U.S. patent application number 14/018322 was filed with the patent office on 2014-03-06 for interchangeable mounting system for rooftop solar energy installations.
The applicant listed for this patent is Eric R. Stephan, Erich Kai Stephan. Invention is credited to Eric R. Stephan, Erich Kai Stephan.
Application Number | 20140060626 14/018322 |
Document ID | / |
Family ID | 50185746 |
Filed Date | 2014-03-06 |
United States Patent
Application |
20140060626 |
Kind Code |
A1 |
Stephan; Erich Kai ; et
al. |
March 6, 2014 |
INTERCHANGEABLE MOUNTING SYSTEM FOR ROOFTOP SOLAR ENERGY
INSTALLATIONS
Abstract
Rooftop solar energy module mounting systems that incorporate
interchangeable mounting bases with a solar energy module
frame.
Inventors: |
Stephan; Erich Kai; (Newport
Beach, CA) ; Stephan; Eric R.; (Gig Harbor,
WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Stephan; Erich Kai
Stephan; Eric R. |
Newport Beach
Gig Harbor |
CA
WA |
US
US |
|
|
Family ID: |
50185746 |
Appl. No.: |
14/018322 |
Filed: |
September 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61632412 |
Sep 4, 2012 |
|
|
|
61699546 |
Sep 11, 2012 |
|
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Current U.S.
Class: |
136/251 ;
29/890.033 |
Current CPC
Class: |
F24S 25/15 20180501;
F24S 25/16 20180501; F24S 2025/015 20180501; H01L 31/049 20141201;
H02S 20/23 20141201; Y02B 10/20 20130101; Y02E 10/47 20130101; Y10T
29/49826 20150115; Y02B 10/10 20130101; F24S 25/10 20180501; H01L
31/048 20130101; F24S 25/33 20180501; F16M 13/02 20130101; F24S
25/50 20180501; H02S 20/24 20141201; Y02E 10/50 20130101; F24S
25/11 20180501; Y10T 29/49355 20150115; F24S 2025/014 20180501;
F24S 2025/021 20180501; H02S 20/30 20141201; F24S 25/61
20180501 |
Class at
Publication: |
136/251 ;
29/890.033 |
International
Class: |
H01L 31/048 20060101
H01L031/048; H01L 31/042 20060101 H01L031/042 |
Claims
1. A solar panel system comprising: a first solar panel assembly,
the first solar panel assembly having a first end and a second end;
a first mounting base configured to mount to a mounting surface,
the first mounting base configured to secure the first end of the
first solar panel assembly and a second end of a second solar
assembly that is positioned in front of the first solar panel
assembly; and a second mounting base configured to mount to the
mounting surface, the second mounting base configured to secure the
second end of the first solar panel assembly and a first end of a
third solar panel assembly that is positioned behind the first
solar panel assembly; wherein the first mounting base and second
mounting base are configured to be interchangeable.
2. The solar panel system of claim 1 wherein the second end is
positioned higher than the first end with respect to the mounting
surface such that the solar panel is placed at an angle relative to
a mounting surface.
3. The solar panel system of claim 2 wherein the second end is
secured to the mounting base by a plurality of articulating
legs.
4. The solar panel system of claim 1 wherein the first and second
mounting base each further comprise elongated connection tabs that
are each U-shaped in cross section and have an internal portion and
an external portion for connecting to the first and/or second solar
panel assemblies.
5. The solar panel system of claim 4 wherein the connection tabs
have slots for receiving mechanical fasteners to mount the first
and second solar panel assemblies.
6. The solar panel assembly of claim 5 wherein the slots are
configured to allow freedom of movement about the mechanical
fastener.
7. The solar panel system of claim 1 wherein the first mounting
base is a ballast type mounting base configured to accept a
weighted object to secure the first mounting base to the mounting
surface and the second mounting base is an adhesive type mounting
base having an adhesive material affixed to its underside for
adhering the second mounting base to the mounting surface.
8. The solar panel system of claim 1 wherein the first mounting
base is a ballast type mounting base configured to accept a
weighted object to secure the first mounting base to the mounting
surface and the second mounting base is an rigid type mounting base
having an aperture for use for attaching the second mounting base
to a fixed structure of the mounting surface.
9. The solar panel assembly of claim 1 wherein the first mounting
base is a rigid type mounting base having an aperture for use for
attaching the second mounting base to a fixed structure of the
mounting surface and the second mounting base is an adhesive type
mounting base having an adhesive material affixed to its underside
for adhering the second mounting base to the mounting surface.
