U.S. patent application number 13/015921 was filed with the patent office on 2012-02-09 for hinged clip to eliminate rail.
This patent application is currently assigned to Northern States Metals Company. Invention is credited to Paul R. Cusson, Michael G. Greenamyer, Joseph A. Nobile.
Application Number | 20120031039 13/015921 |
Document ID | / |
Family ID | 45555034 |
Filed Date | 2012-02-09 |
United States Patent
Application |
20120031039 |
Kind Code |
A1 |
Cusson; Paul R. ; et
al. |
February 9, 2012 |
HINGED CLIP TO ELIMINATE RAIL
Abstract
A panel array support assembly has a lower support joist to
which are directly connected panel holding devices or clips. The
panel clips are configured so that the length of each clip extends
along the length of the lower support joist. The panel clips are
preferable configured to have a sliding top arm, which holds the
upper edge of the panel, and slides back so that they panel can be
placed on a lower holding arm.
Inventors: |
Cusson; Paul R.; (West
Hartford, CT) ; Greenamyer; Michael G.; (Salem,
OH) ; Nobile; Joseph A.; (Boardman, OH) |
Assignee: |
Northern States Metals
Company
West Hartford
CT
|
Family ID: |
45555034 |
Appl. No.: |
13/015921 |
Filed: |
January 28, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12880337 |
Sep 13, 2010 |
|
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|
13015921 |
|
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|
61371370 |
Aug 6, 2010 |
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Current U.S.
Class: |
52/831 ;
52/745.21 |
Current CPC
Class: |
F24S 25/636 20180501;
F24S 25/634 20180501; Y02E 10/47 20130101 |
Class at
Publication: |
52/831 ;
52/745.21 |
International
Class: |
E04C 3/02 20060101
E04C003/02; E04B 1/38 20060101 E04B001/38 |
Claims
1. A bi-directional panel array support assembly having at least
two lower support joists and at least two upper panel holding
structures rotatably attached to said lower support joists, said
upper panel holding structure comprising: a. at least one slidable
upper arm arranged to extend over a first external panel; and, b.
an integral wiring channel.
2. The bi-directional panel array support assembly of claim 1,
wherein said upper panel holding structure further comprises at
least one fixed lower arm opposite and parallel to said slidable
upper arm, said slidable upper arm and said fixed lower arm being
spaced to receive said first external panel.
3. The bi-directional panel array support assembly of claim 2,
wherein said upper panel holding structure further comprises a
second set of parallel arms arranged to receive a second external
panel.
4. The bi-directional panel array support assembly of claim 3,
wherein said second set of parallel arms are fixed and extend
perpendicularly to a longitudinal dimension of said upper panel
holding structure and opposite said slidable upper arm.
5. The bi-directional panel array support assembly of claim 2,
wherein said upper panel holding structure further comprises a
tubular structure supporting said upper and lower parallel
arms.
6. The bi-directional panel array support assembly of claim 5,
wherein said slidable upper arm is connected to said tubular
support structure by a slot extending over the length of said upper
panel holding structure.
7. The bi-directional panel array support assembly of claim 6, said
slidable upper arm interfaces with said slot by a closely fitted
protrusion on a lower end of said sliding arm.
8. The bi-directional panel array support assembly of claim 7,
wherein said tubular support structure comprises an upper wall
having a thickened area.
9. The bi-directional panel array support assembly of claim 8,
wherein said tubular support structure comprises a bottom wall,
said bottom wall comprising a T-slot.
10. The bi-directional panel array support assembly of claim 5,
wherein a lower one of said second set of parallel arms comprises
an upper wall of said integral wiring channel.
11. The bi-directional panel array support assembly of claim 10,
further comprising an elongated bead on said upper wall of said
integral wiring channel, said bead running an entire length of said
integral wiring channel.
12. The bi-directional panel array support assembly of claim 11,
wherein said integral wiring channel comprises a lower wall.
13. The bi-directional panel array support assembly of claim 12,
wherein said upper wall and said lower wall of said integral wiring
channel comprises substantially perpendicular projections.
14. The bi-directional panel array support assembly of claim 12,
wherein said upper panel holding structure further comprises a
T-slot arranged beneath said tubular structure, wherein an upper
wall of said T-slot is comprised by a lower wall of said tubular
structure.
15. The bi-directional panel array support assembly of claim 2,
wherein said upper panel holding structure further comprises a
plurality of fixed lower arms opposite and parallel to said
slidable upper arm.
16. The bi-directional panel array support assembly of claim 15,
comprising a plurality of slidable arms extended along a length of
each said upper panel holding structure.
17. The bi-directional panel array support assembly of claim 1,
wherein said panel array support assembly is foldable from a fully
deployed position to a collapsed position.
18. A method of installing panels onto a panel array support
assembly from above said assembly, said steps comprising: a.
deploying said panel array support assembly to receive said panels;
b. placing one end of a panel into two fixed arms of one side of a
support structure of said panel array support assembly; c. placing
an opposite end of said panel on at least one lower arm of a second
side of an opposite one of said support structure facing said first
support structure; and, d. sliding upper arms along a slot in said
second support structure above said panel.
