U.S. patent application number 12/391623 was filed with the patent office on 2009-10-08 for modular solar panel mounting clamps.
This patent application is currently assigned to RENEWABLE ENERGY HOLDINGS, LLC. Invention is credited to Michael Strizki.
Application Number | 20090250580 12/391623 |
Document ID | / |
Family ID | 41132382 |
Filed Date | 2009-10-08 |
United States Patent
Application |
20090250580 |
Kind Code |
A1 |
Strizki; Michael |
October 8, 2009 |
MODULAR SOLAR PANEL MOUNTING CLAMPS
Abstract
Clamps for mounting frameless, glass paneled, thin-film solar
modules on slant-roof, flat roof, or ground-mounted solar systems.
The clamps of the present invention can be also adapted to use with
existing roof rail systems or other mounting brackets.
Inventors: |
Strizki; Michael; (Hopewell,
NJ) |
Correspondence
Address: |
BROWN & MICHAELS, PC;400 M & T BANK BUILDING
118 NORTH TIOGA ST
ITHACA
NY
14850
US
|
Assignee: |
RENEWABLE ENERGY HOLDINGS,
LLC
Hopewell
NJ
|
Family ID: |
41132382 |
Appl. No.: |
12/391623 |
Filed: |
February 24, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61031244 |
Feb 25, 2008 |
|
|
|
Current U.S.
Class: |
248/309.1 |
Current CPC
Class: |
Y02E 10/50 20130101;
F24S 25/636 20180501; Y02B 10/20 20130101; F24S 2025/011 20180501;
F24S 25/35 20180501; H02S 20/10 20141201; Y02E 10/47 20130101; Y02B
10/10 20130101; H02S 20/23 20141201 |
Class at
Publication: |
248/309.1 |
International
Class: |
A47B 96/06 20060101
A47B096/06 |
Claims
1. An apparatus for mounting frameless solar panels comprising: an
upper plate having a top plane and a bottom plane having an
aperture proximal to a first end; a lower plate having a top plane
and a bottom plane having an aperture proximal to a first end; a
spacer having a top plane, a bottom plane, a first vertical surface
and a second vertical surface; wherein the spacer has a centrally
located aperture therethrough; a fastener system; a plurality of
cushions; a bracket having a long axis with a top plane and a
bottom plane, wherein the top plane is in contact with the bottom
plane of the lower plate; and a rail insert fastener system,
whereby the aperture in the upper plate, spacer, and lower plate
align to form a passage.
2. The apparatus of claim 1, wherein the bottom plane of the upper
plate and the upper plane of the lower plate have a groove
configured to the top plane and the bottom plane of the spacer.
3. The apparatus of claim 1, wherein the bracket has a long axis
which terminates at a first notched end and a second notched end,
wherein the first notched end is on the top plane and the second
notched end is on the bottom plane of the long axis.
4. The apparatus of claim 1, wherein the first notched end and the
second notched end have an elongated opening parallel to the
direction of the long axis of the bracket.
5. The apparatus of claim 1, wherein the brackets have assembly
apertures on the long axis proximal to the first notched end and
the second notched end.
6. The apparatus of claim 1, wherein the fastener system comprises
a nut and bolt, wherein the bolt of the fastener system traverses
the aperture of the upper plate, lower plate, spacer and assembly
aperture of the bracket.
7. The apparatus of claim 1, wherein the nut of the fastener system
is in contact with the bottom plane of the bracket when a frameless
solar panel is secured.
8. The apparatus of claim 1, wherein the first end of the upper
plate and the first end of the lower plate are aligned when a solar
panel is secured.
9. The apparatus of claim 1, wherein the bottom plan of the upper
plate, the top plane of the lower plate and the first vertical
surface have a cushion attached thereto.
10. An apparatus for mounting frameless solar panels comprising: an
upper plate having a top plane and a bottom plane having a
centrally located aperture; a lower plate having a top plane and a
bottom plane having centrally located aperture; a spacer having a
top plane, a bottom plane, a first vertical surface and a second
vertical surface; wherein the spacer has a centrally located
aperture therethrough; a rail insert fastener system; and a
plurality of cushions; whereby the aperture in the upper plate,
spacer, and lower plate align to form a passage.
