U.S. patent application number 14/507753 was filed with the patent office on 2015-07-30 for molded solar panel racking assembly.
This patent application is currently assigned to DYNORAXX, INC.. The applicant listed for this patent is Nathan T. Rizzo. Invention is credited to Nathan T. Rizzo.
Application Number | 20150214884 14/507753 |
Document ID | / |
Family ID | 48141322 |
Filed Date | 2015-07-30 |
United States Patent
Application |
20150214884 |
Kind Code |
A1 |
Rizzo; Nathan T. |
July 30, 2015 |
Molded Solar Panel Racking Assembly
Abstract
The present invention comprises a stackable ballasted roof
mounting solar panel mount unit integrally formed into a single
piece. The mount unit comprises a plurality of generally elevated
side walls of a ballast receiving basket. Each of the generally
elevated side walls taper upward and inward from a generally
downward facing peripheral edge to an apex ridge of the wall. The
generally elevated side walls taper downward and inward from the
apex ridge of the wall. The side wall further extends inward from
the base of the inner face to form a ballast supporting basket lip.
Each side walls defines a downwardly facing open channel that is
configured to receive a corresponding side wall from a
corresponding solar panel mount in a stacking relation. The mount
unit further comprises a plurality of stackable posts that extend
upward from the peripheral edge to the top of the first pair of
posts at a first predetermined height above the generally elevated
side wall. Each of the posts forms a downwardly facing post
receiving first mouth that is configured to receive a corresponding
post from a corresponding first pair of posts of a corresponding
solar panel mount in a stacking relation.
Inventors: |
Rizzo; Nathan T.;
(Williamsville, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Rizzo; Nathan T. |
Williamsville |
NY |
US |
|
|
Assignee: |
DYNORAXX, INC.
Buffalo
NY
|
Family ID: |
48141322 |
Appl. No.: |
14/507753 |
Filed: |
October 6, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13651413 |
Oct 13, 2012 |
8850754 |
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14507753 |
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61548024 |
Oct 17, 2011 |
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61548209 |
Oct 17, 2011 |
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Current U.S.
Class: |
248/346.2 |
Current CPC
Class: |
H02S 20/23 20141201;
H02S 20/00 20130101; Y02E 10/47 20130101; F16B 7/0446 20130101;
F16B 21/065 20130101; F16M 13/02 20130101; Y02B 10/20 20130101;
F24S 25/13 20180501; H02S 20/24 20141201; Y02B 10/10 20130101; Y02E
10/50 20130101; F24S 25/65 20180501; F16B 21/125 20130101; Y10T
29/4995 20150115 |
International
Class: |
H02S 20/23 20060101
H02S020/23; F16M 13/02 20060101 F16M013/02; H02S 20/24 20060101
H02S020/24 |
Claims
1. A stackable ballasted roof mounting solar panel mount unit
integrally formed into a single piece comprising: a plurality of
generally elevated side walls of a ballast receiving basket,
wherein each of the generally side walls taper upward and inward
from a peripheral edge to an apex ridge of the wall and then tapers
downward and inward from the apex ridge of the wall and further
extends inward from the base of the inner face to form a ballast
supporting basket lip, wherein each side wall defines a downwardly
facing open channel that is configured to receive a corresponding
side wall from a corresponding solar panel mount in a stacking
relation; and a first pair of posts, wherein each of the first pair
of posts forms a downwardly facing post receiving first mouth that
is configured to receive a corresponding post from a corresponding
first pair of posts of a corresponding solar panel mount in a
stacking relation.
2. The unit of claim 1, further comprising a second pair of posts
of a second predetermined height above the generally elevated side
wall, wherein each of the second pair of posts forms a downwardly
facing post receiving mouth that is configured to receive a
corresponding post from a corresponding solar panel mount in a
stacking relation.
3. The mount of claim 1, wherein the peripheral edge has a
plurality of raised gaps around the base to allow water to flow
under the base without obstruction.
4. The unit of claim 1, wherein the basket has a large hollow part
that is cut away to prevent water from pooling in the basket.