10. The solar panel system of claim 1 configured such that multiple
solar panels assemblies can be mounted to the solar panel system in
an array.
11. A method for installing a solar panel system, the steps
comprising: attaching a first solar panel assembly, the first solar
panel assembly having a first end and a second end, to a first
mounting base configured to mount to a mounting surface, the first
mounting base configured to secure the first end of the first solar
panel assembly; and, attaching a second end of a second solar
assembly that is positioned in front of the first solar panel
assembly to a second mounting base configured to mount to the
mounting surface, the second mounting base configured to secure the
second end of the first solar panel assembly and a first end of a
third solar panel assembly that is positioned behind the first
solar panel assembly; wherein the first mounting base and second
mounting base are configured to be interchangeable.
12. The method for installing a solar panel system of claim 11
wherein the second end is positioned higher than the first end with
respect to the mounting surface such that the solar panel is placed
at an angle relative to a mounting surface.
13. The method for installing a solar panel system of claim 12
wherein the second end is secured to the mounting base by a
plurality of articulating legs.
14. The method for installing a solar panel system of claim 11
wherein the first and second mounting base each further comprise
elongated connection tabs that are U-shaped in cross section and
have an internal portion wherein the first and second solar panel
assemblies attach to the inside of the respective connection
tabs.
15. The method for installing a solar panel system of claim 14
wherein the connection tabs have slots for receiving mechanical
fasteners to mount the plurality of adjustable legs and plurality
of frame members.
16. The solar panel system of claim 15 wherein the slots are
configured to allow freedom of movement about the mechanical
fastener.
17. The method for installing a solar panel assembly claim 11
wherein the first mounting base is a ballast type mounting base
configured to accept a weighted object to secure the first mounting
base to the mounting surface and the second mounting base is an
adhesive type mounting base having an adhesive material affixed to
its underside for adhering the second mounting base to the mounting
surface.
18. The method for installing a solar panel system claim 11 wherein
the first mounting base is a ballast type mounting base configured
to accept a weighted object to secure the first mounting base to
the mounting surface and the second mounting base is an rigid type
mounting base having an aperture for use for attaching the second
mounting base to a fixed structure of the mounting surface.
19. The method for installing a solar panel system claim 11 wherein
the first mounting base is an rigid type mounting base having an
aperture for use for attaching the second mounting base to a fixed
structure of the mounting surface and the second mounting base is
an adhesive type mounting base having an adhesive material affixed
to its underside for adhering the second mounting base to the
mounting surface
20. The solar panel system of claim 11 configured such that an
array of solar panels assemblies can be mounted to the solar panel
system.
Description
[0001] This application claims the benefit of U.S. Provisional
Patent Application Nos. US 61/632,412 and US 61/699,546, filed on
Sep. 4, 2012, and Sep. 11, 2012, respectively, the disclosures of
which are incorporated herein by this reference.
BACKGROUND
[0002] Many embodiments of the invention relate to mounting
structures for solar energy panels on building rooftops. Such solar
panels may include photovoltaic panels, solar thermal panels among
other solar capture devices.
[0003] Building owners and tenants are increasingly installing
rooftop solar energy systems in order to reduce their electricity
costs, sell power to the back to the grid, and improve their
corporate sustainability posture. As solar energy systems become
more popular, installers have developed several systems for
securing a solar energy module or an array of solar energy modules
to the rooftop of a building. Securing the solar energy module
array to a building rooftop is necessary to prevent damage from
movement caused by wind, earthquakes, building vibrations, and
other external forces. Some installation methodologies include
using weight to hold a solar energy array in place, adhering the
solar energy array to the rooftop membrane, and securing the solar
energy array using roof penetrating connections (e.g. bolts).
BRIEF SUMMARY OF INVENTION
[0004] Many embodiments of the present invention are related to
solar energy modules (or module frames) and mounting bases for roof
mounting of the modules that have standardized connection points
such that mounting bases of different types can be interchanged,
allowing the modules to be secured to the roof by any number of
different securing methods. The solar energy module frame may have
part of the frame extend beyond the solar energy module to act as a
connection point for the mounting bases. In all cases, all modules,
or module frames, will have connection points with the same
location, spacing, orientation, and type of connection (means of
securement) to the mounting bases. Likewise, all mounting bases,
regardless of their means of immobilization on the roof (ballast,
adhesive, or bolt or other rigid attachment), have connection
points with the same location, spacing, orientation, and type of
connection (means of securement) to the modules or module frames.
