity 256 in which a portion of a frame side end 42A of a solar module 42 can be placed. The receiving cavity 256 can be configured to receive a laterally extending bottom of the frame side end 42A of the solar module 42. Further, the horizontal support 260 can comprise a plurality of set screws 250 (as shown in Figures 23A and 23B) that can be secured into the respective plurality of securement apertures 259 of the first and second securement arm 254A. The set screws 250 can have a length to at least extend from the securement arm 254A to apply pressure against the frame side end 42A of the solar module 42 placed in the horizontal support 260 against the abutment arm 254B. The set screws 250 can be configured to be tightened to press against the frame side end 42A of the solar module 42 clamping the frame side end 42A against the abutment arm 254B.

[0145] As above, the securement arm 254A can comprise a respective wire channel 258 on an end distal to the base 252. The wire channel 258 can face inward toward the respective frame side end 42A of the solar module 42 when the horizontal support 260 is placed around the frame side ends 42A, 42B of adjacent solar modules 42. Thus, for example, the wire channels 258 can have an opening facing inward toward the respective receiving cavity 256.

[0146] Referring to Figures 29A-32, another embodiment is provided of a horizontal support 270 for providing support to the securement of two solar modules along adjacent sides of the respective solar modules in a manner similar to the embodiments above. The horizontal support 270 can comprise a base 272 with a first end 273A and a second end 273B. The horizontal support 270 can also comprisea first securement arm 274A that extends upward from the first end 273A of the base 272 and a second securement arm 274B that extends upward from the second end 273B of the base 272. Each of the first and second securement arms 274A, 274B can comprise a plurality of securement apertures 279A, 279B. In some embodiments, the securement apertures 279A, 279B can extend about parallel to the base 272 of the horizontal support 270. Further, the horizontal support 270 can comprise a plurality of set screws (not shown) for engaging the respective plurality of securement apertures 279A, 279B of the first and second securement arms 274A, 274B as described above that are used to apply pressure against a frame side end or of a solar module placed in the horizontal support base 272 between the first and second securement arms 274A, 274B. The support base 272 can include a sitting indention 280 to sit the horizontal support 270 and aid in securing the horizontal support 270 on a roofing support, or rafter, beam. As above, the base 272 of the horizontal support 270 can also have a front end 277A and a rear end 277B. The front end 277A and rear end 277B of each horizontal support 270 can be secured to rafter beams to support the horizontal support 270. Secure apertures 278A, 278B can be used to secure the horizontal support 270 in place on a portion, a component, or extension of the rafter beam. The secure apertures 278A, 278B can be positioned at or near both the front end 277A and rear end 277B of each horizontal support 270. The sitting indention 280 can be on a bottom portion of the front end 277A and rear end 277B of each horizontal support 270 for receiving on a portion, a component, or extension of the rafter beam. The secure apertures 278A, 278B can extend into the sitting indention 280. The secure apertures 278A, 278B can be configured to receive a fastener, for example, a bolt, screw, rivet, or the like, to secure the horizontal support 270 to the portion, component, or extension of the respective rafter beam.

[0147] Additional in some embodiments, as shown in Figure 29A, the support base 272 of the horizontal support 270 can include one or more voids 282 therein. The voids can be used to aid in extrusion of the horizontal support 270 and can potentially aid in heat dissipation and in the reduction of weight, as needed. In some embodiments, as shown in Figure 29B, the support base 272’ of horizontal support 270’ can be solid. The horizontal support 270’ can otherwise be constructed in a similar manner to and have the same or similar features the horizontal support 270 shown in Figure 29A. Thus, same reference numerals are used those features as described above. In some embodiments, a frame spacer 275 can be provided that can extend upward from the base 272 between the first and second securement arms 274A, 274B to form first and second cavities 276A, 276B for reception of portions of the respective frame side ends of the solar modules that are positioned side by side as described with the embodiment above. A gasket 96A can engage the frame spacer 275. The frame spacer 275 can have a height HFS that extends upward from the base 272. The height HFS of the frame spacer 275 is greater than the height of the frame spacer 245 of the embodiment of horizontal support 270 shown in Figures 22-27. Additionally, in some embodiments, the height HFS of the frame spacer 275 can be greater than the height of the first and second securement arms 274A, 274B of the horizontal support 270. The height HFS of the frame spacer 275 can be such that the frame spacer 245 above a point of securement of the frame side ends of the solar modules to the horizontal support 270 to add rigidity to the securement. For example, the height HFS of the frame spacer 275 can be extend above the plurality of securement apertures 279A, 279B of the first and second securement arms 274A, 274B such that set screw that engage securement apertures 279A, 279B of the first and second securement arms 274A, 274B can press against the frame side ends of the solar modules compressing the gasket 96A between the frame side ends of the solar modules and the frame spacer 275.