11. The apparatus of claim 10, wherein the bottom plane of the
upper plate and the upper plane of the lower plate have a groove
configured to the top plane and the bottom plane of the spacer.
12. The apparatus of claim 10, wherein the bottom plan of the upper
plate, the top plane of the lower plate and the first vertical
surface have a cushion attached thereto.
13. The apparatus of claim 10, wherein the rail insert fastener
system comprises a fastener and an insert, wherein the fastener
traverses the passage and is secured to the insert.
14. A process for mounting frameless solar panel modules comprising
the steps of: a. preparing a first solar module panel module
comprising the steps of: i. inserting a solar panel into an
apparatus for mounting frameless solar panels wherein the apparatus
comprises an upper plate having a top plane and a bottom plane
having an aperture proximal to a first end, a lower plate having a
top plane and a bottom plane having an aperture proximal to a first
end, a spacer having a top plane, a bottom plane, a first vertical
surface and a second vertical surface, wherein the spacer has a
centrally located aperture therethrough, a fastener system, a
plurality of cushions, a bracket having a long axis with a top
plane and a bottom plane, wherein the bracket has a long axis which
terminates at a first notched end and a second notched end, wherein
the first notched end is on the top plane and the second notched
end is on the bottom plane of the long axis, wherein the first
notched end and the second notched end has an elongated opening in
the direction of the long axis of the bracket, wherein the brackets
have assembly apertures parallel to the long axis proximal to the
first notched end and the second notched end, wherein the top plane
is attached to the bottom plane of the lower plate and a rail
insert fastener system, whereby the aperture in the upper plate,
spacer, and lower plate align to form a passage, ii. traversing the
passage formed by the aperture in the upper plate, spacer, lower
plate, and assembly aperture with a first member of the fastener
system, and iii. compressing the upper plate, the lower plate and
the bracket by attachment of a second member of the fastener system
to the first member of the fastener system; b. aligning the
assembly apertures of a first notched end of a bracket of the first
module to a second notched end of a bracket of a second module
prepared by step a; c. traversing the elongated opening by a first
member of the rail insert fastener system; and d. securing the
first notched end bracket of a first module to a second notched end
of the second module by attachment of a second member of the rail
insert fastener system within a rail.
Description
REFERENCE TO RELATED APPLICATIONS
[0001] This application claims one or more inventions which were
disclosed in Provisional Application Number 61/031,244, filed,
entitled "Modular Solar Panel Mounting Clamps". The benefit under
35 USC .sctn. 119(e) of the United States provisional application
is hereby claimed, and the aforementioned application is hereby
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to a mounting system for
solar panels. Specifically, the present invention relates to
modular mounting clamps for installing frameless, thin-film solar
panels on a rooftop or on the ground.
[0004] 2. Description of Related Art
[0005] A solar cell or photovoltaic cell is a device that converts
light energy into electrical energy by the photovoltaic effect.
Traditionally the photovoltaic cells are made from crystalline
silicone. Recently a new thin-film manufacturing process enables
the production of photovoltaic cells using amorphous silicon at a
much more reduced cost. Thin-film photovoltaic cells use less of
the raw material (silicon or other light absorbers) compared to
wafer based solar cells, leading to a significant price drop per
kWh. These thin-film photovoltaic cells are produced as frameless,
glass panels. The existing mounting systems designed to mount
framed photovoltaic cells do not fit the requirements for the
mounting thin-film photovoltaic cells on the ground or on
rooftop.
[0006] There exists a demand for a solar panel mounting hardware
specifically designed for the frameless, glass paneled, thin-film
photovoltaic cells that reduces the cost and labor requirement of
installation.