19. A method of claim 18, further comprising the step of: e.
screwing said upper arms to said panel.
20. The method of claim 19, further comprising repeating steps b
through d.
Description
PRIORITY INFORMATION
[0001] This invention claims priority to U.S. application Ser. No.
12/880,337, filed Sep. 13, 2010, which in turn claims priority to
U.S. Provisional Application No. 61/371,370 filed Aug. 6, 2010,
making reference to both documents herein in their entireties.
FIELD OF THE INVENTION
[0002] This invention relates to support systems for panels and
panel-like structures, such as solar energy collection systems, and
more particularly to a support system for an array of photovoltaic
panels, and a method of quickly assembling the same for
activation.
BACKGROUND OF THE INVENTION
[0003] Many conventional photovoltaic (solar) panel arrays include
a plurality of solar panels optimally arranged for converting light
incident upon the panels to electricity. Various support systems
are used for attachment to roofs, free-field ground racks, tracking
units, or other substrates/structures. Typically, these support
systems are costly, labor-intensive to install, heavy, often
structurally inferior, and mechanically complicated. Once the
support structure is in place, mounting the solar panels on the
support structure can be very difficult. Further, some large solar
panels tend to sag and flex, thereby rendering the panel mounting
unstable. Panel repair and adjustment are also rendered more
difficult thereby.
[0004] A conventional two dimensional panel support system
generally includes off-the-shelf metal framing channels having a
C-shaped cross-section, such as those sold under the trademarks
UNISTRUT.TM. or BLIME.TM.. These are improvised for use as vertical
and horizontal support members. The photovoltaic (solar) panels 12,
or other panel-like structures, are directly secured to upper
support members (30 in FIG. 3) and held in place by panel clips or
panel holders 45 (as depicted in FIG. 3). These panel clips are
found in a wide range of sizes and shapes. The panel clips serve as
hold-down devices to secure the panel to the corresponding top
support members (30) in spaced-relationships. The clips 45 are
conventionally positioned and attached about the panel edges once
each panel is arranged in place.
[0005] In a conventional, free-field ground rack system for
mounting solar panels, as depicted in FIG. 1, vertical support
elements, such as I-beams 14, are spaced and securely embedded
vertically in the ground. Tilt mounting brackets 16, are installed
at the top of each I-beam, and each tilt mounting bracket is
secured to the I-beam such that a tilt bracket flange extends above
the I-beam at an angle as best seen in FIG. 2A. In this arrangment,
two UNISTRUT.TM. lower joists 20 span the tilt mounting brackets 16
and are secured thereto. As seen in FIG. 2B, UNISTRUT.TM. rails 30
are positioned across and fastened to lower lower joists 20. To
secure each rail 30 to the corresponding lower joists 20, a bolt
through a bolt hole made in the rail sidewall attaches to a
threaded opening in a nut plate (not shown) inserted inside the
channel of the UNISTRUT.TM. joist, so that the nut-like plate
engages and tightly secures against the upper flange of the joist's
C-channels as depicted in FIG. 2A.
[0006] Once the bi-directional matrix span 10 is assembled, each
solar panel 12 is secured in place by panel holding clips 45, at
least a portion of which are secured to the support rails about the
perimeter of each panel. At least a portion of the panel clips 45
are put in place, and tightened to support rails 30. This
installation process especially if involving multiple clips 45, is
often costly, inaccurate, dangerous and time-consuming.
[0007] Another example of a support system for panel like
structures is shown in U.S. Pat. No. 5,762,720, issued to Hanoka et
al., which describes various mounting brackets used with a
UNISTRUT.TM. channel. Notably, the Hanoka et al. patent uses a
solar cell module having an integral mounting structure, i.e. a
mounting bracket bonded directly to a surface of the backskin layer
of a laminated solar cell module, which is then secured to the
channel bracket by bolts or slideably engaging C-shaped members.
Other examples of panel support systems are shown in U.S. Pat. No.
6,617,507, issued to Mapes et al.; U.S. Pat. No. 6,370,828, issued
to Genschorek; U.S. Pat. No. 4,966,631, issued to Matlin et al.;
and U.S. Pat. No. 7,012,188, issued to Erling. All of these patents
are incorporated herein as reference.
[0008] Foldable support arrays 10 of upper support rails 30 and
lower support joists 20 are found in the newer art developed by the
inventors of the present application. One such example is depicted
in FIG. 4. A detailed view of the intersection between upper
support rail 30 and lower support joist 20 is depicted in FIG. 5.
The present inventor have developed a number of foldable support
systems for solar panels and other panel like structures. These are
listed in attached information disclosure documents.
[0009] The folding support arrays 10 of these support systems solve
many problems well known in the art of panel array supports.
However, even with a reliable, easily-deployed support array, there
are still difficulties in the installation of the panels
themselves, especially solar panel arrays. In particular, existing
support systems require meticulous on-site assembly of multiple
parts, performed by expensive, dedicated field labor. Assembly is
often performed in unfavorable working conditions, i.e. in harsh
weather and over difficult terrain, without the benefit of quality
control safeguards and precision tooling. Misalignment of the
overall support assembly often occurs, especially when mounting
panels to the upper rails 30 with clips 45. This can jeopardize the
supported solar panels.