[0148] The gasket 96A can comprise a V-shaped (or U-shaped) gasket having a channel 96C therein can be provided such that the gasket 96A can fit over the frame spacer 275. In some embodiments, an adhesive can be used to secure the gasket 96A to the frame spacer 275. In particular, the frame spacer 275 and the channel 96C are sized so that the V-shaped gasket 96A fits on the frame spacer 275 with channel walls 96W of the gasket 96A extending along sides of the frame spacer 275. When the gasket 96A is placed on the frame spacer 275, the gasket 96A is positioned to be between to the frame side ends of the solar modules that are adjacent one another with the frame side ends are installed. The height HFS of the frame spacer 275 provides a rigidity to the combination of the gasket 96A and the frame spacer 275 for securing the frame side ends of the solar modules in place in the horizontal support 270 while providing a compressive feature of the channel walls 96W of the gasket 96A to provide a tighter seal between the frame side ends of the solar modules and horizontal support 270. The first and second cavities 276A, 276B can be configured to receive a laterally extending bottom of the respective frame side end of the solar module as described above. The set screws as described above can be tightened to press against the frame side ends of the two solar modules clamping the frame side ends and the gasket 96A together and compressing the gasket 96A between the two frame side ends of the solar modules. In some embodiments, each of the first and second securement arms 274A, 274B can comprise a respective wire channel as described above.

[0149] As shown in Figure 32, the gasket 96A can have a top portion 96T that extends above the frame spacer 275 when installed. The top portion 96T of the gasket 96A can have a height HGT that extends above the frame spacer 275 when installed. The top portion 96T of the gasket 96A provides just gasket between the frame side ends of the solar modules above the frame spacer 275 for sealing above the frame side ends of the solar modules when installed and secured in the horizontal support 270. The channel walls 96W of the gasket 96A can have a length, or height, HGW that extends down from the top portion 96T of the gasket 96A. In some embodiments, the height HGW of the channel walls 96W of the gasket 96A can be the same or similar length as the height HFS of the frame spacer 275 such that the channel walls 96W of the gasket 96A can rest or almost rest upon the support base 272 of the horizontal support 270. In some embodiments, the height HGW of the channel walls 96W of the gasket 96A can be less than the height HFS of the frame spacer 275. In such embodiments, the height HGW of the channel walls 96W of the gasket 96A can be a length that allows the channel walls 96W of the gasket 96A to extend deep enough so that channel walls 96W of the gasket 96A extend past a point of alignment with securement apertures 279A, 279B of the first and second securement arms 274A, 274B. In this manner, when set screws are screwed in the securement apertures 279A, 279B of the first and second securement arms 274A, 274B, the set screws compress the frame side ends of the solar modules against the channel walls 96W of the gasket 96A. In some embodiments, outer sides of the gasket 96A can have grooved surfaces 96B that can facilitate the sealing of the gasket 96A when the frame side ends of the solar modules are installed. In some embodiments, the grooved surfaces 96B of the outer sides of the gasket 96A can extend along the channel walls 96W of the gasket 96A. In some embodiments, the grooved surfaces 96B of the outer sides of the gasket 96A can extend along the top portion 96T and the channel walls 96W of the gasket 96A.

[0150] As with the embodiments described above, the horizontal supports can be used to cap an end of a solar module also. Referring to Figure 33, an embodiment of a horizontal support 290 for providing support to and capping an end frame of a solar module (not shown) can be provided. The horizontal support 290 can comprise a base 292 with a first end and a second end that is distal from the first end. The horizontal support 290 can also comprise a securement arm 294A that extends upward from the first end of the base 292. In particular, the base 292, the securement arm 294A, and the abutment arm 294B can form a receiving cavity 296 in which a portion of the frame side end of a solar module can be placed in the same or similar manner described above. As with the securement arms described above, the securement arm 294A can comprise a plurality of securement apertures (not shown) in the side in which set screws can positioned for securing the frame side end of the solar module in the horizontal support 290. As above, in some embodiments, the securement apertures can extend through the securement arm 294A in a manner that the axes of the securement apertures extend about parallel to the base 292. The horizontal support 290 can also comprise an abutment arm 294B extending upward from the second end configured to abut against a frame side end of a solar module (not shown) placed in the horizontal support 290 similar to the manner described above. The set screws can be tightened to press against the frame side end of the solar module to clamp the frame side end against the abutment arm as described above. The base 292 of the horizontal support 290 can also have a front end and a rear end. Similar to the horizontal support 240, horizontal support 260, or the horizontal support 270, the front end and rear end of each horizontal support 290 can be secured to rafter beams to support the horizontal support 290.

[0151] These and other modifications and variations to the present subject matter may be practiced by those of ordinary skill in the art, without departing from the spirit and scope of the present subject matter, which is more particularly set forth herein above. In addition, it should be understood the aspects of the various embodiments may be interchanged both in whole and in part. Furthermore, those of ordinary skill in the art will appreciate that the foregoing description is by way of example only, and is not intended to limit the present subject matter.

