U.S. patent application number 13/627467 was filed with the patent office on 2013-04-25 for support system for solar panels with modified joists.
This patent application is currently assigned to Northern States Metals Company. The applicant listed for this patent is Paul R. Cusson, Michael G. Greenamyer, Thomas P. Killar, JR., Bernard G. Petro. Invention is credited to Paul R. Cusson, Michael G. Greenamyer, Thomas P. Killar, JR., Bernard G. Petro.
Application Number | 20130098858 13/627467 |
Document ID | / |
Family ID | 48135106 |
Filed Date | 2013-04-25 |
United States Patent
Application |
20130098858 |
Kind Code |
A1 |
Cusson; Paul R. ; et
al. |
April 25, 2013 |
SUPPORT SYSTEM FOR SOLAR PANELS WITH MODIFIED JOISTS
Abstract
A foldable, bi-directional, two-tier panel support system
includes a wide variety of different configurations both for the
lower support joists and the upper panel rails. The overall array
is provided with additional strength through the use of various
diagonal and lateral supports running between adjacent upper panel
rails. Additional panel loads can be accommodated by extended
longitudinal beams on tilt brackets, and additional bracing
attached thereto.
Inventors: |
Cusson; Paul R.; (West
Hartford, CT) ; Greenamyer; Michael G.; (Salem,
OH) ; Petro; Bernard G.; (Campbell, OH) ;
Killar, JR.; Thomas P.; (Boardman, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Cusson; Paul R.
Greenamyer; Michael G.
Petro; Bernard G.
Killar, JR.; Thomas P. |
West Hartford
Salem
Campbell
Boardman |
CT
OH
OH
OH |
US
US
US
US |
|
|
Assignee: |
Northern States Metals
Company
West Hartford
CT
|
Family ID: |
48135106 |
Appl. No.: |
13/627467 |
Filed: |
September 26, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61539653 |
Sep 27, 2011 |
|
|
|
Current U.S.
Class: |
211/189 ;
29/428 |
Current CPC
Class: |
A47B 47/00 20130101;
F24S 25/12 20180501; Y02E 10/47 20130101; Y10T 29/49826 20150115;
F24S 25/65 20180501; F24S 2025/012 20180501 |
Class at
Publication: |
211/189 ;
29/428 |
International
Class: |
A47B 47/00 20060101
A47B047/00 |
Claims
1. A support system for an array of parallel panels, said support
system including a vertical tilt brackets supported by an
underlying substrate, and a foldable support array, said foldable
support array comprising: a) a connection interface for each said
vertical tilt bracket supporting at least two upper panel rails at
connection points; and, b) at least two diagonal supports arranged
between adjacent said upper panel rails, wherein said upper panel
rails are parallel to each other in a deployed position, and said
foldable array is collapsible so that said upper panel rails and at
least one of said diagonal supports are substantially aligned in a
package suitable for motor road transport.
2-9. (canceled)
10. A method of installing a foldable support array of upper panel
rails and diagonal supports to support an array of parallel panels
using on-site vertical tilt brackets, where said bi-level support
array is folded so that all elements are substantially aligned in a
package suitable for motor road transport, said method comprising
the steps of: a) unfolding said support array and attaching to said
on-site vertical tilt brackets; and, b) attaching diagonal supports
between adjacent upper support rails.
11. The method of claim 10, further comprising the steps of: c)
attaching panels to said upper panel rails by screws passing
through panel frames and into said upper panel rails.
12. The method of claim 11, further comprising the step of: d)
attaching auxiliary diagonal braces between at least one said
vertical tilt bracket and at least one said upper panel rail.
13. The method of claim 12, further comprising the step of: e)
attaching perpendicular lateral supports between two adjacent upper
panel rails.
14-15. (canceled)
16. The method of claim 10, wherein said foldable support array
further comprises lower support joists, said lower support joists
are rotatably connected to said upper panel rails to be unitarily
foldable so that said upper panel rails and said lower support
joists are substantially aligned with each other in a folded
position in a package suitable for motor road transport, and said
upper panel rails and said lower support joists are substantially
perpendicular to each other in a bi-level deployed position when
mounted on said vertical tilt brackets.
17. The method of claim 10, wherein adjacent said diagonal supports
are slanted in opposite directions when connected between adjacent
upper panel rails.
18. The method of claim 10, wherein at least two pairs of panel
rails are connected to each said vertical tilt bracket.
19. The support system of claim 1, further comprising steel bearing
washers at intersections between said diagonal supports and said
upper panel rails.
20. The support system of claim 1, wherein said at least two
diagonal supports are aligned opposite each other.
21. The support system of claim 20, further comprising: c) at least
one auxiliary diagonal support arranged from at least one said
upper panel rail to at least one said vertical tilt bracket.
22. The support system of claim 21, wherein said foldable support
array comprises two sets of two interconnected panel rails.
23. The support system of claim 20, wherein said vertical tilt
bracket comprises a C-channel, and at least one of said upper panel
rails comprises two substantially parallel members connected by a
median connecting member.
24. The support system of claim 20, wherein said foldable support
array further comprises lower support joists rotatably connected to
said upper panel rails and said foldable support array is
collapsible, so that said upper panel rails, said lower support
joists and at least one of said diagonal supports are substantially
aligned in a package suitable for motor road transport, and further
wherein said upper panel rails and said lower support joists are
substantially perpendicular to each other in a bi-level deployed
position mounted on said vertical tilt brackets.
25. The support system of claim 24, further comprising steel
bearing washers between said upper panel rails and said lower
support joists at intersections therebetween.
26. The support system of claim 25, wherein said connection
interface comprises an elongated longitudinal beam extending along
an upper portion of said vertical tilt bracket.
27. The support system of claim 26, further comprising an arcuate
support extending from said vertical tilt bracket to said extended
longitudinal beam.
28. The support system of claim 25, wherein said upper panel rails,
said lower support joists, and said diagonal supports are steel.