[0010] Another problem is the spacing of the photovoltaic (solar)
panels 12. This is important to accommodate panel expansion and
contraction due to the change of the weather. It is important,
therefore, that the panels are properly spaced for maximum use of
the bi-directional area of the span. Different panel spacing may be
required on account of different temperature swings within various
geographical areas. It is difficult, however, to precisely space
the panels on-site using existing support structures and panel
clips 45, without advanced (and expensive) technical
assistance.
[0011] For example, with one of the existing conventional designs
described above (as depicted in FIGS. 2A and 2B), until the upper
rails 30 are tightly secured to the lower support joists 20, each
upper rail 30 is free to slide along the lower support joists 2
and, therefore, will need to be properly spaced and secured once
mounted on-site. Further, since the distance between the two lower
joists 2 is fixed on account of the drilled bolt holes through the
bracket, it is preferred to drill the holes on-site, so that the
lower joists can be precisely aligned to attach through the
pre-drilled attachment holes of the tilt bracket. Unfortunately,
the operation of drilling the holes on-site requires skilled
workers, and even with skilled installation, might still result in
misalignment (i.e. improperly spaced or slightly skewed from
parallel) of the support structure and/or the solar panels
supported by that structure.
[0012] An additional degree of difficulty is added by the necessity
of drilling holes 145 to accommodate connectors for the panel clips
or holders 45. If this is done on site, precise placement of the
solar panels becomes extremely difficult. Even if the apertures 145
are precisely drilled at the factory, an additional degree of
imprecision is introduced when the panel clips 45 have to be
connected to the upper support rails 30 while being positioned to
hold panels 12. This is an awkward arrangement, even in the hands
of expert installers. Normally, it is accomplished by connecting
one portion of the panel clip 45 to the upper support rail 30, and
then positioning panel 12 to be secured by another portion of panel
clip 45. Of necessity, this adds an additional assembly step for
each panel clip 45, while still offering opportunities to
accidently introduce misalignment in the overall panel array
10.
[0013] Misalignment difficulties are exacerbated by the flexing of
the panels 12 and sagging permitted by the natural flexibility of
the panels. The sagging of the panels can cause the panels to work
out of their holders, whether they would be holding clips or part
of the overall structure of the upper support rail. Improper
installation, which occurs frequently in conventional systems, can
lead to dislocation of the panels due to sagging or atmospheric
conditions. The use of a wide variety of different mounting
positions and panel array arrangements also exacerbates the
stability problems caused by panel sagging or deflection. Further,
certain mounting positions will make the panels 12 more vulnerable
to atmospheric disruptions, such as those created by wind and
precipitation. All of these variables also complicate electrical
connections to the panels.
[0014] One method of correcting misalignment is through the use of
larger and more effective panel clips 45. However, there are
drawbacks in this approach. In particular, there are only a limited
number of points at which panel clips can be connected.
Accordingly, even with enlarged panel clips 45, only extremely
limited portions of the lengths of panels can be secured.
[0015] The problems of misalignment due to sagging are further
exacerbated in some environments by the accumulation ice on the
panels. This adds additional weight without a commensurate
structural capability. Icing can also be a problem due to the
tendency of water to work into crevasse found throughout the
overall panel array 10. Icing can become particular problematical
with respect to panel clips 45 extending beyond the panels 12, or
the support rails 30. Accordingly, the use of larger panel clips 45
and increased numbers of them have typically added to the problems
of ice formation on the overall panel array 10.
[0016] Therefore, a need exists for a low-cost, uncomplicated,
structurally strong support system, and assembly method, so as to
optimally position and easily attach the plurality of photovoltaic
panels, while meeting architectural and engineering requirements.
Further, there is an urgent need for a panel support system that
will maintain the security of the mechanical connections of the
solar panels to support rails despite the flexing of the panels
(and support structure) caused by any of gravity, vibration, or
environmental factors. Likewise, there is an urgent need to
simplify the assembly of panel support systems, especially the
connections between the upper support rails and panel clips. Such
simplification should not compromise the stability or strength of
the connections between the panels and the support system.
[0017] At present, none of the conventional panel support systems
offers these capabilities. An improved support system would achieve
a precise configuration in the field without extensive work at the
installation site. The use of such an improved system would
facilitate easy placement of solar panels onto the support
structure. The shipping configuration of the improved support
system would be such so as to be easily handled in transit while
still facilitating rapid deployment. Rapid deployment must be
facilitated on any type of substrate providing stable support for
the panels, without damaging or otherwise compromising the panels,
or substrate. Rapid deployment would also include rapid mechanical
connection of the panels using simple panel clips in a manner that
would keep the panels secure despite panel flexing, or any number
of other factors. The preferred system would also minimize ice
accumulation on the panel array, especially at the panel clips.
SUMMARY OF THE INVENTION
[0018] It is a primary object of the present invention to improve
upon conventional photovoltaic solar panel systems, especially with
regard to assembly and installation.