Claims

What is Claimed is:

1. A stabilizing apparatus for providing level mounting plates for structures, the stabilizing apparatus comprising: a head device comprising: a head base having a first end and a second end, the first end of the head base having a receiving cavity therein configured to receive a top end of an anchor that is securable in a ground surface; and a ball connected to the second end of the head base, the ball having a majority of a spherical surface exposed; a mounting plate assembly comprising: a yoke having a yoke body with a front face and a bottom, the yoke body having a socket therein with an interior configured to accept the ball of the head device and an opening on the front face and the bottom of the yoke body; and a mounting plate secured on the yoke, the mounting plate having a flat top surface distal from the yoke for securing a base portion of a structure; and wherein, when installed, the yoke is rotatable about the ball of the head device positioned within the socket to position the flat top surface of the mounting plate in a level position.

2. The stabilizing apparatus according to claim 1, wherein a rear of the yoke body has a locking aperture for receiving a locking bolt, upon positioning the flat top surface of the mounting plate in level position when installed, tightening the locking bolt against the ball of the head device to lock the mounting plate assembly in place.

3. The stabilizing apparatus according to claim 1 , wherein the mounting plate assembly further comprises a neck extending between the yoke and the mounting plate.

4. The stabilizing apparatus according to claim 1 , wherein the ball is removable from the head base of the head device.

5. The stabilizing apparatus according to claim 4, wherein the ball has a threaded shaft extending from a base of the ball and the head base of the head device comprises a ball receiving threaded aperture in the second end for receiving the threaded shaft.

6. The stabilizing apparatus according to claim 5, wherein the head base of the head device comprises a ball locking threaded aperture that engages the ball receiving threaded aperture in the second end of the head base for receiving a set screw to secure the ball to the head base.

7. The stabilizing apparatus according to claim 1, wherein the head base of the head device comprises an anchor locking threaded aperture that engages the receiving cavity for receiving a set screw to secure the head device to the anchor.

8. The stabilizing apparatus according to claim 1, wherein mounting plate of the mounting plate assembly further comprises securement apertures for aligning with securement apertures in a post base to enable securement of a post base to the mounting plate.

9. A horizontal support for providing support to two solar modules along adjacent sides of the respective solar modules, the horizontal support comprising: a base with a first base side end and a second base side end; and a first securement arm extending upward from the first base side end of the base and a second securement arm extending upward from the second base side end of the base, each of the first and second securement arms configured to facilitate securement of a frame side end of a solar module placed in the base between the first and second securement arms.

10. The horizontal support according to claim 9, wherein each of the first and second securement arms comprising a plurality of securement apertures for receiving securement devices.

11. The horizontal support according to claim 10, wherein the securement devices comprise a plurality of set screws for engaging the respective plurality of securement apertures of the first and second securement arms, each set screw of the plurality of set screws having a length to at leastextend from the respective first and second securement arms to apply pressure against a frame side end of a solar module placed in the base between the first and second securement arms.

12. The horizontal support according to claim 9, further comprising a frame spacer extending upward from the base between the first and second securement arms to form first and second cavities for reception of portions of the respective frame side ends of the solar modules positioned side by side.

13. The horizontal support according to claim 12, wherein the frame spacer is alignable with a gasket placed between to the frame side ends of the solar modules positioned side by side.

14. The horizontal support according to claim 13, wherein the frame spacer has a width that is less than a width of the gasket when the gasket is uncompressed.

15. The horizontal support according to claim 13, wherein frame spacer has a height that extends above the first and second securement arms.

16. The horizontal support according to claim 15, wherein the gasket comprises a V-gasket that fits over at least a portion of the frame spacer.

17. The horizontal support according to claim 12, wherein each of the first and second cavities is configured to receive a laterally extending bottom of the frame side end of the solar module.

18. The horizontal support according to claim 12, wherein each of the first and second securement arms comprise a wire channel on an end distal to the base, the wire channel having an opening facing inward toward the respective first and second cavities.

19. The horizontal support according to claim 12, wherein the base comprises a front end and a rear end with a sitting indention in the front end and rear end of the base for securement to a respective rafter beam of a structure.

20. A horizontal support for securement on an end frame of a solar module, the horizontal support comprising: a base with a first end and a second end; a securement arm extending upward from the first end of the base, the securement arm comprising a plurality of securement apertures; an abutment arm extending upward from the second end configured to abut against a frame side end of a solar module placed in the horizontal support; and a plurality of set screws that can be secured into the respective plurality of securement apertures of the first and second securement arm, each set screw of the plurality of set screws having a length to at least extend from the respective first and second securement arms to apply pressure against the frame side end of the solar module placed in the horizontal support against the abutment arm.

21. The horizontal support according to claim 20, wherein the base, the securement arm and the abutment arm form a receiving cavity for reception of a portion of the frame side end of the solar module.

22. The horizontal support according to claim 21, wherein the receiving cavity is configured to receive a laterally extending bottom of the frame side end of the solar module.

23. The horizontal support according to claim 21, wherein the securement arm comprises a wire channel on an end distal to the base, the wire channel having an opening facing inward toward the receiving cavity.

24. The horizontal support according to claim 20, wherein set screws of the plurality of set screws are configured to be tightened to press against the frame side end of the solar module clamping the frame side end against the abutment arm.

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