Description
PRIORITY INFORMATION
[0001] The present Utility application claims priority as a
continuation-in-part application from U.S. Provisional Patent
Application Ser. No. 61/539,653, filed Sep. 27, 2011 (now
abandoned); and priority as a continuation-in-part of U.S. patent
application Ser. No. 13/115,506, filed May 25, 2011 (currently
pending), which is a continuation-in-part of U.S. patent
application Ser. No. 12/686,598, filed Jan. 13, 2010 (now issued as
U.S. Pat. No. 8,256,169), which is a continuation-in-part of U.S.
patent application Ser. No. 12/567,908, filed Sep. 28, 2009 (now
issued as U.S. Pat. No. 8,240,109), which is a continuation-in-part
of U.S. patent application Ser. No. 12/383,240, filed Mar. 20, 2009
(now issued as U.S. Pat. No. 8,316,590). References made to all
listed applications, and their contents, are incorporated herein by
reference in their entirety.
FIELD OF THE INVENTION
[0002] This invention relates in general to support systems for
panels and panel-like structures, such as solar energy collection
systems. More particularly, the present invention is directed to a
ground-supported mounting system for an array of photovoltaic
panels, and a method of assembling the same for activation. The
panel support system can include a bi-directional, two-tier matrix
having specifically configured support, and bracing elements
arranged for attachment to a tilting ground substrate supported
system.
BACKGROUND OF THE INVENTION
[0003] A standard photovoltaic (solar) panel array includes a
plurality of substantially parallel solar panels 12 (FIG. 3),
optimally arranged for converting light incident upon the panels to
electricity. Various panel support systems are used for attachment
to roofs, free-field ground (supported by a ground substrate, such
as a concrete pad) racks (14, 15 in FIG. 1) or tracking units.
Typically, these support systems are costly, labor-intensive to
install, heavy, structurally inferior, and mechanically
complicated.
[0004] Placing the photovoltaic or solar panels 12 on the support
structure 10 can be very difficult, as can wiring of the solar
panels for array activation. Further, some large solar panels tend
to sag and flex, thereby rendering the panel mounting unstable.
Unstable panel arrangements also jeopardize the integrity of the
wiring arrangement, which is necessary for the photovoltaic panels
to be useful.
[0005] All of these difficulties are exacerbated when the solar
panel array is mounted at an angle, such as 45.degree. from
horizontal. Tilting support systems (16, 14 in FIGS. 1 and 3),
whether they are free-field ground racks or variable tilt racks
mounted on buildings, are examples of installations that can be
particularly difficult when mounting solar panel arrays. Examples
of conventional tilt-mounted configurations are depicted in FIGS.
1-3, 4a, 4b. Most structural, bi-directional arrays used for
mounting panels are designed so that optimum stress characteristics
occur when the support array is in a horizontal position. Placing
such an array at an angle to horizontal introduces an additional
set of stresses that can degrade the structural integrity of the
array under any number of conditions. Even if the tilt support for
the array is adjustable so that the array can be mounted to the
tilt support in a horizontal position, the stresses are still
introduced once the tilt support is moved so that the array is at
an angle to the original horizontal position. Also, in many cases,
the tilt support (such as tilt bracket 16) is not adjustable after
it is originally installed. Consequently, the panel array must be
mounted under the additional stresses created by placing the panel
array in a non-horizontal position. Very often, this is difficult,
time-consuming, and even dangerous.
[0006] With advanced rigging techniques, it is possible to effect
safe installation of support matrices or arrays 10 at
non-horizontal angles. However, this is normally done using special
rigging or installation equipment. Once this equipment is removed,
the stresses encountered when at the non-horizontal mounting angles
begin to take effect. These stresses are increased by environmental
conditions, such as the wind, rain or snow, may ultimately serve to
degrade certain structural numbers of the support matrix. The
amount of degradation depends upon the overall external force and
weight of the panel support matrix and the angle at which the
support matrix is ultimately placed in reference to those external
environmental forces. It has been discovered that tubular
structures (17 and 18 in FIG. 2a) especially those forming the
lower support joists (11, 13 in FIGS. 2a, 2b), can be especially
vulnerable to destructive stresses developed by a non-horizontal
mounting of the panel support matrix.
[0007] One traditional panel support system includes off-the-shelf
metal framing channels (upper members 19 constituting panel rails
15 in FIGS. 2a, 2b) having a C-shaped cross-section, such as those
sold under the trademarks UNISTRUT.TM. or BLIME.TM., improvised for
use as upper and lower support members forming the bi-directional
support matrix. The photovoltaic (solar) panels 12 or other
panel-like structures are directly secured to the support members
and held in place by panel clips or panel holders in a wide range
of sizes and shapes. The panel clips serve as hold-down and
grounding devices to secure the panel against the corresponding top
support member in a spaced relationship. The panel clips are
positioned and attached about the panel edges once each panel is
arranged in place on the bi-directional support matrix.
[0008] For a conventional free-field ground rack system (for
mounting solar panels) as shown in FIGS. 1-3, vertical support
elements, such as I-beams 14, are spaced and securely embedded
vertically in the ground or substrate. 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 or
top section extends above the I-beam at a 90.degree. angle to the
side of the tilt-mounting bracket as best seen in FIGS. 1 and 3. As
shown in this case, two UNISTRUT.TM. joists 13 span the
tilt-mounting brackets 16 and are secured thereto. As seen in FIG.
2b, UNISTRUT.TM. upper panel rails 15 are positioned across and
fastened to the lower support joists 13. To secure each upper panel
rail 15 to the corresponding lower support joists 13, a bolt
(through a bolt hole made in the rail sidewall) attaches to a
threaded opening in a transverse nut-like plate slideably mounted
inside the channel of the UNISTRUT.TM. rail, so that the nut-like
plate engages and tightly secures against the upper flange of the
joist's C-channel 11 as seen in FIG. 2a. Importantly, the width of
the plate is slightly less than the width of the channel, so that
the plate can be slideably adjusted in the channel, without the
plate rotating therein.