[0019] It is another object of the present invention to provide a
support and installation system for solar panels in which the
panels are less likely to be damaged during installation.
[0020] It is a further object of the present invention to provide a
simplified support system for solar panels that is easily installed
while still facilitating a precise configuration.
[0021] It is an additional object of the present invention to
provide a solar panel support system that can be assembled very
quickly on site, due to fewer assembly steps.
[0022] It is still another object of the present invention to
provide a solar panel support system that can achieve close
tolerances during field installation without the necessity of
skilled on-site labor.
[0023] It is still an additional object of the present invention to
provide a solar panel support system which can be easily adapted to
a wide variety of solar panel array sizes and shapes.
[0024] It is yet another object of the present invention to provide
a solar panel support system which minimizes the necessity for
precise measurements at the installation site.
[0025] It is again a further object of the present invention to
provide a solar panel support system that can be arranged at a
variety of different positions and exposure angles.
[0026] It is still an additional object of the present invention to
provide a solar panel support system that can be precisely
configured to a specific environment.
[0027] It is another object of the present invention to provide a
support system for solar panels and other panel-like structures in
which degradation caused by metal-to-metal contact is substantially
reduced.
[0028] It is again another object of the present invention to
provide a support system for panel-like structures in which
accommodation is made for movement caused by changes in
temperatures, humidity or other environmental considerations.
[0029] It is still a further object of the present invention to
provide a simplified connection system for a solar panels using a
reduced number of parts.
[0030] It is still an additional object of the present invention to
provide a solar panel mounting system that can accommodate easy
installation and removal of panels on adjacent frameworks.
[0031] It is yet another object of the present invention to provide
a roof interface framework for a solar panel support structure
which allows easy installation of adjacent panel support systems,
without interfering with previously installed panels.
[0032] It is again an additional object of the present invention to
provide a panel support system that permits deployment of multiple
support structures on a wide variety of different substrates.
[0033] It is still another object of the present invention to
provide a panel support system wherein a wide variety of different
sizes and shapes of panel configurations can be accommodated, and
easily installed, as well as removed.
[0034] It is again a further object of the present invention to
provide a panel support system in which panels can be easily
attached to support brackets without incurring damage to the
panels.
[0035] It is still another object of the present invention to
provide a support system for panels or panel-like structures for a
wide range of uses, positions, and configurations.
[0036] It is still a further object of the present invention to
provide a panel mounting system which is entirely self-contained
with its own installation interface.
[0037] It is again an additional object of the present invention to
provide a panel mounting system which facilitates quick, secure
mounting of the panels once the support system is deployed.
[0038] It is yet another object of the present invention to provide
a panel support system that can accommodate flexing, sagging and
other deformation of the panels while maintaining a secure
connection thereto.
[0039] It is yet a further object of the present invention to
provide a panel mounting system which facilitates increased panel
clip capacity.
[0040] It is again an additional object of the present invention to
provide a panel mounting system that facilitates safe tightening of
panel clips.
[0041] It is yet another object of the present invention to provide
a panel clip or connector that can accommodate for flexing of both
the panel and the support system.
[0042] It is still a further object of the present invention to
provide a panel connection system that can facilitate rapid
installation while maintaining a secure hold on the panels or panel
like structures.
[0043] It is yet an additional object of the present invention to
provide support rails configured to ensure a secure panel
connection.
[0044] It is yet a further object of the present invention to
reduce the cost of panel support structures by eliminating the
overall length of structural aluminum, such as those currently used
in conventional systems, without sacrificing the strength of the
overall structure.
[0045] It is still an additional object of the present invention to
provide a panel support system admitting to substantial flexibility
of configuration.
[0046] It is again another object of the present invention to
provide a panel support system which limits ice formation at
various parts of the panel array.
[0047] It is again a further object of the present invention to
provide a panel support system having a profile which limits or
avoids overhanging structures extending from the supported
panels.
[0048] It is again another objection of the present invention to
provide a panel support system that accommodates folding for
transport.
[0049] It is still an additional object of the present invention to
provide a panel support system accommodating protection of panel
wiring.
[0050] It is yet a further object of the present invention to
provide a panel support system in which panel clips combine with
upper support rails providing reduced weight for the overall panel
support array.
[0051] It is again an additional object of the present invention to
provide a panel support system including panel clips that are not
susceptible to loosening, or allowing panels to shift as occurs
with conventional arrangements having separate support rails and
panel support clips.
[0052] It is the overall goal of the present invention to provide a
comprehensive panel mounting system that facilitates rapid, secure
installation, including deployment of the panel support structure,
and placement of the panels on that support structure.