5. A plurality of units of claim 1 that are arranged in a single
vertically aligned stack, wherein a first of the plurality of units
is placed onto the bottom and a second of the plurality of units is
vertically aligned with the first of the plurality of units,
wherein the distance between any point on the first of the
plurality of units and the same corresponding point on the second
of the plurality of units is less than 1/2 the height of the
distance from the peripheral lip to the apex ridge of any one
unit.
6. The plurality of units as set forth in claim 5, wherein the
plurality are arranged in one vertically aligned stack on a
pallet.
7. The plurality of units of claim 2, wherein the plurality of
units are arranged in one vertically aligned stack, wherein a first
of the plurality of units is placed directly onto the pallet on the
bottom of the stack and a second of the plurality of units is
vertically aligned with and stacked upon the first of the plurality
of units, wherein the distance between any point on the first of
the plurality of units and the same corresponding point on the
second of the plurality of units is less than 1/2 the height of the
distance from the peripheral lip to the apex ridge of any one
unit.
8. The plurality of units as set forth in claim 7, wherein
unassembled rails and other hardware can be stacked between the
first pair of posts and the second pair of posts in the plurality
of stacked units on the pallet.
9. The mounting unit of claim 1, wherein a ballast block is placed
in the basket over the plurality of lips to anchor the unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of Ser. No. 13/651,413
filed Oct. 13, 2011, which claims the benefit of U.S. Provisional
Application No. 61/548,209 filed Oct. 17, 2011, which is
incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates generally to systems for mounting
solar panels or photovoltaic cells and more specifically to
ballasted roof mounted racking systems for mounting photovoltaic
cells.
[0004] 2. Discussion of Related Art
[0005] Solar energy provides the opportunity to generate
electricity without consumption of fossil fuels and is considered
clean technology. In recent years, the development of technology
for solar thermal systems and photovoltaic systems has improved the
overall viability of solar energy. Increasing prices of fossil fuel
and the prospect of expending world oil reserves has created a
demand for alternative energy sources that can supplement and/or
replace some of the energy needs consumed presently by fossil
fuels. Thus, the demand for solar energy has increased. Because of
the overall accessibility of solar energy, individuals or small
businesses can own and control all or a significant portion of its
energy production free from dependence upon the power grid. With
the advances of electric powered automobiles, even transportation
needs can be met by solar generated electricity. Presently, solar
power technology is one of the most widely-accessible form of
alternative fuel to the general population of the world. All is
needed is access to direct sunlight.
[0006] The cost of solar panel technology includes not only cost of
the photovoltaic panels, but a significant investment installation
equipment and the labor to construct a solar electric system. Thus,
a technology advance that reduces the cost of installation of
photovoltaic modules (whether through reducing material cost,
shipping costs, or labor costs) makes photovoltaic technology more
viable and attractive from an investment perspective. The quality
of installation also affects the efficiency of solar panel
installation. The direction of the solar panels relative to the
sun, the angle of the solar panels relative to the horizon, the
density of solar panels in a given area, as well as position of
solar panels relative to other panels can have a positive or
negative effect on performance of the solar powered system.
[0007] A large percentage of commercial solar panel systems are
installed on generally flat roofs of office buildings. Generally
flat means that the roof is designed to be generally horizontal
without a predefined pitch. It should be understood that while
generally flat, flat roofs are often uneven due to settling of the
building, construction imperfections, etc. A flat roof structure is
an attractive place to locate a solar panel installation because
there is often a large surface area of unused space with relatively
few obstructions of sunlight. The traffic on a roof is typically
restricted. Because access is restricted, the likelihood of
intentional or accidental damage or theft is naturally reduced with
relatively inexpensive safety precautions. Consequently, there is a
significant effort in the solar panel industry to design effective
flat roof mounts or racks to support arrays of solar panels on flat
roofs.
[0008] The ability to assemble with one additional row of solar
panels without causing overlap of the solar panels in sunlight or
compromising optimal positioning would be a great advantage.
