U.S. patent application number 12/102557 was filed with the patent office on 2009-10-15 for apparatus for mounting a solar panel and method and apparatus for forming the mounting apparatus.
This patent application is currently assigned to ABT, Inc.. Invention is credited to Charles E. Gunter.
Application Number | 20090255530 12/102557 |
Document ID | / |
Family ID | 41162961 |
Filed Date | 2009-10-15 |
United States Patent
Application |
20090255530 |
Kind Code |
A1 |
Gunter; Charles E. |
October 15, 2009 |
APPARATUS FOR MOUNTING A SOLAR PANEL AND METHOD AND APPARATUS FOR
FORMING THE MOUNTING APPARATUS
Abstract
A support member for a solar panel is provided comprising a base
member having first and second surfaces and first and second sides,
the first surface defining a recess configured to receive the solar
panel. The first side of the support member defines a first flange
extending therefrom that is flush with the first surface of the
base member and the second side of the support member defines a
second flange extending therefrom that is flush with the second
surface of the base member.
Inventors: |
Gunter; Charles E.;
(Mooresville, NC) |
Correspondence
Address: |
MOORE & VAN ALLEN PLLC
P.O. BOX 13706
Research Triangle Park
NC
27709
US
|
Assignee: |
ABT, Inc.
|
Family ID: |
41162961 |
Appl. No.: |
12/102557 |
Filed: |
April 14, 2008 |
Current U.S.
Class: |
126/704 ;
29/897.3 |
Current CPC
Class: |
H02S 20/23 20141201;
Y02E 10/50 20130101; F24S 25/00 20180501; Y10T 29/49623 20150115;
Y02B 10/10 20130101; Y02B 10/20 20130101; F24S 20/67 20180501 |
Class at
Publication: |
126/704 ;
29/897.3 |
International
Class: |
F24J 2/46 20060101
F24J002/46; B21D 47/00 20060101 B21D047/00 |
Claims
1. A support member for a solar panel, comprising: a base member
having first and second surfaces and first and second sides, said
first surface defining a recess configured to receive the solar
panel, said base member being formed of polymer concrete.
2. A support member according to claim 1 wherein said recess is
configured such that the solar panel can be positioned within said
recess with relatively insubstantial gaps between the sides of said
recess and the sides of the solar panel and with the front of the
solar panel being substantially flush with said first surface of
said base member.
3. A support member according to claim 1 wherein said first surface
defines at least one aperture within said recess structured to
provide space for air to circulate about the back of the solar
panel and to reduce the weight of said base member.
4. A support member according to claim 1 wherein said at least one
aperture comprises at least one slot.
5. A support member according to claim 1 wherein said at least one
aperture comprises at least one circular opening.
6. A support member according to claim 1 wherein said first surface
of said base member defines a plurality of raised members within
said recess that are structured to engage the solar panel and to
provide space between said first surface of said base member and
the solar panel.
7. A support member according to claim 6 wherein at least one of
said plurality of raised members comprises at least one elongate
rib.
8. A support member according to claim 1 wherein said first side of
said base member defines a first flange extending therefrom that is
flush with said first surface of said base member and wherein said
second side of said base member defines a second flange extending
therefrom that is flush with said second surface of said base
member.
9. A support member according to claim 8 wherein said first flange
defines a first lip at the distal end of said first flange and a
groove between said first lip and said first side of said base
member and said second flange defines a second lip at the distal
end of said second flange and a groove between said second lip and
said second side of said base member.
10. A support member according to claim 1 wherein said first
surface of said base member defines a second recess configured to
receive a junction box, said second recess defining an aperture
configured to receive the electrical wiring of the solar panel and
to provide space for air to circulate about the back of the solar
panel.
11. A solar panel array, comprising: at least two solar panels; at
least two support members, each of said at least two support
members comprising a base member having first and second surfaces
and first and second sides, said first surface of each of said base
members defining a recess configured to receive one of said at
least two solar panels, said first side of each of said base
members defining a first flange extending therefrom that is flush
with said first surface of the corresponding one of said base
members, said second side of each of said base members defining a
second flange extending therefrom that is flush with said second
surface of the corresponding one of said base members; and wherein
said at least two support members are positioned adjacent to one
another such that said first flange of one of said at least two
support members overlaps said second flange of the adjacent one of
said at least two support members.