[0053] These and other goals and objects of the present invention
are provided by a panel array support assembly having a lower
support joist and an upper panel holding structure detachably
mounted to said lower support joist, said upper panel holding
structure comprising at least one slideable upper arm arranged to
fit over an external panel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0054] Having generally described the nature of the invention,
reference will now be made to the accompanying drawings used to
illustrate and describe the preferred embodiments thereof. Further,
the aforementioned advantages and others will become apparent to
those skilled in this art from the following detailed description
of the preferred embodiments when considered in light of these
drawings, in which:
[0055] FIG. 1 is a perspective view of an assembled conventional
field ground rack support system for securing a plurality of solar
panels;
[0056] FIG. 2A is a side view of a conventional tilt bracket mount
with prior art C-shaped sectional channels secured back-to-back to
form support joists to which upper support rails, also shown in
FIG. 2B, are secured;
[0057] FIG. 2B shows an end view of prior art upper support rails,
each with a C-shaped sectional channel;
[0058] FIG. 3 is a perspective view of a previously-disclosed
support system in a configuration as used with solar panels
arranged in a column and in spaced relationship thereon;
[0059] FIG. 4 is a top view illustrating the bi-directional support
frame collapsed to an intermediate folded position;
[0060] FIG. 5 is an end elevation and partial sectional view
depicting a conventional arrangement of a lower support joist, and
upper support rail, and a panel clip;
[0061] FIG. 6A is an end view of a support clip of the present
invention, with a sliding arm in a first position;
[0062] FIG. 6B is a top view of FIG. 6A;
[0063] FIG. 6C is an end view of FIG. 6A with the sliding arm in a
second or withdrawn position;
[0064] FIG. 7 is a top view of a section of the sliding arm; and
FIG. 8 is a side view depicting a first installed panel and a
partially installed second panel.
[0065] FIG. 8 is a side view of a panel assembly according to the
present invention.
[0066] FIG. 9 is an end view of a second embodiment of the present
invention.
[0067] FIG. 10 is a side perspective view of a second embodiment of
the present invention.
[0068] FIG. 11 is an end perspective view of a second embodiment of
the present invention.
[0069] FIG. 12 is an end perspective view of the second embodiment
of present invention, depicting a connection to two external
panels.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0070] As has been previously discussed, conventional panel (solar
and other types) support systems tend to be constituted by two
dimensional arrays having lower support joists 20 and upper support
rails 30. Panel clips or holders 45 are then field-mounted on the
upper support rails so that the panels 12 can be placed thereon,
and secured with additional portions of the clips. Even with
factory pre-alignment and set up of support joists 20 and upper
support raised, conventionally, there is little that can be done
about the many assembly steps required to place both the panel
clips 45 and the panels on the upper support rails 30.
[0071] The present invention, as depicted in FIGS. 6(a-c), 7 and 8,
is a departure from this arrangement. Reinforced clip structure
400, as depicted in detail by FIGS. 6(a)-6(c), provides a
reinforced structure to serve as a clip, and as a substitute for
upper support rail 30, such as that provided in the conventional
art previously described herein. This substitution is performed
without detriment to the strength and stability of the overall
panel array system 10. The structural stability of the conventional
tubular upper support rail 30 depicted in FIG. 5 is provided by
tubular support structure 405 constituting the main body of
inventive support clip 400. The tubular support structure 405
includes two side walls 405(a), 405(b), a lower wall 405(c) and an
upper thickened wall 405(d). The upper thickened wall 405(d)
includes a threaded portion 405(e) to receive an external
connecting screw 406.
[0072] Inventive reinforced structure clip 400 is held to a
conventional lower support joist 20 (as depicted in FIG. 8) through
the use of a U-shaped structure, which operates as a slide. This
structure includes two extending legs 402(a), 402(b), which extends
on either side of the sidewalls of support joist 20 (not shown in
FIG. 6(a & c)). The two extending legs 402(a), 402(b) are
attached to the rest of clip structure 400 through horizontal
shoulders 401(a), 401(b), respectively. Besides forming the
U-shaped structure to attach clip structure 400, to a lower support
joist 20, the two shoulder structures 401(a), 401(b) also serve as
supports for external panels 12 (as depicted in FIG. 8).
[0073] T-slot 409 is provided between shoulders 401(a), 401(b) to
accommodate a bolt head (not shown) that passes through the lower
support joists 20 (depicted in FIG. 8). By using T-slot channel
409, the panel clip structure can be held securely to the lower
support joists 20, an advantage that was not easily achieved in the
conventional art where the panel clip had to be attached separately
to the upper support rail 30. By incorporating both the
conventional panel clip 45 and the conventional upper support rail
30 into the same structure, (clip structure 400), the present
invention has achieved superior structural integrity, as well as
greater simplicity. Further, enhanced stability is added by the
extending legs 402(a), 402(b), of the U-shaped structure so that
even greater stability between the two structures (clip structure
400 and lower support joists 20) is achieved than has previously
been possible with the conventional art.
[0074] It should be noted that clip structure 400 is preferably
made of aluminum. Conventional support joists 20, upon which the
clip structure 400 is mounted, are preferably made of steel.
Accordingly, provision must be made for some kind of barrier to
prevent a metal-to-metal contact between the aluminum clip
structure and the steel support joists. One way of effecting this
is through the use of a nylon gasket (not shown) formed over the
interior of the U-shaped structure formed by legs 402(a), 402(b),
and shoulders 401(a) and 401(b). The gasket can have a hole, to
accommodate the bolt (not shown) which will interface with T-slot
409. The gasket can be formed of nylon, and be contiguous over the
U-shape of the support clip 400. However, other gasket
configurations and arrangements can be used.