Moreover, it would be advantageous if photovoltaic panels could be
installed by an unskilled laborer or layperson (do-it-yourselfer)
without a lot of formal training. It would be further advantageous
if the system could be installed by hand without tools. It would be
further advantageous if the product was light-weight, could be
stacked or configured in a compact manner to ship a larger number
of system components per unit of shipping volume and thereby reduce
shipping costs. An additional advantage would be to have a system
that can be easily adapted to avoid obstructions in the roof such
as common rooftop fixtures without having to cut and resize parts
of the solar panel system. Reducing installation time reduces labor
cost making solar technology more accessible to the common
individual.
[0009] U.S. Patent Publication 2008/0210221 to Genschorek discloses
a relatively compact frame assembly that mounts solar panels at an
angle for mounting on a flat structure such as a roof or ground.
The metal frame system is supported by carrier profile elements
with feet having holes forming connections to connect the carrier
profile elements to the ground or roof surface--presumably by bolt,
screw or penetrating fastener. The system has multiple parts
requiring factory or on site assembly--potentially increasing
product or installation cost.
[0010] U.S. Pat. No. 8,281,524 to Hund is a stackable wire frame
design. The wire design is relatively lightweight, compact and
stackable. The system is designed to have one framework support one
panel so the system does not have the benefit of
interconnectedness. Furthermore, the system is made from a wire
grate connected by welds at wire intersections. It is pressed into
the desired form. The wire is potentially vulnerable to damage by
bending, corrosion, or breakage at weld points.
[0011] U.S. Pat. No. 6,105,316 to Bottger discloses an injection or
blow molded device for supporting solar panels. The device has a
bottom wall and a rear wall and two side walls integrally joined.
Concrete blocks are place in the interior of the device. The solar
panel is fastened to side edges of the bottom wall and rear wall.
Each device supports a solar panel individually. There is one
vertical member for each side. Thus, the panel array is not
structurally interconnected.
[0012] U.S. Publ. No. 2006/0196128 to Duke discloses a mounting for
solar panels with fixings on the front and side that enable it to
be easily attached to other mountings for solar arrays. The devices
are interconnected and stackable.
[0013] U.S. Publ. No. 2012/0036799 to Kneip discloses an injection
molded support device that is compact and stackable. The height of
the base is greater than its width and thus top-heavy relying upon
the panels for side-to side stability. Thus, the device could have
improved stability from side to side. Each device potentially
supports one side of two adjacent panels.
[0014] U.S. Publ. No. 2012/0223032 to Rothschild discloses a solar
panel mounting system of injection molded bases that are designed
to support the panels at their respective corners. The bases can be
nested like buckets for easy transport. Each device potentially
supports four panels. Each bucket has four side walls.
[0015] Additionally, there is a need for systems that are lighter
weight, easier to install and can be transported and lifted to
rooftops with greater efficiency because a greater number of units
can fit on a similar size pallet.
[0016] Thus, there still exists a need for a system that has many
of the needs expressed above. The present invention addresses these
and other needs.
SUMMARY OF THE INVENTION
[0017] The present invention comprises a stackable, ballasted, roof
mounting unit integrally formed into a single piece. Each side is
formed by two-walls for extra strength and stability. The mount
unit comprises a plurality of generally elevated side walls of a
ballast receiving basket. Each of the generally elevated side walls
taper upward and inward from a generally downward facing peripheral
edge to an apex ridge of the wall to form the outer face of each of
the side walls. The generally elevated side walls taper downward
and inward from the apex ridge of the wall to form the inner face.
The side wall further extends inward from the base of the inner
face to form a ballast supporting basket lip. Each side walls
defines a downwardly facing open channel that is configured to
receive a corresponding side wall from a corresponding solar panel
mount in a stacking relation.
[0018] The mount unit further comprises a first pair of posts,
wherein each of the first pair of posts extend upward from the
peripheral edge to the top of the first pair of posts at a first
predetermined height above the generally elevated side wall to form
the outer side of each of the first pair of posts. Each of the
first pair of posts taper downwardly and inwardly from the top of
each of the first pair of posts to form the generally inner side of
each of the posts. Each of the first pair of posts forms a
downwardly facing post receiving first mouth that is configured to
receive a corresponding post from a corresponding first pair of
posts of a corresponding solar panel mount in a stacking
relation.