12. A solar array according to claim 11 wherein said first surface
of each of said base members defines a plurality of raised members
within said recess that are structured to engage the back of said
one of said at least two solar panels and to provide space between
said first surface of each of said base members and the back of
said one of said at least two solar panels.
13. A solar array according to claim 12 wherein at least one of
said plurality of raised members comprises at least one elongate
rib.
14. A solar array according to claim 11 wherein said first flange
of each of said base members defines a first lip at the distal end
of said first flange and a groove between said first lip and said
first side of the corresponding one of said base members and said
second flange of each of said base members defines a second lip at
the distal end of said second flange and a groove between said
second lip and said second side of the corresponding one of said
base members.
15. A solar array according to claim 11 where in each of said at
least two support members is formed of polymer concrete.
16. A solar array according to claim 11 wherein said recess of each
of said base members is configured such that said one of said at
least two solar panels can be positioned within said recess with
relatively insubstantial gaps between the sides of said recess and
the sides of said one of said at least two solar panels and with
the front of said one of said at least two solar panels being
substantially flush with said first surface of the corresponding
one of said base members.
17. A solar array according to claim 17 wherein said first surface
of each of said base members defining at least one aperture within
said recess to enable air to circulate about the back of said one
of said at least two solar panels and to reduce the weight of the
corresponding one of said at least two support members.
18. A solar array according to claim 17 wherein said at least one
aperture comprises at least one slot.
19. A solar array according to claim 17 wherein said at least one
aperture comprises at least one circular opening.
20. A solar array according to claim 11 further comprising at least
two junction boxes and wherein said first surface of each of said
base members defines a second recess configured to receive one of
said at least two junction boxes, said second recess defining an
aperture configured to receive the electrical wiring of said one of
said at least two solar panels and to provide space for air to
circulate about the back of said one of said at least two solar
panels.
21. A method of forming a support member for a solar panel,
comprising: providing a first mold defining a plurality of
protuberances; encasing the first mold with a form; filling the
first mold with liquid polymeric material and aggregate;
positioning a second mold on the first mold within the form; urging
the first and second molds together; curing the polymeric material
to form a support member, the support member comprising a base
member having first and second surfaces and first and second sides,
said first surface of said base member defining a recess configured
to receive a solar panel; and removing the support member from the
first and second molds.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to solar panel support
apparatuses and methods and apparatuses for constructing the
same.
[0003] 2. Description of Related Art
[0004] The use of reusable energy sources is becoming increasingly
more important to national and local governments due to concerns
over global warming; the eventual exhaustion of certain
conventional energy supplies, such as oil, natural gas and coal;
and the increasing cost for such energy supplies. One reusable
energy source is solar energy or sunlight, which is captured and
converted into electricity using solar energy cells or panels of
such cells, as is well known in the art. While solar energy is an
abundant energy source and the technology involved in capturing and
converting the solar energy into electricity relatively well
developed, solar energy remains relatively underused due to, among
other factors, the need to have large, unobstructed areas to
position the panels and the adverse aesthetic impact of such
panels.
[0005] One proposal to increase the usage of solar panels is to
locate the panels on roof tops of residential and/or industrial
structures. However, there remain aesthetic concerns with locating
conventional solar panels on a roof top due to the height such
panels extend above the roof line. In addition, the weight of the
solar panels and support structure on the roof top and the
structural ability of the panels and support structure to withstand
high winds and other ambient conditions is also a concern. Finally,
the efficiency of a solar panel decreases as the temperature of the
panel increases, so an important objective in developing a solar
energy system is to ensure that heat does not build up around the
panels. Thus, there remains a need for a support structure for a
solar panel that can be used to position one or more panels
inconspicuously on a roof top, that is light enough not to
adversely affect the structural integrity of the roof top but that
still has sufficient mechanical strength and weight to withstand
high winds and other ambient conditions, and that allows for air to
circulate around the solar panel to reduce overheating.