[0009] Once the bi-directional, two-tier support system 10 is
assembled, each solar panel 12 is mounted on a lower portion of
conventional panel holding clips which are secured to the upper
panel rails about the perimeter of each panel. The other portion of
the panel clips is put in place and tightened. This installation
process is usually inaccurate and time-consuming, even with
expensive, skilled installers.
[0010] Another conventional example of a panel support system 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
a bolt or slideably engaging C-shaped members. Other examples 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 examples of conventional systems are incorporated herein
by reference as background.
[0011] Notably, existing conventional 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. This can jeopardize the supported
solar panels 12, or other supported devices. Further, wiring of the
solar panels, once electrically connected, is also problematic in
conventional systems.
[0012] Proper spacing of the photovoltaic (solar) panels 12 is
important to accommodate expansion and contraction due to the
change in weather. It is also important that the panels are
properly spaced for maximum use of the bi-directional area of the
span. Different 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 without advanced (and expensive)
technical assistance.
[0013] For example, with one of the existing designs described
above (with reference to FIGS. 2a and 2b), until the upper panel
rails are tightly secured to the lower support joist, each rail is
free to slide along the lower support joists and, therefore, will
need to be properly spaced and secured once mounted on-site.
Further yet, since the distance between the two support joists is
fixed on account of the drilled bolt holes through the rails, it is
preferred to drill the holes on-site, so that the lower support
joists can be aligned to attach through the pre-drilled attachment
holes of the tilt bracket. Consequently, the operation of drilling
the holes on-site requires skilled workers, and even with skilled
installation, might still result in misalignment of the support
structure and/or the solar panels supported by that structure.
[0014] One major advantage of free-field ground racks, such as the
tilt brackets (14, 16) depicted in FIGS. 1, 2a and 3, is that very
large solar panel arrays can be supported. The space that permits
the elaborate support structure of a free field support, such as
those depicted, usually means that a very large solar array can be
accommodated, at least in the space available. Unfortunately, there
are limitations other than the available ground space.
[0015] In particular, the tilt bracket 16 in conventional
arrangements can accommodate only two lower support joists 20. This
substantially limits the size of the solar array that can be
accommodated. Conventionally, larger arrays require additional
ground or substrate installations to support additional tilt
brackets. This can be an expensive, an often intolerably awkward
option for creating substrate or ground support for large solar
panel arrays.
[0016] Even if arrangements can be made to support larger solar
panel arrays with expanded tilt bracket capacity, new problems
arise. For example, new sets of stresses are introduced by the
larger array when secured to its non-horizontal position provided
by the tilt brackets. These stresses have been examined, and
results indicate increased array warping or deflection, especially
over time. This can lead to a very unstable arrangement for holding
panels.
[0017] It is important to note that misalignment difficulties are
exacerbated by the flexing of the support array 10, and the sagging
permitted by the flexibility of the panels. The sagging of the
panels can cause the panels to work out of their clips or holders,
whether they are secured by separate 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 and/or changing
environmental conditions and stresses. A wide variety of different
mounting positions and array arrangements also exacerbate the
stability problems caused by panel sagging and deflection. Further,
certain mounting positions will make the panels more vulnerable to
environmental disruptions created by wind and precipitation.
Freeze-thaw cycles can also be a major factor. All of these
variables are further complicated by non-horizontal mounting of the
panel support array.
[0018] Existing panel clips or holders are generally configured to
avoid damage to the solar panel framework and to facilitate easy
installation, often at the cost of panel security. Once panels
loosen, the integrity of the electrical connections (in particular
ground connections) between the panel and the supporting panel rail
30 is compromised. While a break of the electrical circuit is not
necessarily the immediate result, resistance will increase at the
loosened connections, thereby degrading electrical efficiency. If
such a condition persists, degradation of the metal at the
electrical contact points can also occur, thereby even further
degrading the electrical system.
[0019] Conventional panel clips or holders can be problematical for
a number of reasons. Firstly, installation for use of the clips is
very time-consuming, even for skilled installers. If the clips are
not sufficiently tight, loosening of the panels will certainly
occur. If the clips are overly tight, the panels can be deformed or
otherwise degraded. Further, the cost of numerous panel clips, as
well as the gaskets that are used therein, can substantially
increase the overall equipment costs, as well as add adding to the
installation costs.
[0020] The arrangements depicted in FIGS. 1, 3, 4a, 4b, and 5a are
limited to rather constrained configurations. In particular, only
two support joists 20 can be mounted on the ground support and tilt
bracket configuration (14, 16). This severely limits the size and
shape of the solar panel arrays that can be used with this type of
ground support. If sufficient space exists and the ground support
and tilt bracket configuration (14, 16) are sufficiently strong,
then larger panel arrays with more than two support joists 20 would
be highly desirable.
[0021] Therefore, a need exists for a low-cost, uncomplicated,
structurally strong support system and assembly method, so as to
optimally position and easily attach a plurality of photovoltaic
panels while meeting architectural and engineering requirements,
especially with regard to durability. Likewise, there is an urgent
need for a non-horizontal mounted solar panel system that will
maintain the security of the mechanical connections of the solar
panels to panel rails despite the flexing of the panels (and
support structure) caused by gravity, vibration, and the other
environmental factors previously discussed.
[0022] At present, none of the conventional systems has these
capabilities. With this invention, an improved panel support system
is achieved having a more precise configuration in the field,
without requiring extensive and extra work at the installation
site. The use of such an improved system would facilitate easy
placement of solar panels onto the support structure. Further, a
simple panel holding arrangement could be used within the overall
concept of the system, while providing secure mechanical and
electrical connections. The shipping configuration of the improved
support system would be such so as to be easily handled in transit
while still facilitating rapid deployment. With this invention,
rapid deployment on a ground support and tilt-mounting bracket
would not sacrifice stable support for the panels. Rapid deployment
includes rapid mechanical and electrical connections of the panels
to panel support rails in a manner that keeps the panels
electrically and mechanically secure, despite panel flexing caused
by the several factors discussed.