SUMMARY OF THE INVENTION
[0007] In a first embodiment, the invention is directed to an
apparatus for mounting frameless solar panels wherein the apparatus
includes an upper plate, having a top plane and a bottom plane and
an aperture proximal to a first end, a lower plate, having a top
plane and a bottom plane and an aperture proximal to a first end. A
spacer is included having a top plane, a bottom plane, a first
vertical surface and a second vertical surface, wherein the spacer
has a centrally located aperture therethrough. The apparatus
further includes a fastener system, a plurality of cushions,
brackets having a long axis with a top plane and a bottom plane,
wherein the top plane is in contact with the bottom plane of the
lower plate, and a rail insert fastener system. The aperture in the
upper plate, spacer, and lower plate align to form a passage.
[0008] The bottom plane of the upper plate and the upper plane of
the lower plate have a groove configured to the top plane and the
bottom plane of the spacer.
[0009] The bracket has a long axis which terminates at a first
notched end and a second notched end, wherein the first notched end
is on the top plane and the second notched end is on the bottom
plane of the long axis. The first notched end and the second
notched end each have an elongated opening parallel to the
direction of the long axis of the bracket. The brackets have
assembly apertures on the long axis proximal to the first notched
end and the second notched end.
[0010] The fastener system comprises a nut and bolt, wherein the
bolt of the fastener system traverses the aperture of the upper
plate, lower plate, spacer and assembly aperture of the bracket.
The nut of the fastener system is in contact with the bottom plane
of the bracket when a frameless solar panel is secured.
[0011] The first end of the upper plate and the first end of the
lower plate are aligned when a solar panel is secured. The bottom
plane of the upper plate, the top plane of the lower plate and the
first vertical surface of the spacer have a cushion attached
thereto.
[0012] In another embodiment, the invention is directed to an
apparatus for mounting frameless solar panels including an upper
plate having a top plane and a bottom plane and a centrally located
aperture, a lower plate having a top plane and a bottom plane
having centrally located aperture. A spacer is included having a
top plane, a bottom plane, a first vertical surface and a second
vertical surface, wherein the spacer has a centrally located
aperture therethrough. In addition, the apparatus includes a rail
insert fastener system and a plurality of cushions, whereby the
aperture in the upper plate, spacer, and lower plate align to form
a passage.
[0013] The bottom plane of the upper plate and the upper plane of
the lower plate have a groove configured to the top plane and the
bottom plane of the spacer. The bottom plane of the upper plate,
the top plane of the lower plate and the first and second vertical
surfaces have a cushion attached thereto. The rail insert fastener
system comprises a fastener and an insert, wherein the fastener
traverses the passage and is secured to the insert.
[0014] In another embodiment, the invention is directed to a
process for mounting frameless solar panel modules comprising the
steps of a) preparing a first solar module panel comprising the
steps of i.) inserting a solar panel into an apparatus for mounting
frameless solar panels wherein the apparatus comprises an upper
plate having a top plane and a bottom plane having an aperture
proximal to a first end, a lower plate having a top plane and a
bottom plane having an aperture proximal to a first end, a spacer
having a top plane, a bottom plane, a first vertical surface and a
second vertical surface, wherein the spacer has a centrally located
aperture therethrough, a fastener system, a plurality of cushions,
a bracket having a long axis with a top plane and a bottom plane,
wherein the bracket has a long axis which terminates at a first
notched end and a second notched end, wherein the first notched end
is on the top plane and the second notched end is on the bottom
plane of the long axis, wherein the first notched end and the
second notched end has an elongated opening in the direction of the
long axis of the bracket, wherein the brackets have assembly
apertures parallel to the long axis proximal to the first notched
end and the second notched end, wherein the top plane of the
bracket is attached to the bottom plane of the lower plate and a
rail insert fastener system, whereby the aperture in the upper
plate, spacer, and lower plate align to form a passage, ii.)
traversing the passage formed by the aperture in the upper plate,
spacer, lower plate, and assembly aperture with a first member of
the fastener system, and iii.) compressing the upper plate, the
lower plate and the bracket by attachment of a second member of the
fastener system to the first member of the fastener system.