[0075] For example, the gasket, or gaskets, can be made to be
discontiguous, in a variety of shapes and sizes. Further, while
nylon has been proven to work admirably as an insulator, to prevent
metal-to-metal contact between aluminum and steel, other materials
can also be used. Thus, while some type of gasket is necessary
between clip structure 400 and support joists 20, virtually any
arrangement is permissible within the concept of the present
invention.
[0076] FIG. 6(b) depicts a top view of support clip 400. Included
in the view is an external tightening screw 406. The entirety of
the width of support clip 400 is approximately 13/4 inches.
However, while this is one preferred size, other sizes can be used
within the concept of the present invention. Also, the length of
slip structure 400 is shown to be foreshortened, and contain only a
single tightening screw 406. While this is suitable for one
embodiment of the present invention, not all embodiments of the
present invention are so limited.
[0077] In a first embodiment of the present invention, clip
structure 400 can be the approximate length of a conventional clip
45 (as depicted in the conventional art drawings). However, with
this configuration, the present invention would still suffer from
some of the drawbacks of the conventional art. For example, there
would still be a very limited number of points at which the panels
12 could be connected to an underlying support array. While this is
adequate for some panel support arrangements 10, this is not always
the case.
[0078] In another embodiment of the present invention, the length
of clip structure 400 can be much greater than that suggested in
FIG. 6(b). For example, the length of clip structure 400 can extend
for the entire length of the underlying support joists 20. An
appropriate number of tightening screws 406 and accompanying
threaded portions could also be provided based upon the
requirements of the specific panel array to be mounted. A
continuous connection between the clip structure 400 and the panel
that the clip is holding for a major portion of the length of that
panel provides a much more secure connection than is currently
available with conventional art. As a result, many panel flaws and
eccentricities (such as sagging, warping, or the like) can be
adequately addressed with the present invention.
[0079] Secure, contiguous connections are only part of the
advantage provided by the present clip structure 400. The present
invention further addresses the difficulties normally occurring
with placement and securing of panels during the assembly process,
and any subsequent repair or maintenance operations that might
require removal or adjustment of panels 12.
[0080] In order to appreciate the advantages of the present
invention, it is necessary to consider the parts of clip structure
400 that hold or otherwise interfacing with external panels 12.
Normally, the panels 12 would rest upon shoulders 401(a) or 401(b).
The upper part of the panel would interface with an upper fixed arm
such as 408. In order for clip structure 400 to hold an external
panel 12 using shoulder 401(b) and fixed arm 408, the panel 12
would have to be slid between these two fixed arms. While this may
be suitable for one side of the panel, the opposite side would
present severe problems if there is an attempt to mount the panel
12 in the same manner. Normally, a panel 12 would have to be slid
perpendicularly (in the Z axis extending out of the drawing) in
order to be fit into two fixed panel clips on either side of the
panel where the clip has fixed upper and lower arms, such as
shoulder 401(b) and fixed arm 408. While this may be practical in
some arrangements, it is very often not practical, so that even if
the sliding of multiple panels 12 is possible, it can be very
awkward.
[0081] The problem of mounting and dismounting panels 12 within
clip structure 400 is solved through the use of hinge or sliding
arm 410, a top view of which is depicted in FIG. 7. Sliding arm 410
is attached to the rest of the clip structure 400 by means of slot
410(b) and tightening screw 406. This means that the entirety of
sliding arm 410 is capable of being moved from the position
depicted in FIG. 6(a) to the position depicted in FIG. 6(c). In the
FIG. 6(c) position, sliding arm 410 is entirely clear of side wall
405(b). This allows a panel 12 (not shown therein) to be placed
atop shoulder 410(a) from the top of the clip structure 400, rather
than being slid sideways.
[0082] Movement of sliding arm 410 is controlled through tension
generated by spring 407 and tightening screw 406. The spring
tension generated can render movement of sliding arm 410 to be very
difficult. This difficulty can be easily overcome by means of
beveled shoulder 410(a) which allows sliding arm 410 to slide
easily over the top surface of structure 405(d). The movement of
sliding arm 410 is further facilitated by the beveled shoulder
408(a) of fixed arm 408. The result of this arrangement is that
sliding arm 410 can be effectively controlled so that it can be
slid back from its extended position (as depicted in FIG. 6(a)) to
a retracted position (as depicted in FIG. 6(c)), and held there
without any difficulty. Replacement of the sliding arm 410 into its
FIG. 6(a) position is easily facilitated by the same structures
that permitted easy sliding and retention in the retracted
position. Once sliding arm 410 is returned to the extended position
(as depicted in FIG. 6(a)), the panel 12 can be tightened in place
with little additional effort by simply operating tightening screw
406 to increase the tension of spring 407 on sliding arm 410 (and
thus the panel 12 being held firmly by sliding arm 410).