SUMMARY OF THE INVENTION
[0023] It is a primary object of the present invention to improve
upon conventional photovoltaic solar panel systems, especially with
regard to assembly, wiring, and overall installation
durability.
[0024] It is another object of the present invention to provide a
support and installation system for solar panels in which the
panels and installation site are less likely to be damaged during
installation.
[0025] It is a further object of the present invention to provide a
support system for solar panels that is easily installed on-site
while still resulting in a precise configuration for purposes of
mounting the solar panels.
[0026] It is an additional object of the present invention to
provide a solar panel support system that can be assembled very
quickly on-site.
[0027] 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 labor at the installation site.
[0028] 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.
[0029] 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 during
installation.
[0030] 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 ground environment.
[0031] 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.
[0032] 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 wind, changes in
temperatures, or other environmental conditions.
[0033] It is again another object of the present invention to
provide a flexible arrangement for adapting a solar panel support
system to accommodate a wide variety of different panel
configurations.
[0034] 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.
[0035] It is still a further object of the present invention to
provide a folding solar panel support system in which rotation of
structural members with respect to each other can be advantageously
controlled.
[0036] It is yet another object of the present invention to provide
panel clips for a solar panel support structure which allow easy
installation without interfering with adjacent panels.
[0037] It is still an additional object of the present invention to
provide a collapsible panel support system wherein deployment of
the support system using rotating connection members can be
precisely adjusted.
[0038] It is again a further object of the present invention to
provide a panel support structure which integrates easily in a wide
range of mounting sites, and needs minimal mounting or deployment
time.
[0039] 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 structures.
[0040] It is again an additional object of the present invention to
provide a panel support system in which the relative rotation of
the structural members to each other, when deploying the support
system, is carefully calibrated and controlled without adjusting or
tightening of the rotating joints at the installation site.
[0041] It is still another object of the present invention to
provide a panel support system which can be easily fixed to a
"hard" mounting ground support using bolts, without causing damage
to the panel support system.
[0042] It is yet another object of the present invention to provide
a panel support system that can be easily deployed or removed by
rotating intersecting structural members, without fouling, jamming
or binding at the intersections of the structural members.
[0043] 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, without
complex panel-holding devices.
[0044] 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.
[0045] It is yet a further object of the present invention to
provide a panel mounting system which facilitates easy electrical
connections to the panels.
[0046] It is again an additional object of the present invention to
provide a panel support system that facilitates secure and easy
connection and disconnection of electrical wires running throughout
the system.
[0047] It is still another object of the present invention to
provide a panel support system that facilitates secure electrical
connections between the panels and the supporting panel rails under
a wide variety of conditions and circumstances.
[0048] It is again a further object of the present invention to
provide a panel support system that accommodates secure support
when positioned in a non-horizontal position.
[0049] It is yet another object of the present invention to provide
a panel support system that reduces degradation due to metal
fatigue, even when the support system is exposed to extreme weather
conditions when mounted in a non-horizontal position.
[0050] It is again a further object of the present invention to
provide a panel support system that aligns and installs easily to
substrate support installations.
[0051] It is still an additional object of the present invention to
provide a panel support system that holds up to the accumulation of
snow and/or water, as well as shifting forces and torque caused by
wind, particularly when the support system is mounted in a
non-horizontal (i.e. inclined) position.
[0052] It is still another object of the present invention to
provide a panel support system that is particularly effective with
ground supported, tilt bracket installations.
[0053] 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,
placement of the panels on that support structure, and wiring of
the panels for activation.
[0054] These and other goals and objects of the present invention
are achieved with a support system for an array of parallel panels,
wherein the support system includes vertical tilt brackets
supported by an underlying substrate. This support system also has
a foldable support array which includes a connection interface for
each vertical tilt bracket supporting at least two upper panel
rails at connection points, and at least two diagonal supports
arranged between adjacent upper panel rails. The foldable support
array is arranged so that the upper panel rails are parallel to
each other in a deployed position and is collapsible so that the
upper panel rails, and at least one of the diagonal supports are
substantially longitudinally aligned with each other in a package
suitable for motor road transport.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] 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:
[0056] FIG. 1 is a perspective view of an assembled conventional
field ground rack support system for securing a plurality of solar
panels;
[0057] 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 panel rails, also shown in FIGS.