[0015] The process further includes b) aligning the assembly
apertures of a first notched end of a bracket of the first module
to a second notched end of a bracket of a second module prepared by
step a., c) traversing the elongated openings with a first member
of the rail insert fastener system; and d) securing the first
notched end of a bracket of a first module to a second notched end
of a second module by attachment of a second member of the rail
insert fastener system within a rail.
BRIEF DESCRIPTION OF THE DRAWING
[0016] FIG. 1 is a side view of a pair of apparatus of a first
embodiment of the present invention with inserted solar panels,
installed on a rail;
[0017] FIG. 2 is a perspective view of a pair of apparatus wherein
a first apparatus is assembled and a second apparatus is
illustrated in an exploded view prior to installation on a
rail;
[0018] FIG. 3 is a perspective view of the bracket of the present
invention;
[0019] FIG. 4A is a plan view of a perpendicular bar bracket
support configuration;
[0020] FIG. 4B is a plan view of a crossing bar bracket support
configuration;
[0021] FIG. 5 is a cross-sectional view of a second embodiment of
the apparatus of the present invention installed on a rail;
[0022] FIG. 6 is an exploded view of the apparatus of the
embodiment of FIG. 5 prior to installation on a rail;
[0023] FIG. 7 is a perspective view of the embodiment of FIGS. 1
and 2 having an installed solar panel and installed on a rail.
[0024] FIG. 8 is a perspective view of the embodiment of FIGS. 5
and 6 having an installed solar panel and installed on a rail.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The present invention teaches clamp designs for mounting
frameless, glass paneled, thin-film solar modules on slant-roof,
flat roof, or ground-mounted solar systems. A first embodiment of
the present invention is a clamp designed to act as an adapter to
attach thin-film solar modules to roof rail systems already
available from Professional Solar Products, or UniRac.RTM. mounting
systems and others. The clamp provides a means to attach
universally to frameless panels from any manufacturer using readily
available standard mounting hardware. The advantages of this clamp
design are that it is significantly more cost effective, easy to
manufacture, easy to install, and provides an optimal means to
attach the panel while providing maximum support and gripping
ability. Minor modifications can be made to this clamping device to
accommodate different sizes of glass or gripping pressure by only
adding different sized shims within the clamp. This system with
adapter bar can be used on both the sloped roof system or on ground
mounting systems.
[0026] Referring to FIGS. 1 and 2, a pair of apparatus 100 of the
first embodiment of the invention is illustrated installed on a
rail 1000. Referring to FIG. 2, the pair of apparatus of the first
embodiment of the invention is illustrated prior to installation on
a rail 1000. In FIG. 2, a first apparatus 100 is illustrated
assembled for receipt of a solar panel 2000 and a second apparatus
100 is illustrated prior to assembly. Each apparatus 100 includes
an upper plate 102 having a top plane 102A and a bottom plane 102B,
having an aperture 102C proximal to a first end 102D and a lower
plate 104, having a top plane 104A and a bottom plane 104B, having
an aperture 104C proximal to a first end 104D. A spacer 106 is
included having a top plane 106A, a bottom plane 106B, a first
vertical surface 106C and a second vertical surface 106D; wherein
the spacer 106 has a centrally located aperture 106E therethrough.
In addition, in this embodiment the invention includes a bracket
108 having a long axis 108A with a top plane 108B and a bottom
plane 108C, wherein the top plane 108B is in contact with the
bottom plane 104B of the lower plate 104.
[0027] The bottom plane 102B of the upper plate 102 and the upper
plane 104A of the lower plate 104 each have a groove 110, 112
configured to the top plane 106A and the bottom plane 106B of the
spacer 106. The grooves reduce the amount of movement of the spacer
106 during assembly and installation. As it is will be recognized
by those skilled in the art that the components of the apparatus
100 can be of one piece construction or multiple pieces, the
grooves 110, 112 will allow additional support and strength. The
upper plate 102, bottom plate 104 and spacer 106 are composed of
materials such as aluminum or galvanized steel.