[0019] In one embodiment, the mount unit further comprises a second
pair of posts. Each of the second pair of posts extends upward from
the peripheral edge to a second predetermined height to form the
outer side of a support post. The support posts taper downwardly
and inwardly from the second predetermined height to form the
generally inner side of each of the posts. The second predetermined
height is above the generally elevated side wall. Each of the
second pair of posts forms a downwardly facing post receiving mouth
that is configured to receive a corresponding post from a
corresponding solar panel mount in a stacking relation.
[0020] The mounting unit of one embodiment where the peripheral
edge has a plurality of raised gaps around the base to allow water
to flow under the base without obstruction.
[0021] The mounting unit of another embodiment, wherein the basket
has a large hollow part that is cut away to prevent water from
pooling in the basket.
[0022] In still another embodiment, there is a plurality of units
according to one or more of the embodiments set forth above. The
plurality of units is arranged in a single vertically aligned
stack. A first of the plurality of units is placed onto the bottom
and a second of the plurality of units is vertically aligned with
the first of the plurality of units. The distance between any point
on the first of the plurality of units and the same corresponding
point on the second of the plurality of units is less than
one-half, preferably less than one quarter, more preferably less
than one-eighth, and even more preferably less than one tenth of
the height of the distance from the peripheral lip to the apex
ridge of any one unit.
[0023] The plurality of stacked units of one embodiment, wherein
the plurality are arranged in one vertically aligned stack on a
pallet. A first of the plurality of units is placed directly onto
the pallet on the bottom of the stack and a second of the plurality
of units is vertically aligned with and stacked upon the first of
the plurality of units, wherein distance between any point on the
first of the plurality of stacked units and the same corresponding
point on the second of the plurality of units is less than
one-half, preferably less than one quarter, more preferably less
than one-eighth, and even more preferably less than one tenth of
the height of the distance from the peripheral lip to the apex
ridge of any one unit.
[0024] In one embodiment, unassembled rails and other hardware can
be stacked between the first pair of posts and the second pair of
posts in the plurality of stacked units on the pallet.
[0025] In one embodiment, there is a solar panel mounting system.
The solar panel mounting system comprises a front row of units as
described above. Wherein the first pair of posts of each front row
unit is the only pair of posts on the unit. The mounting system
further comprises a first medial row of units as described above
where the first pair of posts of each first medial row unit are
defined as front posts and the second pair of post of each first
medial row units are defined as back posts and the back posts are
smaller than the front posts.
[0026] The system further comprises a plurality of rails extending
from and fastened to the top of the first pair of posts of each
front row unit. The rails extend towards and are fastened to the
top of front posts of the first medial row of units that are placed
behind the front row of units;
[0027] The system also has a row of solar panels in solar panel
frames. The solar panel frames are fastened to respective pairs of
adjacent rails. The system also has a plurality of ground wires
that are connected to adjacent solar panels in the front row and
the first medial row by ground wire fasteners. The ground wire
fasteners create an electrical connection between the panel frames.
In one embodiment, the fasteners are sufficient to break the
annealed surface of the solar panel frame to effect a favorable
connection.
[0028] The present invention is described hereinafter in Detailed
Description of the Invention in reference to the drawings and
examples, which are intended to teach, describe and exemplify one
or more embodiments of the invention and is in no way intended to
limit the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a perspective view of a four posted mounting unit
of one embodiment of the present invention.
[0030] FIG. 2 is a front elevated view of the solar panel mounting
unit of FIG. 1.
[0031] FIG. 3 is a side elevated view of the solar panel mounting
unit of FIG. 2 taken along the lines 3-3.
[0032] FIG. 4 top view of the solar panel mounting unit of FIG. 2
taken along the lines 4-4.
[0033] FIG. 5 is a bottom view of the solar panel mounting unit of
FIG. 2 taken along the lines 5-5.
[0034] FIG. 6 is a side elevated view of a stack of solar panels of
one embodiment.