All connections can be releasable. Connection points on all
mounting base types can thus connect with all solar energy module
connection point types. The connection points may allow for limited
spatial movement in the X, Y, and Z directions between the solar
energy module and mounting bases. This limited movement will allow
different assemblies of mounting bases and solar energy modules to
connect to neighboring mounting bases and solar energy modules on
an uneven surface.
[0005] Many embodiments are related to mounting base types that can
include a mounting base which uses weight (e.g. ballast) to secure
the solar energy module to the rooftop, a mounting base that
adheres to a rooftop membrane, and a mounting base which allows for
a secure connection to a rigid rooftop structure, such as a roof
penetrating pipe, bolt, air conditioning duct, parapet, or similar
structure. The ballast type mounting base can include a tray in
which to place ballast (e.g. concrete bricks), where simply the
weight and friction between the ballast tray and rooftop secures
the solar energy array. An adhered type mounting base may include
material similar to that of the roofing membrane to allow the
mounting base to be securely adhered to the rooftop membrane with
an appropriate adhesive. A rigid attachment type mounting base may
include a beam, pipe, or cross structure to allow a connection from
the mounting base to a rigid structure on the roof.
[0006] Many embodiments of the invention include connection trays
installed on the various types of mounting base. The connection
trays have inside tray walls and outside tray walls. The inside
tray walls connect to mounting bases using a weld, rivet, screw,
staple, mechanical bend, or other securement method. Devices to be
mounted to the connection tray, such as a solar energy module, have
protrusion for resting in the connection trays. The connection
trays are able to accept multiple mounted devices on either end,
such that each connection tray may have four or more components
secured therein. Mounting slots through inside tray wall and
outside tray wall accept mechanical type fasteners to connect the
device to be mounted. The mounting slots may be circular in shape,
or slot-like to allow some freedom of movement. Each connection
tray may have multiple mounting slots on either end in order to
accept a range of mounting positions for the device to be mounted.
Apertures through connection tray allow for the installation of
additional items to be connected on the underside of the mounting
base, such as a sacrificial wear material.
[0007] The ability to have interchangeable mounting base types with
the same solar energy module frame, as well as the ability to use a
combination of mounting base types for an array of many solar
energy modules is a significant advantage over previous art.
Benefits of this system include, but are not limited to, the
ability to use multiple methods of securing the solar energy
modules for a single rooftop array, simplified construction and
takedown, and easier management of components for installers.
Further, a single solar energy module frame can be manufactured to
be used with all mounting base types, eliminating the need for a
specialized mounting base for different building rooftop types. The
interchangeable mounting bases allows for the same solar energy
module frame to be secured to the rooftop in any preferred method
by the installer. The mounting bases could be installed prior to
arriving at the installation location (e.g. at the factory), or
immediately by the installers on the roof. An array of solar energy
modules with standard frames could employ a single mounting base
type, or a combination of mounting base types to best secure the
solar energy array to that particular roof. The present invention
also offers benefits in manufacturing and distribution, where a
single solar energy frame design is used for all mounting base
types.
[0008] In many embodiments of the invention, extension brackets or
mounts may be attached to a solar energy module frame and be
connected in such a way to provide the same connection type,
orientation, and location as the connections points to connect with
all the mounting base types.
[0009] Many embodiments are related to a solar panel system
comprising having first solar panel assembly with a first end and a
second end secured to a first mounting base configured to mount to
a mounting surface. The first mounting base may be configured to
secure the first end of the first solar panel assembly and a second
end of a second solar assembly that is positioned in front of the
first solar panel assembly. There may also be a second mounting
base configured to mount to the mounting surface where the second
mounting base is configured to secure the second end of the first
solar panel assembly and a first end of a third solar panel
assembly that is positioned behind the first solar panel assembly
and the first mounting base and second mounting base are configured
to be interchangeable.
[0010] Many embodiments are related to a method for installing a
solar panel system where, the steps include attaching a first solar
panel assembly, the first solar panel assembly having a first end
and a second end, to a first mounting base configured to mount to a
mounting surface, the first mounting base configured to secure the
first end of the first solar panel assembly and attaching a second
end of a second solar assembly that is positioned in front of the
first solar panel assembly to a second mounting base configured to
mount to the mounting surface, the second mounting base configured
to secure the second end of the first solar panel assembly and a
first end of a third solar panel assembly that is positioned behind
the first solar panel assembly, where the first mounting base and
second mounting base are configured to be interchangeable.