[0028] Referring to FIGS. 1, 2 and 3, each bracket 108 has a long
axis 108A which terminates at a first notched end 108D and a second
notched end 108E, wherein the first notched end 108D is on the top
plane 108A and the second notched end 108E is on the bottom plane
108B of the long axis 108A. The first notched end 108D and the
second notched end 108E have elongated openings 108D1, 108E1
parallel to the direction of the long axis 108A of the bracket 108.
The brackets 108 have assembly apertures 108F, on the long axis
108A proximal to the first notched end 108D and the second notched
end 108E.
[0029] The aperture in the upper plate 102C, spacer 106E, lower
plate 104C and assembly aperture 108F align to form a passage 111.
A fastener system 112 can be of various securing mechanism but will
most likely includes a nut 112A and bolt 112B (partially shown in
phantom in FIG. 1), wherein the bolt 112B of the fastener system
112 traverses the passage 111 and is secured by the nut 112A. The
nut 112B of the fastener system 112 is in contact with the bottom
plane 108C of the bracket 108 when a frameless solar panel 2000 is
secured in the apparatus 100. The first end of the upper plate 102D
and the first end of the lower plate 104D are aligned when a solar
panel is secured.
[0030] A plurality of cushions 114 are used to contact the solar
panel 2000 upon installation so as to prevent damage. The cushions
114 provide a "snug" fit but allow variations in the amount of
compression/pressure applied during manual installation. This
"variation" allows reduced labor and installation as the objective
of the installer is a "snug" fit without any additional
measurements needed. The cushions 114 are applied to the bottom
plane 102B of the upper plate 102, the top plane 104A of the lower
plate 104 and the first vertical surface 106D of the spacer 106 on
each apparatus 100, thereby assuring all contact between the
apparatus 100 and the solar panels 2000 is via a cushion 114.
[0031] A rail insert fastener system 116 can be of various designs
which will be effective to secure each apparatus 100 to a standard
roof rail 1000 as discussed herein. For example, the fastener
system 116 includes a threaded bolt 116A and a rail insert 116B,
wherein the threaded bolt 116A can be secured to the rail insert
116B within the standard rail. This allows each "module", e.g. a
solar panel 2000 having an attached apparatus 100 to be secured to
the standard rail 1000. The bolt 116A traverses the elongated holes
108D1, 108E1 on the brackets and is secured by a rail insert 116B,
as best illustrated in FIG. 1. As best illustrated in FIG. 7,
multiple apparatus 100 are shown having an installed solar panel
2000, wherein the apparatus 100 is installed on a rail 1000.
[0032] As illustrated in FIGS. 4A and 4B, the mounting brackets 108
are parallel to each other when attached to the solar panels 2000.
As illustrated in FIG. 4A, this configuration can be supported and
strengthened by a brace 118 which connects the brackets 108. The
brace 118 is a bar perpendicular to the brackets 108, wherein each
end of the brace 118 connects each bracket 108 attached to a solar
panel 2000. As illustrated in FIG. 4B, the system could include two
intersecting braces 118 wherein each intersecting brace 118 is
attached to brackets 108 attached to a solar panel 2000. Attachment
of the brace 118 to the brackets 108 can be by various methods,
e.g. adhesive, fasteners or weld.
[0033] Additional embodiments of the invention will now be
described wherein like parts are numbered with like reference
numbers.
[0034] A second embodiment of the present invention is designed to
mount frameless solar panels of varying thicknesses using a single
set of clamps per two adjacent modules The advantages of this
embodiment is that it allows for a cost effective means in which to
mount the modules on a sloped roof using existing module mounting
hardware such as those manufactured by Professional Solar Products,
or UniRac.RTM., it is easy to manufacture, easy to install, and
provides an optimal means to attach the panel while providing
maximum support and gripping ability. This embodiment can be used
effectively on sloped roof systems.
[0035] Referring to FIGS. 5 and 6, an apparatus 200 is illustrated
for mounting frameless solar panels includes an upper plate 202
having a top plane 202A and a bottom plane 202B and a centrally
located aperture 202C, a lower plate 204 having a top plane 204A
and a bottom plane 204B and a centrally located aperture 204C In
addition, a spacer 206 is included having a top plane 206A, a
bottom plane 206B, a first vertical surface 206C and a second
vertical surface 206D, wherein the spacer 206 has a centrally
located aperture 206E therethrough. The aperture in the upper plate
202C, spacer 206E, and lower plate 204C align to form a passage
211.