SUMMARY OF THE INVENTION
[0006] Embodiments of the present invention provide improved
apparatus for mounting a solar panel and method and apparatus for
forming the mounting apparatus. More particularly, embodiments of
the present invention provide a support member for a solar panel
comprising a base member having first and second surfaces and first
and second sides, wherein the first surface defines a recess
configured to receive a solar panel. In one embodiment, the support
member is formed of polymer concrete. In another embodiment, the
recess is configured such that the solar panel can be positioned
within the recess with relatively insubstantial gaps between the
sides of the recess and the sides of the panel and with the front
of the panel being substantially flush with the first surface of
the support member. The first surface of the base member defines at
least one aperture within the recess to provide space for air to
circulate and to reduce the weight of the support member. In one
embodiment, the at least one aperture comprises at least one slot.
In another embodiment, the at least one aperture comprises at least
one circular opening.
[0007] In another embodiment of the present invention, the first
surface of the base member defines a plurality of raised members
within the recess that are structured to engage the solar panel and
to provide space between the first surface of the base member and
the solar panel. In one embodiment, the raised members within the
recess comprise an elongate rib.
[0008] In yet another embodiment, the first side of the base member
defines a first flange extending therefrom that is flush with the
first surface of the base member and the second side defines a
second flange extending therefrom that is flush with the second
surface of the base member. In one embodiment, the first flange
defines a first lip at the distal end of the first flange and a
groove between the first lip and the first side of the base member
and the second flange defines a second lip at the distal end of the
second flange and a groove between the lip and the second side of
the base member.
[0009] In still another embodiment of the invention, the base
member defines a second recess configured to receive a junction
box, wherein the second recess defines an aperture configured to
accommodate the wiring of the solar panel and to provide space for
air to circulate about the back of the solar panel.
[0010] Embodiments of the invention also provide a solar panel
array, comprising at least two solar panels and at least two
support members in accordance with the present invention. Each of
the support members comprises a base member having first and second
surfaces and first and second sides. The first surface of each of
the base members defines a recess configured to receive one of the
solar panels. In one embodiment, the first surface of each of the
base members defines at least one aperture within the recess to
enable air to circulate about the back of the corresponding solar
panel and to reduce the weight of the support member. The first
side of each base member defines a first flange extending therefrom
that is flush with the first surface of the base member, the second
side of each base member defines a second flange extending
therefrom that is flush with the second surface of the base
members. In one embodiment, the first flange of each base member
defines a first lip at the distal end of the first flange and a
groove between the first lip and the first side of the base member
and the second flange of each base member defines a second lip at
the distal end of the second flange and a groove between the second
lip and the second side of the base member. At least two support
members are positioned adjacent to one another such that the first
flange of one of the at least two support members overlaps said
second flange of the adjacent one of said at least two support
members.
[0011] The invention also provides a method of forming a solar
panel support member. In one embodiment, the method includes
providing a first mold defining a plurality of protuberances,
encasing the first mold with a form, and filling the first mold
with liquid polymeric material and aggregate. Thereafter, a second
mold is provided and positioned on the first mold within the form
and the first and second molds are urged together. Finally the
polymeric material is cured to form a support member in accordance
with the present invention and the support member is removed from
the first and second molds.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0012] Having thus described the invention in general terms,
reference will now be made to the accompanying drawings, which are
not necessarily drawn to scale, and wherein:
[0013] FIG. 1 is a perspective view illustrating a solar panel
support, according to one embodiment of the present invention;
[0014] FIG. 2 is front view illustrating the solar panel support of
FIG. 1;
[0015] FIG. 3 is a side view illustrating the solar panel support
of FIG. 1;
[0016] FIG. 4 is a rear view illustrating the solar panel support