2b, are secured;
[0058] FIG. 2b shows an end view of prior art upper panel rails,
each with a C-shaped sectional channel;
[0059] FIG. 3 is a perspective view of a previously-disclosed,
inventive support system in a configuration as used with the
instant invention showing solar panels arranged in a column and in
a spaced relationship thereon, wherein the support system has
horizontally-aligned lower support joists and (relative thereto)
vertically-aligned upper panel rails;
[0060] FIG. 4a is a top plan view of the bi-directional span of the
assembly as used in the instant invention, in the open position
showing vertically-aligned upper panel rails attached atop
horizontally-aligned lower support joists;
[0061] FIG. 4b is an end elevational view of the bi-directional
span of the assembly shown in FIG. 4a;
[0062] FIG. 5a is a top view illustrating the bi-directional
support frame of the assembly shown in FIG. 4a collapsed to an
intermediate semi-folded position;
[0063] FIG. 5b is a top view depicting, in enlarged detail, the
support system in a collapsed or folded position, and in
particular, a steel bearing washer between the upper panel rail and
the lower support joists, as well as a connector for holding the
lower support joist to a support and/or tilt bracket or similar
structure, i.e. held between adjacent, folded panel rails;
[0064] FIG. 5c is a side view of FIG. 5b depicting the steel
bearing washer and the connector for holding the lower support
joist to a support and/or tilt bracket or similar structure;
[0065] FIG. 6 is an end view of a lower support joist used as part
of the present invention;
[0066] FIG. 7a is a top view of a support system configured with
diagonal cross supports according to the present invention;
[0067] FIG. 7b is an end view of the support system of FIG. 7a;
[0068] FIG. 7c is a side view of the support system of FIG. 7a;
[0069] FIG. 7d is a front view of a portion of the support system
of FIG. 7c;
[0070] FIG. 7e is yet another view of a portion of the support
system of FIG. 7d;
[0071] FIG. 8 is an end perspective view of the lower support joist
of the present invention with a plurality of upper panel rails
attached thereto;
[0072] FIG. 9 is a side perspective view of a tilt mounting bracket
used as part of the present invention;
[0073] FIG. 10 is an end perspective view of the tilt mounting
bracket of FIG. 9;
[0074] FIG. 11 is a front perspective view of a lower support joist
of the present invention;
[0075] FIG. 12 depicts a top perspective view of an alternative
longitudinal beam used in the configuration of the present
invention;
[0076] FIG. 13 is a side view of an alternative arrangement for a
ground-mounted tilt structure; and
[0077] FIG. 14 is a front perspective view of an additional
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0078] The present invention is used in the conventional
environment depicted in FIGS. 1-2(b), and is an improvement upon
the previously disclosed inventions depicted in FIGS. 3-5(a-c). The
previously disclosed inventions by some of the same inventors are
found in U.S. patent application Ser. No. 12/383,240 (filed Mar.
20, 2009); U.S. patent Ser. No. 12/567,908 (filed Sep. 28, 2009);
and, U.S. patent application Ser. No. 12/686,598 (filed Jan. 13,
2010). All of these patent applications describe the referenced
support systems. The present patent application relies on all three
for priority and incorporates all by reference for purposes of
providing a more complete background for the instant invention.
[0079] FIGS. 3-5(a-c) are relied upon as disclosing the
bi-directional, two-tier panel support matrix environment in which
the improvements of the present application operate. Only a summary
of the structures depicted in FIGS. 3-5(a-c) is provided herein,
sufficient for an understanding of the background of the present
invention. Full, detailed descriptions of the structures depicted
in FIGS. 3-5(a-c) are found in the aforementioned, incorporated
applications.
[0080] A summary of certain aspects of the previous inventions
incorporated herein by reference is provided below. In accordance
with one previously described inventive embodiment constituting the
background of which the present invention is an improvement, FIG. 3
depicts a support system 10 for an array or photovoltaic array of
solar panels 12, attached to a conventional, free-field vertical
support arrangement (14, 16). The support system 10 is constituted
by a bi-directional, two-tier support frame of horizontally-aligned
lower support joists 20 and vertically-aligned upper panel rails 30
(identified as 30-1 through 30-n), as also seen in FIGS. 4a and
4b.
[0081] For purposes of convenience when describing the new
embodiments of the present invention, the orientation description
of "upper" and "lower" will be used. While the array of support
system 10 can be placed in any orientation with respect to
longitudinal or latitudinal descriptors, for the sake of clarity
the present invention always has lower support joists 20 and upper
panel rails 30. The designation of "upper" and "lower" appears to
be the most straight-forward for dealing with the two-tier aspects
of the new invention considered herein.
[0082] The terminology "support joist" has been used previously
with regard to the prior art structural members 11, 13. The same
functional type of lower structural member is designated here as
"lower support joist" 20 for the descriptions of both past and
present inventive embodiments. The upper structural member,
previously denoted as an upper support rail 15 is more accurately
described by the designation "upper panel rail" 30 in the present
embodiments. This is appropriate since the structural element 30,
denoted as an upper panel rail 30, is always located above lower
support joist 20 and constitutes the elements to which the external
solar panels 12 are held to the support system 10.
[0083] In one alternative to the first support system 10 described
above, the bi-directional, two-tier support system 10 can have the
lower support joists 20 aligned along the length of tilt-mounting
brackets 16. As a result, upper panel rails 30 extend
longitudinally, as described and depicted in the subject previous
applications. It should be understood that within the context of
the present invention any orientation of the substantially
perpendicular structural elements (lower support joists 20 and
upper support rails 30) can be used.
[0084] Further, a wide variety of different shapes, sizes and
configurations are encompassed by the concept of the present
invention, which is not to be limited by the examples provided
herein. The present array of support members (20, 30) can be
adjusted to conform to any support structure or any "footprint"
available for the deployment of solar panels 12, or any other
panel-like structure to be supported by the present invention.
Further, as described infra, both the upper panel rails 30 and
lower support joists can be modified.
[0085] The present invention is directed in particular to the use
of a folding support system 10 mounted on a tilt bracket ground
support substructure, in particular, vertical ground supports 14
depicted in FIGS. 1, 2a and 3. The various embodiments of the
present invention include modifications to the tilt-mounting
brackets 16 and the lower support joists 20, as well as
improvements to the interface between the two. These improvements
are meant to address the different stresses caused by
non-horizontal mounting in conjunction with increased panel array
sizes, and various and ever changing environmental forces caused by
wind, snow and rain. This increased capability is provided without
degrading the convenience of off-site pre-assembly, compact
transport configuration or rapid deployment of earlier versions of
the folding support system 10.
[0086] One variation of the present invention is the increased size
of the tilt-mounting bracket 16 as depicted in FIG. 13. In distinct
contrast to the earlier versions depicted in FIGS. 1, 2a and 3, the
tilt-mounting bracket 16 is sized to accommodate more than two
lower support joists 20. As a result, longer panel rails 30 can be
supported, and much larger solar panel arrays 12 can be
accommodated. A major advantage is that only one ground support,
such as concrete pier 2 shown on FIG. 13, is required for each tilt
bracket 16. While a stronger vertical support 14 is needed for the
increased weight, an increase in expense for such support
structures is relatively minor compared to the economic benefit of
the increased size of the panel array 10 being supported.