[0036] The bottom plane 202B of the upper plate 202 and the upper
plane 204A of the lower plate 204 have a groove configured 210, 212
to the top plane 206A and the bottom plane 206B of the spacer 206.
The grooved surfaces 210, 212 ensure a secure fit and limits
movement of the spacer 206 during installation of the solar panel
2000.
[0037] The apparatus 200 includes a plurality of cushions 214
wherein the bottom plane 202B of the upper plate 202, the top plane
204A of the lower plate 204 and the first and second vertical
surfaces 206C, 206D of the spacer 206, have a cushion 214 attached
thereto. As in the previous embodiment, the cushions provide a
"snug" fit and prevent damage to the solar panel 2000 when
installed in the apparatus 200.
[0038] Similar to the previous embodiment, a rail insert fastener
system 216 can be of various designs which will be effective to
secure each apparatus 200 to a standard roof rail as discussed
herein. For example, the fastener system 216 includes a threaded
bolt 216A and a rail insert 216B, wherein the threaded bolt 216A
can be secured to the rail insert 216B within the standard rail
1000 wherein the threaded bolt 216A traverses the passage 211 and
is secured to the rail insert 216B. This allows each module to be
secured to the standard rail 1000. As best illustrated in FIG. 8,
multiple apparatus 200 are shown having an installed solar panel
2000, wherein the apparatus 200 is installed on a rail 1000.
[0039] In another embodiment, the invention is directed to a
process for mounting frameless solar panel modules comprising the
steps of a) preparing a first solar module panel module comprising
the steps of i.) inserting a solar panel into an apparatus for
mounting frameless solar panels wherein the apparatus comprises an
upper plate having a top plane and a bottom plane having an
aperture proximal to a first end, a lower plate having a top plane
and a bottom plane having an aperture proximal to a first end, a
spacer having a top plane, a bottom plane, a first vertical surface
and a second vertical surface, wherein the spacer has a centrally
located aperture therethrough, a fastener system, a plurality of
cushions, a bracket having a long axis with a top plane and a
bottom plane, wherein the bracket has a long axis which terminates
at a first notched end and a second notched end, wherein the first
notched end is on the top plane and the second notched end is on
the bottom plane of the long axis, wherein the first notched end
and the second notched end has an elongated opening in the
direction of the long axis of the bracket, wherein the brackets
have assembly apertures parallel to the long axis proximal to the
first notched end and the second notched end, wherein the top plane
is attached to the bottom plane of the lower plate and a rail
insert fastener system, whereby the aperture in the upper plate,
spacer, and lower plate align to form a passage, ii.) traversing
the passage formed by the aperture in the upper plate, spacer,
lower plate, and assembly aperture with a first member of the
fastener system, and iii.) compressing the upper plate, the lower
plate and the bracket by attachment of a second member of the
fastener system to the first member of the fastener system;
[0040] The process further includes b) aligning the assembly
apertures of a first notched end of a bracket of the first module
to a second notched end of a bracket of a second module prepared by
step a., c) traversing the elongated holes of the brackets with a
first member of the rail insert fastener system; and d) securing
the first notched end bracket of a first module to a second notched
end of the second module by attachment of a second member of the
rail insert fastener system within a rail.
[0041] These and other advantages of the present invention will be
apparent to those skilled in the art from the foregoing
specification. Accordingly, it will be recognized by those skilled
in the art that changes or modifications may be made to the
above-described embodiments without departing from the broad
inventive concepts of the invention. It should therefore be
understood that this invention is not limited to the particular
embodiments described herein, but is intended to include all
changes and modifications that are within the scope and spirit of
the invention. Reference herein to details of the illustrated
embodiments is not intended to limit the scope of the claims, which
themselves recite those features regarded as essential to the
invention.
* * * * *