[0011] In many embodiments the second end is positioned higher than
the first end with respect to the mounting surface such that the
solar panel is placed at an angle relative to a mounting surface.
In various embodiments the second end is secured to the mounting
base by a plurality of articulating legs.
[0012] In many embodiments the first and second mounting base each
have elongated connection tabs that are each U-shaped in cross
section and have an internal portion and an external portion for
connecting to the first and/or second solar panel assemblies.
[0013] In many embodiments the connection tabs have slots for
receiving a mechanical fasteners to mount the plurality of
adjustable legs and plurality of frame members the slots are
configured to allow freedom of movement about the mechanical
fastener.
[0014] In many embodiments the first mounting base is a ballast
type mounting base configured to accept a weighted object to secure
the first mounting base to the mounting surface and the second
mounting base is an adhesive type mounting base having an adhesive
material affixed to its underside for adhering the second mounting
base to the mounting surface.
[0015] In many embodiments the first mounting base is a ballast
type mounting base configured to accept a weighted object to secure
the first mounting base to the mounting surface and the second
mounting base is an rigid type mounting base having an aperture for
use for attaching the second mounting base to a fixed structure of
the mounting surface.
[0016] In many embodiments the first mounting base is a rigid type
mounting base having an aperture for use for attaching the second
mounting base to a fixed structure of the mounting surface and the
second mounting base is an adhesive type mounting base having an
adhesive material affixed to its underside for adhering the second
mounting base to the mounting surface.
[0017] In many the solar panel system can be configured so that
multiple solar panels assemblies can be mounted to the solar panel
system in an array. An array can be a system of solar panel
assemblies in multiple columns and rows or in just one column or
just one row.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a profile view of the integrated solar energy
module and frame with a ballast type mounting base attached with an
adhesive type mounting base and rigid attachment type mounting base
in view representing one example of the present invention.
[0019] FIG. 2 is a profile view of the integrated solar energy
module and frame demonstrating where a ballast type mounting base
would install representing one example of the present
invention.
[0020] FIGS. 3A, 3B, and 3C are profile views of the ballast type
mounting base, adhered type mounting base, and rigid attachment
type mounting base representing a few examples of the present
invention.
[0021] FIG. 4 is a side view of an array of solar energy modules
mounted using the standard connection points of the mounting bases
representing one example of the present invention.
[0022] FIG. 5 is a top view of an array of solar energy modules
mounted using a ballast type mounting base and an adhered type
mounting base representing an example installation of the present
invention.
[0023] FIG. 6 is an alternative embodiment of the present invention
showing alternative connection trays.
DETAILED DESCRIPTION
[0024] FIG. 1 is a profile view of a solar energy module frame 100
housing a solar energy module 101 and connected to a ballast type
mounting base 102 using standard connection tabs 103. The adhered
type mounting base 200 and the rigid attachment type mounting base
300 are shown to demonstrate the standard connection tabs 103
common among all types of mounting bases within the scope of this
invention. The standard connection tabs 103 on the ballast type
mounting base 102, adhered type mounting base 200, and rigid
attachment type mounting base 300 all have connection points with
the same location, spacing, orientation, and type of connection
(means of securement) to the mounting, and the connections at these
points to the solar energy module frame 100 can be releasable
connections. The solar energy module frame 100 is tilted at a
desired angle by the pivotally attached leg 104. The pivotally
attached leg 104 is connected to a second ballast type mounting
base 102 in order to secure the two mounting bases 102 to opposite
sides of the solar energy module.
[0025] FIG. 2 is a profile view demonstrating the installation of
the ballast type mounting base 102 on both the front and back side
of the integrated solar energy module and standard frame assembly.
The same installation methodology is used for any mounting base
type, such as the adhered type mounting base and the rigid
attachment type mounting base. In FIG. 2, the ballast type mounting
base 102 attaches to the solar energy module frame 100 at the
standard connection tabs 103 using a pin 105, or similar fastener
such as a bolt, screw, clip, rope, nylon webbing, etc. A second
ballast type mounting base 102 with standard connection tabs 103
attaches to the pivotally attached leg 104 using pin 105, or
similar fastener such as a bolt, screw, slip, rope, etc.