[0035] FIG. 7 is a front elevated view of the stack of solar panels
of FIG. 6 taken along the lines of 7-7.
[0036] FIG. 8 is a perspective view of a two posted mounting unit
of one embodiment of the present invention.
[0037] FIG. 9 is a front elevated view of the solar panel mounting
unit of FIG. 8.
[0038] FIG. 10 is a side elevated view of the solar panel mounting
unit of FIG. 9 taken along the lines 10-10.
[0039] FIG. 11 bottom view of the solar panel mounting unit of FIG.
9 taken along the lines 11-11.
[0040] FIG. 12 is a bottom view of the solar panel mounting unit of
FIG. 9 taken along the lines 12-12.
[0041] FIG. 13 is a front view of a stack of solar panel mounting
units of one embodiment.
[0042] FIG. 14 is a side elevated view of the solar panel mounting
units of FIG. 13 taken along the lines 14-14.
[0043] FIG. 15 is a solar panel mounting system of one
embodiment.
[0044] FIG. 16 is an enlarged view of the fastening system of FIG.
15 taken around circle A.
[0045] FIG. 17 is a perspective view of a panel grounding system of
the present invention.
[0046] FIG. 18 is an elevated view of the grounding system
including grounding wire and grounding clamps of one
embodiment.
[0047] FIG. 19 is an end view of the system of FIG. 18 taken along
the lines of 19-19.
[0048] FIG. 20 is a side view of a C-clamp housing of one
embodiment.
[0049] FIG. 21 is a rear view of the housing of FIG. 20 taken along
the lines 21-21.
[0050] FIG. 22 is an unassembled C-clamp housing.
[0051] FIG. 23 is one embodiment of a pin fastener for tool-less
assembly according to of the present invention.
[0052] FIG. 24 shows four mounting units partly assembled with
supporting rails.
[0053] FIG. 25 shows the mounting units of FIG. 24 with a solar
panel affixed to supporting rails.
[0054] FIG. 26a-d shows a process for affixing a solar panel to
supporting rails by a tool-less fastener according to one
embodiment of the present invention.
[0055] FIG. 27-36 illustrate the sequential assembly of a solar
panel supporting system of FIG. 25.
DETAILED DESCRIPTION
[0056] With reference to FIG. 1 and FIGS. 2-5, the present
invention comprises a stackable ballasted roof mounted solar panel
mount unit 10. The ballasted unit is integrally formed into a
single molded piece. By integrally formed, it is meant that the
piece is molded and contoured from a sheet that is preferably a
single unitary piece, but may include multiple pieces that are
adhered together into a single piece that cannot be separated
without destroying the integrity and function of the piece. For
example and without limitation, the piece could not be separated
without cutting the mount unit 10. The mount unit 10 is made of
fiberglass in one embodiment. In another embodiment, it is made of
plastic such as polyethylene and polypropylene preferably high
density polyethylene and high density polypropylene or blends of
polypropylene or polyethylene of any density. In one embodiment the
mount unit is formed from a composite that is capable of being
molded into the desired shape. For example, graphite composites or
other high strength composites known to a person of ordinary skill
in the art may be suitable in one embodiment.
[0057] The mount unit 10 forms a plurality of generally elevated
side walls 12, 14, 16, or 18 of a ballast receiving basket 21. Each
of the generally elevated side walls taper upward and inward from a
generally downward facing peripheral edge 23 to respective apex
ridges 28, 30, 32, and 34 of the wall to form the outer face 20,
22, 24, 26 of each of the side walls 12, 14, 16, and 18. The
generally elevated side walls taper downward and inward from the
apex ridges of the walls to form the inner faces 12B, 14B, 16B and
18B. The side walls further extend inward from the base of the
inner face to form a ballast supporting basket lip 46. With
reference to the bottom view of FIG. 5, each side wall 12, 14, 16
and 18 defines a plurality of downwardly facing open channels 48,
50, 52, and 54 that are configured to receive a corresponding side
wall from a corresponding solar panel mount in a stacking
relation.