[0083] An example of the aforementioned operation is depicted in
FIG. 8. In this arrangement, lower support joists 20 are arranged
on a substrate 100 (which can be constituted by any surface from a
concrete slab, to a roof, to a metal mounting bracket, for example,
atop a tilt bracket for an extended length of joist). The lower
support joists 20 are held to the substrate by any number of
different, conventional mounting techniques, which has been
elaborated on in a substantial number of conventional art examples.
Further details of these mounting techniques are not necessary for
an understanding of the present invention.
[0084] Multiple clip structures 400 are mounted to the lower
support joists 20 as previously described, using the U-shaped
structure of the lower support clip, and if desired, bolts
extending through the support joists and into the T-slot 409 of
support clip 400. As depicted in FIG. 8, the right-hand panel 12
has been fit into a first support clip structure 400, and the
right-hand side of the panel is about to be lowered onto the far
right-hand clip structure 400 from above. The sliding arm 410 of
the far right-hand support clip 400 has been retracted, and is in
the same position as depicted in FIG. 6(c).
[0085] The arrangement depicted in FIG. 8 allows for very easy and
rapid deployment of panels 12, in a wide variety of different
configurations. The ease of mounting and dismounting panels 12 for
arrangements as depicted in FIG. 8 renders the installation and
maintenance of solar panel arrays much less expensive than is the
prevailing condition for conventional arrays.
[0086] A further advantage of the present invention is that the
sliding arm 410 can be arranged in virtually any length (along the
longitude of clip structure 400) that is considered desirable for a
particular panel array, or even individual panels. Accordingly, a
single panel array can contain any number of different lengths and
configurations of sliding arms 410 to better facilitate ease of
installation and security of the panels for a particular place in
the panel array, or even a particular panel. Likewise, because clip
structure 400 is arranged parallel to the lower support joists 20,
the numbers of tightening screws 406 can be changed as needed for a
particular place or position in the panel array. For example, a
three foot length of clip structure 400 could have two feet of
sliding arm 410 arranged at different positions along the length of
the clip structure 400. The lengths of sliding arm 410 could be
manufactured to have different numbers of slots for increasingly
secure connections between the sliding arm 410 and the panel 12 to
be held.
[0087] Besides the capability of customizing clip structure 400 for
a wide variety of uses, there are other advantages. The increased
flexibility facilitated by the subject invention is further
enhanced by the strength of tubular structure 405, which provides
reinforcement in the holding of the panel 12 that cannot be
duplicated with conventional arrangements. Even if sliding arm 410
provides only a limited amount of holding capability, the side
walls of tubular structure 405 hold the panels 12 solidly in place.
This holding capability limits panel sagging and warping. The
result is a much more stable panel array. This is especially
important when dealing with solar panels.
[0088] Another advantage with this embodiment of clip structure 400
is that there are far fewer surfaces and other structures for water
accumulation and ice formation. By limiting both, the present
design reduces environmental stresses on the overall panel system
and its supports. Since less weight must be supported, money can be
saved on underlying sub straight supports. If the array is deployed
on a structure, such as a roof, then there is far less stress on
that structure, minimizing chances of structural failure. Of
course, to minimize water accumulation and ice formation, the clip
structures 400 must be kept quite short in length. Because of the
effectiveness of clip structure 400, only short lengths are
required to securely hold panels 12 in many situations without
allowing the panels to become loosened. This arrangement is
sufficiently flexible and adaptable that a wide variety of
different panel arrangements and environmental conditions can be
adequately addressed.
[0089] In the embodiments depicted by FIGS. 9 through 12, the
combination panel clip/panel rail 500 is also supported by support
joists 20 (not shown). These embodiments are depicted as having
substantial length, generally equal to that of panel rails 20 in
the conventional art. This is generally different from the first
group of embodiments (FIGS. 6-8) in which the combined panel
clip/panel rail 400 is preferably of an abbreviated length.
However, it should be noted that the length of clip structure 500
can be adjusted so as to be shorter than the normal panel rail 20
length found in the conventional art. However, this is often not an
optimum arrangement.
[0090] The perspective view of FIG. 10 best depicts the variations
possible with these embodiments with the present invention. The
structure as depicted is a combined panel clip and panel rail 500.
In contrast with the earlier embodiments, there are no U-shaped
arms to fit on either side of a lower support joist 20. Rather,
this group of embodiments uses support from a support joist 20 (not
shown), using a bolt head (not shown) in T slot 509. Because of the
greater lengths preferred of clip structure 500, the U shaped arms
of the previous embodiments are not needed for extra support.
Rather, the plurality of bolts (not shown) in T slot 509 is
sufficient to hold clip structure 500 to the supporting lower joist
20 (not shown). Preferably, clip structure 500 runs the entire
length between two support joists 20 to provide a high level of
structural support.
[0091] Unlike one of the previous embodiments in which a plurality
of clip structures 400 are located along the length of support
joist 20, in the present embodiments clip structures 500 are
contiguous along the entire length of the span between support
joist 20 so that panels 12 are held securely along the entireties
of the panel edges facing clip structures 500. Further, this
support is particularly robust since is effected by a continuous
tubular structure 505 along the panel edges.