[0087] While the cost of the increased size of vertical support 14
(and its substrate interface 2) is not necessarily significant, the
cost of the enlarged tilt-mounting bracket 16 can be. For example,
tilt-mounting bracket 16 in FIG. 13 can be constituted by a
structural truss, depending upon the size of panel array 10 that is
to be supported, as well as the use to which the overall structure
is to be put. For example, the overall structure can be used as a
shelter, carport, or the like. Consequently, the overall size of
the structure and the panel array 10 can be virtually any value
that can be accommodated for the size of the installation site.
Accordingly, additional variations are appropriate.
[0088] Different variations are found in the different designs
depicted in FIGS. 9 and 10, as well as that depicted in FIG. 12. In
both cases, a longitudinal beam 60 is located atop (or as part of)
the tilt-mounting bracket 16.
[0089] In FIGS. 5 and 10 the longitudinal beam 60 forms the
extended length of the top of the tilt-mounting bracket 16, being
welded thereto. In contrast, longitudinal beam 60 in FIG. 12 is not
welded to tilt-mounting bracket 16. Rather, longitudinal beam 60 is
configured to interface with certain structural aspects of the
tilt-mounting bracket 16, and can be connected thereto in a wide
variety of different techniques, such as bolting. This arrangement
admits to greater flexibility, and can accommodate a wider range of
longitudinal beam 60 sizes and configurations. As a result, the
selection of longitudinal beam 60 size and configuration can be
made based upon the load to be placed upon the overall structure so
that a more stable structure can be obtained.
[0090] In FIGS. 9 and 10, an L-shaped channel as beam 60 is
depicted. It should be noted that the tilt-mounting bracket 16 can
be formed with a substantial top surface 161 or only a top edge
welded so that the longitudinal beam 60 forms the top surface of
the tilt-mounting bracket 16. Either variation is entirely
acceptable within the concept of the present invention. While the
longitudinal beam 60 is depicted as an L-shaped structure, other
shapes are permissible within the concept of the present
invention.
[0091] Tilt-mounting bracket 16, as depicted in FIGS. 9 and 10, has
a sidewall 162 and two end walls 163(a), 163(b). As depicted, the
top wall 161 is constituted by one side (top side 61) of the angle
iron constituting longitudinal beam 60. The top side 61 of
longitudinal beam 60 (constituted by an L-channel with sides 61,
62) includes a slotted aperture 1611 for alignment of the lower
support joists 20 of support matrix 10. This is used to receive
connecting bolts that hold a lower support joist 20 to the combined
longitudinal beam 60 and tilt-mounting bracket 16, which helps to
align the support matrix 10 during the unfolding step. Preferably,
the combined tilt-mounting bracket structure (16, 60) is made of
steel, as is the lower support joist 20. The bolts can be any type
currently used to hold the support matrix 10 to the tilt-mounting
bracket 16. As stated, the slotted opening 1611 provides a level of
adjustability that helps facilitate easy alignment and connection
of the support matrix 10 to the tilt-mounting bracket 16 (as
supported by substrate support structures 14, 2).
[0092] It has already been noted that the ground support or
substrate support structure 2 and vertical beam 14 must be larger
to accommodate the weight of an increased panel array 12. Likewise,
the tilt-mounting bracket 16 is preferably modified to accommodate
the greater weight and dimensions of the larger support system 10
and the panels 12 that are ultimately contained therein. The
tilt-mounting bracket 16 is not part of vertical support 14 in
these embodiments. Consequently, it must be attached thereto. To
accommodate the greater weight, a more elaborate and robust
connection scheme is needed. Consequently, the sidewall 162 of the
tilt-mounting bracket 16 contains slotted openings 1621 (for bolts)
to more easily mount it to the vertical support 14 and to provide
greater structural stability. Also, increased connectivity to the
longitudinal beam 60 must be facilitated to maintain the necessary
structural stability. One such method is to use the L-shaped
channel as the longitudinal beam 60 formed as part of the
tilt-mount bracket 16 as discussed.
[0093] In the embodiment depicted in FIG. 12, the longitudinal beam
60 is separate from the tilt-mounting bracket 16. It must be fitted
to the top of the tilt-mounting bracket 16 before support system 10
is deployed. In this embodiment, because longitudinal beam 60 is
longer than that in FIGS. 9 and 10, mounting the longitudinal beam
60 on the tilt-mounting bracket 16 can be somewhat awkward. To
facilitate easy mounting, the tilt bracket 16 of either or both of
end walls 163(a) or 163(b) is provided with an alignment finger
165. A slotted guide opening 65 on the upper surface 61 of
longitudinal beam 60 allows an easy fit of the longitudinal beam
onto the tilt-mounting bracket 16. The looseness of the interface
between slotted guide opening 65 and the alignment finger 165
permits easy adjustment of beam 60 on tilt-mounting bracket 16
before the final connectors are tightened, holding the longitudinal
beam 60 to the tilt-mounting bracket 16.
[0094] Because the present invention allows for longer longitudinal
beams 60, a drawback occurs when increasing the size of the
supported panel array. In particular, as longitudinal beam 60
becomes longer, more support is needed to support longitudinal beam
60 and the overlying extended support matrix 10. This is especially
true at the ends of the longitudinal beam 60, which tends to sag
under the extra weight of panel support system 10, and its load of
panels 12.
[0095] To address this situation, arcuate vertical bracing 80 is
applied to the tilt-mounting brackets 16, as depicted in FIG. 9.