of FIG. 1; and
[0017] FIG. 5 is a sectional view illustrating the solar panel
support of FIG. 4 along the lines 5-5;
[0018] FIG. 6 is a sectional view illustrating the solar panel
support of FIG. 5 along the lines 6-6;
[0019] FIG. 7 is a sectional view illustrating the solar panel
support of FIG. 4 along the lines 7-7;
[0020] FIG. 8A is a perspective view illustrating a first portion
of a mold for constructing the solar panel support of FIG. 1,
according to one embodiment of the present invention;
[0021] FIG. 8B is a side view illustrating the first portion of the
mold in FIG. 8A;
[0022] FIG. 8C is a top view illustrating the first portion of the
mold in FIG. 8A;
[0023] FIG. 8D is a sectional view illustrating the first portion
of the mold in FIG. 8C along the lines 8D-8D;
[0024] FIG. 8E is a sectional view illustrating the first portion
of the mold in FIG. 8C along the lines 8E-8E;
[0025] FIG. 8F is a sectional view illustrating the first portion
of the mold in FIG. 8C along the lines 8F-8F;
[0026] FIG. 9A is a perspective view illustrating a second portion
of a mold for constructing the solar panel support of FIG. 1,
according to one embodiment of the present invention;
[0027] FIG. 9B is a side view illustrating the second portion of
the mold in FIG. 9A;
[0028] FIG. 9C is a top view illustrating the second portion of the
mold in FIG. 9A;
[0029] FIG. 9D is a sectional view illustrating the second portion
of the mold in FIG. 9C along the lines 9D-9D;
[0030] FIG. 9E is a sectional view illustrating the second portion
of the mold in FIG. 9C along the lines 9E-9E;
[0031] FIG. 9F is a sectional view illustrating the second portion
of the mold in FIG. 9C along the lines 9F-9F;
[0032] FIG. 10 is a perspective view illustrating a solar panel
support and a solar panel, according to one embodiment of the
present invention; and
[0033] FIG. 11 is a perspective view illustrating a plurality of
solar panel supports and solar panels installed on a roof top,
according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0034] Embodiments of the present invention now will be described
more fully hereinafter with reference to the accompanying drawings,
in which some, but not all, embodiments of the inventions are
shown. Indeed, the invention may be embodied in many different
forms and should not be construed as limited to the embodiments set
forth herein; rather, these embodiments are provided so that this
disclosure will satisfy applicable legal requirements. Like numbers
refer to like elements throughout.
[0035] Referring to the drawings and, in particular, FIGS. 1-7,
there is illustrated a solar panel support member 10, according to
one embodiment of the present invention. The dimensions of the
support member 10 illustrated in FIGS. 1-4 are provided for
purposes of example only and may be modified depending on the
dimensions and configuration of the solar panel to be supported. As
illustrated in FIGS. 1, 2 and 4, the support member 10 includes a
base member 11 having first and second surfaces 14a, b and a first
pair of lateral sides 16a, b and a second pair of lateral sides
18a, b. The support member 10 can be formed of a variety of
materials including metal, wood, plastic or cementitious materials.
In one preferred embodiment, the support member 10 is formed of a
polymer concrete.
[0036] As illustrated in FIGS. 1 and 2, the front surface 14a of
the support member 10 defines a recess 12 structured to receive a
solar panel 20, as illustrated in FIG. 10. More particularly, the
width, length and depth of the recess 12 is such that the solar
panel 20 can be positioned within the recess with relatively
insubstantial gaps between the sides of the recess and the sides of
the panel and with the front of the panel being substantially flush
with the front surface 14a of the support member 10.
[0037] The support member 10 defines a plurality of apertures 22
therethrough within the recess 12. The apertures 22 can include
slots 24 and circular apertures 26 that advantageously allow for
circulation of air around the exposed areas on back of the solar
panel 20 and reduce the weight of the support member 10 by removing
excess material. The remaining material between the apertures 22
defines a framework that provides the structural strength to the
support member 10 to support the solar panel 20. The slots 24 and
circular apertures 26 are shown for illustration purposes only. The
dimensions and configurations of the apertures 22 can vary
depending on, without limitation, the size and shape of the support
member 10, the excess material that needs to be removed, and the
structural requirements of the support member and solar panel 14 as
determined by the weight of the support member and solar panel, the
anticipated wind forces and other ambient conditions, and the
load-bearing ability of the roof or other underlying structure to
which the support member will be anchored. According to another
embodiment of the present invention (not shown), the support member
defines a honey-comb configuration or pattern within the recess
12.