[0058] The mount unit 10 further comprises a first pair of posts 56
and 58, wherein each of the first pair of posts 56 and 58 extend
upward from the peripheral edge 23 to the top 60 and 62 of the
first pair of posts 56 and 58 at a first predetermined height above
the generally elevated side walls 12, 14, 16 and 18 to form the
outer side of each of the first pair of posts 56 and 58. Each of
the first pair of posts 56 and 58 taper downwardly and inwardly
from the top of each of the first pair of posts to form the
generally inner side of each of the posts 56 and 58. Each of the
first pair of posts 56 and 58 forms a downwardly facing post
receiving first pair of mouths 60 and 62 (See FIG. 5) that is
configured to receive a corresponding post from a corresponding
first pair of posts of a corresponding solar panel mount in a
stacking relation.
[0059] In one embodiment, the mount unit 10 further comprises a
second pair of posts 66 and 68. Each of the second pair of posts 66
and 68 extend upward from the peripheral edge 23 to the top 70 and
72 of the second pair of posts at a second predetermined height to
form the outer side of the support posts 66 and 68. The support
posts 66 and 68 taper downwardly and inwardly from the second
predetermined height to form the generally inner side of each of
the posts 66 and 68. The second predetermined height is above the
generally elevated side walls 12, 14, 16, and 18. Each of the
second pair of posts 66 and 68 forms a downwardly facing post
receiving mouths 74 and 76 (See FIG. 5) that is configured to
receive a corresponding post from a corresponding solar panel mount
in a stacking relation.
[0060] The mounting unit of one embodiment where the peripheral
edge has a plurality of raised gaps 78 around the base to allow
water to flow under the base without obstruction.
[0061] The mounting unit of another embodiment, wherein the basket
has a large hollow part that is cut away 80 to prevent water from
pooling in the basket.
[0062] With reference to FIGS. 6 and 7, there are a plurality of
units 64A, 64B, 64C, and 64D according to one or more of the
embodiments set forth above. The plurality of units 64A, 64B, 64C,
and 64D is arranged in a single vertically aligned stack 65. A
first unit 64A of the plurality of units 64A, 64B, 64C, and 64D is
placed onto the bottom and a second unit 64B of the plurality of
units is vertically aligned with the first unit 64A of the
plurality of units. The distance between any point on the first of
the plurality of units and the same corresponding point on the
second of the plurality of units is less than one-half, preferably
less than one quarter, more preferably less than one-eighth, and
even more preferably less than one tenth of the height of the
distance from the peripheral lip to the apex ridge of any one
unit.
[0063] The mounting unit of one embodiment where the peripheral
edge has a plurality of raised gaps 78 around the base to allow
water to flow under the base without obstruction.
[0064] The mounting unit of another embodiment, wherein the basket
21 has a large hollow part that is cut away 80 to prevent water
from pooling in the basket.
[0065] With reference to FIGS. 8-12, the present invention
comprises a stackable ballasted roof mounted solar panel mount unit
110. The ballasted unit is integrally formed into a single molded
piece. By integrally formed, it is meant that the piece is molded
and contoured from a sheet that is preferably a single unitary
piece, but may include multiple pieces that are adhered together
into a single piece that cannot be separated without destroying the
integrity and function of the piece. For example and without
limitation, the piece could not be separated without cutting the
mount unit 110. The mount unit 110 is made of fiberglass in one
embodiment. In another embodiment, it is made of plastic such as
polyethylene and polypropylene preferably high density polyethylene
and high density polypropylene or blends of polypropylene or
polyethylene of any density. In one embodiment the mount unit is
formed from a composite that is capable of being molded into the
desired shape. For example, graphite composites or other high
strength composites known to a person of ordinary skill in the art
may be suitable in one embodiment.
[0066] The mount unit 110 forms a plurality of generally elevated
side walls 112, 114, 116, or 118 of a ballast receiving basket 121.
Each of the generally elevated side walls taper upward and inward
from a generally downward facing peripheral edge 123 to respective
apex ridges 128, 130, 132, and 134 of the wall to form the outer
face 120, 122, 124, 126 of each of the side walls 112, 114, 116,
and 118. The generally elevated side walls taper downward and
inward from the apex ridges of the walls to form the inner faces.