[0092] The panel clip/rail structure 500 is built on tubular
structure 505, which is constituted by two side walls 505(b),
505(a), an upper wall 505(d), and a lower wall 505(c). There is
additional thickening in at least a portion of upper wall 505(d) to
provide increased stiffness, and in an alternative embodiment to
provide a substrate for threading to receive a screw. Further, the
T slot structure 509 adds to the stiffness of the lower wall
505(c). Enhanced stiffness is also provided by the wiring channel
507. This structure is constituted by an upper wall 501, and a
lower wall 502. Both of these structures have angled extensions
501(a), 502(a), respectively to help hold the wire within wiring
channel 507. These angled extensions, 501(a), 502(a), respectively,
also provide additional stiffness along the length of clip
structure 500.
[0093] On one side of clip structure 500 is a fixed upper arm 508.
Parallel thereto is a lower wall 501, constituting the top wall of
wiring channel 507. The fixed upper arm 508 and the parallel lower
wall 501 are spaced apart from with each other so that thickness of
a panel 12 can be slid between the two. In the effect, the top wall
501 of the wiring channel serves in the same way as shoulder 401(b)
(in FIG. 6A) to support the panel 12 from beneath. The wiring
channel 507 and its top wall 501 run the entire length of clip
structure 500.
[0094] Preferably, the side wall 505(a) with the fixed upper arm
508 and the top wall 501 of wiring channel 507 faces an arrangement
such as that seen on the left side of the clip structure 500 in
FIG. 10. In this arrangement, hinge or sliding arm 510 can be slid
out of the way so that a panel 12 can be dropped in from above. The
panel 12 is supported from below by a series of short shelves 503,
such as that depicted in FIG. 10. The number of shelves 503 can be
adjusted based upon the length and weight of panel 12 to be
supported, as well as other environmental considerations. The use
of the sliding arm 510 on one side of the clip structure 500 allows
installation of panels 12 from above the support array, as depicted
in FIG. 8.
[0095] While the tightening screw 406 and the spring 407 are not
depicted in FIGS. 9 through 12, they can nonetheless be used (in an
alternative embodiment) in the same manner as depicted in FIGS. 6A
and 6C. However, in the embodiment depicted in FIGS. 9 through 12,
the hinge or sliding arm 510 can be secured to the rest of the
structure in other ways. For example, in one preferred embodiment a
slot 511 is formed in the top of clip structure 500 so that a
protrusion 512 in sliding arm 510 can interface therewith at any
point along the length of the clip structure 500. Virtually any
number of hinges or sliding arms 510 can be slid along slot 511 to
hold a panel 12. Screw slots 510(a) are provided so that sliding
arm 510 can hold the panel 12 to clip structure 500. This is done
by drilling a screw hole in the top of clip structure 500, or in a
framed panel 12.
[0096] The structure depicted in FIGS. 9-12 is such that there is
very little surface on which water can accumulate and form ice. For
example, slot 511 allows water to drain. The use of intermittent
shelves 503 limits lower surfaces on which water can accumulate.
Bead 513 on top wall 501 prevents water from migrating into the
corner of top wall 501 and side wall 505(a). The angle protrusions
501(a), 502(a) also prevent the accumulation of water. The top of
the structure is substantially flat, with the exception of sliding
arm 510. This reduces water accumulation and structures which can
accumulate ice. Further, most water falling on the top of both clip
structures 500 and the panels 12 is drained by slot 511. As a
result, the totality of this arrangement provides an anti-icing
configuration.
[0097] One advantage of using the sliding arms 510 over those
depicted in FIGS. 6A and 6C is that the sliding arms 510 do not
have to be installed until after the panel 12 is put in place.
There is no necessity of holding back a spring-biased sliding arm
while the panel 12 is installed from above. As a result, the
installation technique depicted in FIG. 8, wherein the panel 12 can
be installed from above the support array, can be carried out. This
is done by sliding one edge of panel 12 between fixed arms (either
those depicted in FIG. 6A, 6C, or those depicted in FIGS. 9-12),
and then allowing the other end of panel 12 to be placed onto a
lower support arm 503 before placing the hinged arms over the newly
placed panel 12. This is much more easily carried out if the hinged
arms do not have to be held back against a spring bias.
[0098] Further, the number of spring-biased hinged arms (in the
FIGS. 6A, 6C embodiments) is fixed in number. Any addition of
hinged arms requires drilling and placement of both screws and
springs. Deletion requires that the screws be removed. Both can be
arduous processes during the overall installation efforts. With the
embodiments of FIGS. 9-12, the hinges or sliding arms 510 can be
put in place simply by placing a protrusion 512 into slot 511, and
then sliding the sliding arm 510 to the desired point along the
length of clip structure 500. Any number of sliding arms 510 can be
used, based upon the requirements of the panels 12 being held and
the general environment.
[0099] While a number of preferred embodiments have been described
by way of example, the present invention is not limited thereto.
Rather, the present invention should be understood to include any
and all variations, modifications, adaptations, permutations,
derivations, and embodiments that would occur to one skilled in
this art in possession of the teachings of the present invention.
Accordingly, the present invention should be construed to be
limited only by the following claims.
* * * * *