[0026] FIGS. 3A, 3B, and 3C are profile views of three types of
mounting bases. FIG. 3A shows the ballast type mounting base 102
with standard connection tabs 103. FIG. 3B shows the adhered type
mounting base 200 with standard connection tabs 103. The adhered
type mounting base 200 has a material 201 that is compatible with
the adhesive necessary for adhering the mounting base to the
rooftop membrane. The adhered type mounting base 200 may be built
with different types of material 201 in order to match a particular
rooftop membrane's material type. The material 201 may extend
beyond the width of the main body of the mounting base, or beyond
the width of the standard connection tabs 103 in order to maximize
surface area for better adhesion. FIG. 3C shows a rigid attachment
type mounting base 300 with standard connection tabs 103. The rigid
attachment mounting base 300 may be a box beam, or similar beam
shape such as a pipe, "I" shape beam, "T" shape beam, "L" shape
beam, etc. The key feature of the rigid attachment mounting base
300 is structural integrity such that it can withstand typical
shear and lateral forces common to rooftop solar energy arrays, as
well as the ability to be a universal attachment fixture for
multiple types of connections. An array can be a system of solar
panel assemblies in multiple columns and rows or in just one column
or just one row, or any combination of these. In the FIG. 3C, the
rigid attachment type mounting base 300 is an "L" shaped beam with
mounting holes 301 along the top surface. The mounting holes 301
offer options as to where a secure connection to a rigid roof
structure is made. In FIG. 3C, the rigid type mounting base 300 is
connected to a rigid roof structure 303 using a connecting bar 302.
The rigid roof structure 303 may be a roof penetrating pipe secured
to the roof joists (not shown), or similar rigid structure such as
a roof penetrating bolt, ventilation duct structure, roof parapet,
etc.
[0027] FIG. 4 is a side view of an array of solar energy modules
with solar energy module frame 100. An end of the solar energy
module frame 106 connects to a standard connection tab 103 at
standard connection tab end hole 107. The solar energy module frame
100 and pivotally attached leg 104 may connect to standard
connection tab end holes 107 when the standard connection tab 103
and associated mounting bases are mounted to a solar energy module
on both ends. In cases where only one solar energy module is
connected to a mounting base (i.e. at the end of an array), the
pivotally attached leg 104 may connect to the standard connection
tab central hole 108. The standard connection tab central hole 108
allows for the weight of the solar energy module to be evenly
distributed along the mounting base. The pin 105 connects standard
connection tab 103 to pivotally attached leg 104 (shown), as well
as solar energy module frame 106 to standard connection tabs 103.
The standard connection tab end hole 107 and the standard
connection tab central hole 108 may be slotted in order for the pin
105 to be able to move some limited distance. This feature will
allow the mounting bases to articulate from the solar energy module
due to an uneven surface, such as a bump in a rooftop.
[0028] FIG. 5 is a top down view of an array of solar energy
modules with solar energy module frame 100 connected with ballast
type mounting bases 102 and adhered type mounting bases 200. Solar
energy module frames 100 connect to adhered type mounting bases 200
using pin 105.
[0029] FIG. 6 is an alternative embodiment of the present invention
showing alternative connection trays 401, which act as the
connection tabs of other embodiments. The connection trays 401 may
be installed on the three types of mounting bases shown in FIGS.
3A, 3B, and 3C, or other types of mounting bases conceived. The
connection tray 401 has inside tray wall 402 and the outside tray
wall 403. In the figure shown, the inside tray walls 401 connect to
the ballast mounting base 102 using a weld, rivet, screw, staple,
mechanical bend, or other securement method. Devices to be mounted
to this system, such as a solar energy panel, would have
protrusions resting in the connection trays 401. The connection
trays 401 may be able to accept multiple mounted devices on either
end, such that each connection tray 401 may have four or more
components secured. The mounting slots 404 through the inside tray
wall 402 and outside tray wall 403 accept mechanical fasteners to
connect the device to be mounted. The mounting slots 404 may be
circular in shape, or slot-like to allow some freedom of movement.
Each connection tray 401 may have multiple mounting slots 404 on
either end in order to accept a range of mounting positions for the
device to be mounted. The hole 405 through connection tray 401
allows for the installation of any device to be connected on the
underside of the mounting base, such as a sacrificial wear
material.
[0030] In the claims appended hereto, the term "a" or "an" is
intended to mean "one or more." While the exemplary embodiments
have been described in some detail for clarity of understanding and
by way of example, a number of modifications, changes, and
adaptations may be implemented and/or will be obvious to those as
skilled in the art. Hence, the scope of the present invention is
limited solely by the claims as follows.
* * * * *