[0038] In one embodiment of the present invention, as illustrated
in FIG. 2, the support member 10 includes a second recess 28 that
is structured to receive or accommodate a junction box (not shown)
on the back of the solar panel 20. An aperture 30 may be provided
through the support member 10 within the second recess 28 to
accommodate the wiring of the solar panel 20 and to allow air to
circulate around the exposed surface of the junction box. In other
embodiments, the wiring of the solar panel 20 can be configured
substantially within the plane of the back surface of the solar
panel, in such case, the second recess 28 and aperture 30 may be
omitted.
[0039] As illustrated in FIGS. 1 and 2, the support member 10
includes a plurality of raised members 40 on the framework within
the recess 12 that contact the back of the solar panel 20 and
create a further gap between the support member and the back of the
panel, substantially increasing the exposed area of the back of the
panel so that air can circulate around a greater portion of the
back of the panel. The configuration of the raised members 40 can
vary. In the embodiment illustrated in FIG. 2, the raised members
40 are configured as elongate ribs. In other embodiments (not
shown), the raised members 40 can have other configurations,
including, without limitation, circular, elliptical, square, or
rectangular configurations.
[0040] As illustrated in FIGS. 1 and 3, the lateral sides 16a, b of
the support member define a pair of opposed first and second
flanges 32a, b. The first flange 32a extends from the first lateral
side 16a and is flush with the first surface 14a. The second flange
32b extends from the second lateral side 16b and is flush with the
second surface 14b. As illustrated in FIGS. 1 and 3, each flange
32a, b defines a lip 33 at the distal end of the flange and a
groove 35 between the lip and the corresponding lateral side 16a,
b. As illustrated in FIG. 11, a plurality of the support members 10
can be positioned on a roof top adjacent one another wherein the
first flange 32a of one support member 10 overlaps and secures the
second flange 32b of an adjacent support member to thereby
interconnect the support members and secure them to the roof top.
The first and second flanges 32a, b are secured together by the lip
33 of the first flange 32a being inserted into the groove 35 of the
second flange 32b and by the lip 33 of the second flange being
inserted into the groove 35 of the first flange. The support
members 10 are preferably positioned on a roof top so that the
second surface 14b of each support member is substantially flush
with, and parallel to, the plane defined by the roof top so that
the support members and solar panels 14 are relatively
inconspicuous and aesthetically blend into the covering of the roof
top. In other embodiments, the flanges 32a, b can be omitted and
the support member 10 secured to the roof top with fasteners via
apertures 36 (for example, as shown in FIGS. 2 and 4), which can
also be used to mount the support member and solar panel on a
vertical wall.
[0041] Referring to FIGS. 8a-8f and 9a-9f, there is illustrated a
two-part mold 34a, b that can be used to form the support member 10
using cementitious, metal or plastic materials, such as polymer
concrete. As can be seen, the individual parts of the mold have
protuberances and recesses corresponding to the apertures 22 and
recesses 12, 28 of the support member 10. The support member 10 is
formed by positioning the first part 34a of the mold within an
external form, such as a wood form. The cementitious, metal or
plastic material is pored into the first part of the mold 34a to
the height of the protuberances and then the second part 34b of the
mold is placed on top of the material and the first part of the
mold. The two parts of the mold 34a, b are then urged together to
form the support member and, thereafter, the material is allowed to
cool or cure. The second part of the mold 34b is then removed and
the support member removed from the first part of the mold 34a. If
necessary, apertures 36 can be formed in the support member 10 by
drilling.
[0042] The solar panel 20 is secured within the recess 12 of the
support member 10 using suitable fasteners and/or adhesives, such
as silicone caulk. The support members 10 can then be mounted to
the roof top either by overlapping the opposed flanges 32a, b
extending from the lateral sides 16a, b of the support member or
using fasteners.
[0043] Many modifications and other embodiments of the invention
set forth herein will come to mind to one skilled in the art to
which these inventions pertain having the benefit of the teachings
presented in the foregoing descriptions and the associated
drawings. Therefore, it is to be understood that the invention is
not to be limited to the specific embodiments disclosed and that
modifications and other embodiments are intended to be included
within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive
sense only and not for purposes of limitation.
* * * * *