The arcuate vertical brace 80 is connected to the sidewall 162 of
tilt-mounting bracket 16. The end surfaces 163(a), 163(b) of the
tilt-mounting bracket 16 are cut so that the arcuate vertical brace
80 fits into the resulting openings and is welded to the end
surfaces 163(a), 163(b). These help support the arcuate vertical
brace 80. However, other support is needed and is preferably
provided by welding the arcuate vertical brace 80 to the sidewall
162 of tilt-mounting bracket 16. While welding is preferred, other
connection methods, such as bolts, can also be used. Further, any
combination of welding and bolting is also appropriate. With regard
to the design shown in FIGS. 12a and 12b, an angled support member
82 (best seen in FIG. 8) is used for added structural support.
[0096] The use of larger panel arrays 10 on ground supported
tilt-mounting brackets 16 of this invention leads to additional
weight and stresses on the lower support joists 20, especially the
tubular structures relied upon in the aforementioned patent
applications, incorporated herein by reference. These stresses are
substantially increased by environmental factors such as wind,
precipitation, and freeze cycles. Over long periods, tubular
structures which are entirely adequate for smaller support arrays,
begin to experience metal fatigue when arrayed in larger area
configurations. Even if this metal fatigue does not result in
immediate failure, additional deformation and panel loosening can
result.
[0097] The inventive solution to this difficulty is a new design
for the lower support joist 20, depicted in FIGS. 6 and 8. This
type of lower support joist 20 includes an upper member 21 and a
lower member 22, each substantially parallel to the other member. A
median connecting member 23 extends between the two parallel upper
and lower members 21, 22. While the median connecting member 23 is
depicted in FIGS. 6 and 8 as being perpendicular to the parallel
upper and lower members 21, 22, the support joist 20 of the present
invention is not limited thereto. Rather, the median connecting
member 23 can be diagonal, extending between opposite rear edges of
the parallel upper and lower members 21, 22. Further, the median
connecting member 23 could be a curve such as an S-shaped
structure, or any other structurally appropriate configuration.
[0098] The outer, opposite edges of the upper and lower members 21,
22 have angled end portions 211, 221, respectively. The end
portions can be straight, as depicted in FIG. 6, or they can be
curved. These end portions 211, 221 help strengthen the overall
support joist 20. However, additional functionality can be obtained
when the end portions 211, 221 are curved to serve as wiring
troughs, or even drainage structures.
[0099] The lower support joists 20 are connected to the supporting
longitudinal beams 60 using bolts 240 as depicted in FIG. 11.
Slotted openings 24 are formed in the lower member 22 to facilitate
easy connection between the panel support system 10 and the
tilt-mounting bracket with longitudinal beam assembly (16, 60). As
previously described with respect to the cited folding panel
support system 10 design, only connection to one longitudinal beam
need be made in order to allow the entire panel support system 10
to be unfolded and then be fully deployed for complete
connection.
[0100] Besides easy connection, the slotted openings 24 also
provide a means for draining precipitation. It is important to note
that if the slotted openings 24 prove to be inadequate for
precipitation drainage, then additional openings (not shown) can be
formed in the lower member 22 of support joist 20.
[0101] An additional expedient for strengthening the lower support
joist 20 and the overall panel support system 10 is the use of
diagonal braces 70 as depicted in FIGS. 7a-7d. The key aspect of
the cross-bracing arrangement is constituted by cross-braces 70
arranged in a substantially A-shaped configuration. Preferably,
diagonal braces 70 are U-shaped channels which rest upon lower
support joists 20. More specifically, these diagonal braces 70 rest
on the upper members 21 of lower support joists 20, on the same
surfaces as upper panel rails 30. The diagonal braces 70 are
arranged between panel rails 30 to form the A-shaped configuration
depicted in FIG. 7a. While a U-shape for the diagonal brace 70 is
preferred, any number of other shapes can be used to affect the
necessary bracing on the lower support joist 20 of the panel
support system 10.
[0102] As depicted in FIG. 7a, the diagonal braces 70 are connected
to the lower support joists 20 at three separate points. The
diagonal braces 70 need to be pre-connected to the folding panel
support system 10 only at the middle portion in order to permit
folding of the entire structure 10 as previously described with
respect to the earlier folding array configurations. The ends of
each diagonal brace 70 are then bolted to one of the upper members
21 of the lower support joist 20 once the entire panel support
system 10 has been unfolded for deployment.
[0103] The diagonal bracing configuration of FIG. 7a results in
less deflection than a support matrix 10 having only parallel
bracing. It was discovered that in one test case the difference in
deflection was 0.2 of an inch less with the cross-bracing of FIG.
7a. A matter of 0.2 of an inch can be crucial when compounded with
environmental factors such as wind, accumulated precipitation,
freeze cycles and the like. It can be the difference between
maintaining a grip on the panels 12 (with standard panel clips or
holders) and losing that grip, thereby undermining the entire
purpose of the panel support system 10.
[0104] Encompassing the aforementioned improvements, the panel
support system 10 of this invention still allows for off-site
assembly (at a convenient staging site) to precise engineering
specifications. Once the support members (30, 20) are assembled,
the bi-directional span of panel support system 10 can be folded or
collapsed on itself, as shown with reference to FIG. 5a. The panel
support system 10 is easily transported (by motor road vehicle) to
the installation site.
[0105] In one method of installation, the panel support system 10
is positioned and secured to at least one tilt-mounting bracket 16,
via one of the longitudinal beams 60, while still in the folded
position. After attaching one lower support joist 20 to one of the
tilt-mounting brackets 16, using a pair of tilt-mounting bracket
attachment bolts 240 (as shown in FIGS. 5b and 5c) the
bi-directional support system 10 is unfolded to the position of
FIG. 4a, and the other lower support joist(s) 20 is/are attached to
second and/or third tilt-mounting bracket 16, via second and/or
third paired bolts 240 being connected to either of the
longitudinal beam(s) 60 described above with reference to FIGS. 9,
10 12a and 12b. This arrangement of panel support system 10
provides the capability of rapid, accurate deployment, requiring
little skilled labor. Other installation methods, such as unfolding
the support system 10 first, and then attaching it to the
tilt-mounting brackets 16, can also be used.
[0106] Another method of strengthening the overall support system
10 is to use steel elements for both the lower support joists 20
and the upper panel rails 30. This can be especially critical when
the size of the support system (and the panel configuration
supported) becomes even larger. The enhanced strength of all-steel
construction is also very important when environmental conditions
(heavy winds, snow, hail, icing, or the like) lead to increased
stresses of all types. Steel elements can be used with virtually
any of the element shapes, sizes, and configurations previously
described herein, as well as any number of shapes and
configurations known in the structural steel arts.
[0107] While the steel-to-steel connections between upper panel
rails 30 and lower support joists 20 permit the omission of
insulation between these two structural members, there is still the
possibility of binding if either of the structural elements (20,
30) deforms. To address this, stainless steel bearing washer 85, as
depicted in FIGS. 5a and 5b, are placed between the upper panel
rails 30 and the lower support joists 20 at each intersection. The
stainless steel bearing washers 85 facilitate easy, controlled
rotation of the upper panel rails 30 and the lower support joists
20 with respect to each other. This is important for easy
installation, especially when only a single lower support joist is
attached to a tilt bracket while the rest of array 10 is unfolded
to continue the installation. Steel bearing washer 85 is sized to
easily span adjustment slot 216 in lower support joist 20, with
bolt 240 passing therethrough.
[0108] Another variation of the present invention eliminates the
use of panel clips or holders (120 in FIG. 3). Since framed
photovoltaic panels are expected for use with the inventive support
structure 10, they can be held to the upper panel rails 30 by means
of screws (not shown) suitable for metal connections. Most framed
photovoltaic panels come with pre-drilled holes for screws, in
standard configurations. These can be used with pre-drilled holes
(not shown) in the upper panel rails 30 to facilitate rapid
installation of the framed solar panels 12 once the support array
10 is fully unfolded and attached to the underlying supports (tilt
brackets 16). By using the pre-drilled holes in the framed solar
panels 12, the expensive panel clips or holders 120 can be entirely
eliminated, along with the additional steps of installing the panel
clip bottoms 100 using bolts 145 through pre-drilled holes 145',
and then placing the solar panels 12 within those clips. The top
portions 100, of the clips are then tightened to hold panel 12 in
place. These steps are now eliminated.
[0109] The result is a faster and more secure installation than can
be achieved with conventional panel clips 120. The elimination of
the panel clips 120 also removes the requirement for expertise with
panel clips on the part of the installers. Virtually no skill is
required to run screws through the standard holes in the framed
solar panels 12 into predrilled holes (not shown) in the upper
panel rails 30.
[0110] FIG. 14 depicts another embodiment of the present invention.
In this configuration, lower support joists 20 are constituted by
C-channels, which also serve as tilt brackets 16. These support
joists (i.e, tilt brackets) 20 are connected to upright supports
16. In this particular configuration, the C-channel 20 constitutes
both the tilt bracket and support joists found in previous
embodiments.
[0111] The upper panel rails 30 are constituted by the type of
structural elements previously described with respect to FIG. 6.
However, other configurations can be used for the upper panel rails
30 in this particular arrangement. The attachment between the upper
panel rails 30 and the lower support joists 20 can be accomplished
using bolts, as previously described. The upper panel rails 30 and
the lower support joists 20 are separated by steel bearing washers
85 in order to prevent binding between the two structural elements
when they rotate with respect to each other.
[0112] As with earlier embodiments of the present invention,
diagonal braces 70 are used between adjacent upper panel rails 30.
As in previous embodiments, the diagonal braces 70 are slanted
opposite each other so as to suggest a roughly A-shaped
configuration. Because the diagonal braces 70 are slanted opposite
each other, at least one end of one of the diagonal braces must be
disconnected so that the overall support array 10 can be folded as
previously described. Usually one end of one of the diagonal braces
70 is left connected to one of the upper panel rails 30, and the
other end left loose for the folding process necessary for
transport. Accordingly, the other diagonal braces 70 can be
rotatably connected to panel rails 30. The diagonal braces 70 are
aligned with the upper panel rails 30 when the support array 10 is
folded for transport on a motor road vehicle such as a truck.
[0113] Upon reaching the installation site, the folded support
array 10 of FIG. 14 will preferably be placed on a pre-existing
tilt bracket 20 attached to an existing vertical support 16. Then
the entire support array 10 can be unfolded and panel rails 30
attached to the other tilt bracket 20. The loose ends of the
diagonal braces 70 are then attached to panel rails 30 as
appropriate to form the configuration depicted in FIG. 14.
[0114] The diagonal braces 70, in the opposing slanted
configuration as previously described, provide a much higher level
of stiffness to the overall support array 10 than is found in
previous designs. Additional stiffening of the overall support
array 10 can be provided by auxiliary diagonal braces 72 connected
between tilt bracket 20 and upper panel rail 30. As depicted in
FIG. 14, auxiliary diagonal brace 72 is connected between the
median connecting member 23 of upper panel rail 30 and a lower
portion of the C-channel constituting the tilt bracket 20.
Auxiliary diagonal brace 72 can be configured with a surface and a
drilling hole configuration to accommodate the connection between
perpendicular pieces. Further stiffening can also be provided by
lateral braces 74, which are mounted at the ends of the upper panel
rails 30. While lateral braces 74 are depicted as being attached to
the lower edge of the upper panel rail structure, other connection
arrangements are also possible. The result of the FIG. 14
configuration is a panel support system 10 that can withstand a
wide range of stresses that might be caused by both extensive panel
loading and environmental occurrences.
[0115] While a number of embodiments have been described as
examples of the present invention, the present invention is not
limited thereto. Rather, the present invention should be construed
to include every and all modifications, permutations, variations,
adaptations, derivations, evolutions and embodiments that would
occur to one having skill in this technology and being in
possession of the teachings of the present application.
Accordingly, the present invention should be construed as being
limited only by the following claims.
* * * * *