The side walls further extend inward from the base of the inner
face 112B, 114B, 116B, 118B to form a ballast supporting basket lip
146. With reference to the bottom view of FIG. 5, each side wall
112, 114, 116 and 118 defines a plurality of downwardly facing open
channels 148, 150, 152, and 154 that are configured to receive a
corresponding side wall from a corresponding solar panel mount in a
stacking relation.
[0067] The mount unit 110 further comprises a first pair of posts
156 and 158, wherein each of the first pair of posts 156 and 158
extend upward from the peripheral edge 123 to the top 160 and 162
of the first pair of posts 156 and 158 at a first predetermined
height above the generally elevated side walls 112, 114, 116 and
118 to form the outer side of each of the first pair of posts 156
and 158. Each of the first pair of posts 156 and 158 taper
downwardly and inwardly from the top of each of the first pair of
posts to form the generally inner side of each of the posts 156 and
158. Each of the first pair of posts 156 and 158 forms a downwardly
facing post receiving first pair of mouths 160 and 162 (See FIG.
11) that is configured to receive a corresponding post from a
corresponding first pair of posts of a corresponding solar panel
mount in a stacking relation.
[0068] The mounting unit basket 121 has a large hollow part that is
cut away 180 to prevent water from pooling in the basket.
[0069] With reference to FIGS. 13 and 14, there is a plurality of
units 164A, 164B, 164C, and 164D according to one or more of the
embodiments set forth above. The plurality of units 164A, 164B,
164C, and 164D is arranged in a single vertically aligned stack 65.
A first unit 164A of the plurality of units 164A, 164B, 164C, and
164D is placed onto the bottom and a second unit 64B of the
plurality of units is vertically aligned with the first unit 164A
of the plurality of units. The distance between any point on the
first of the plurality of units and the same corresponding point on
the second of the plurality of units is less than one-half,
preferably less than one quarter, more preferably less than
one-eighth, and even more preferably less than one tenth of the
height of the distance from the peripheral lip to the apex ridge of
any one unit.
[0070] The method of installing an array 95 of solar panels is
illustrated with reference to FIGS. 15, 16 and 23-36. Installation
begins following a site plan indicating where the panels are to be
located. A chalk line is snapped to square and center the system.
The chalk line represents the line along which the front row
mounting units are aligned.
[0071] There is a front row mounting unit 82 and a first medial row
mounting unit 81 aligned behind the front row mounting unit 82. The
front row mounting unit has a first pair of posts 84. The first
medial row mounting unit 81 has a first pair of posts 88 and a
second pair of posts 83. A rail 86 is shown extending from one of
the first posts 84 of the front row mounting unit 82 to the second
posts of the first medial row mounting units 81. The rail 86 is
fastened to the posts by a fastener known in the art. In one
embodiment the fastener is a pin fastener 85 that is the subject of
U.S. Patent Appl. No. 61/548,024 filed Oct. 17, 2011, which is
incorporated herein by reference in its entirety. In another
embodiment, it is a clevis pin, a detent pin, a locking pin, a
hitch pin or a nut and bolt.
[0072] With reference to FIG. 16 and FIGS. 26a through 26d
illustrating how a solar panel 90 having a lipped frame 91 is
fastened to a rail 86. The rail 86 is configured with a pair of
fastener clamps 87 and 89 that fasten the solar panel 90 to the
rail 86. Step one 26a of the fastening procedure places the lip 92
of the frame 91 on the rail 86 in front of the clamp 89 in its
desired position.
[0073] Then the clamp mechanism 89 is slid forward until the lip 92
of the frame 91 is positioned between a top clamp plate 93 and the
rail 94 surface as shown in FIG. 26b. A wedge plate 95 is pivoted
into position between the bottom surface of the lip 92 and the top
surface of the rail 94. This wedge action clamps the frame 91 to
the rail 94 thereby securing the solar panel to the mounting
system.
[0074] With continued reference to FIG. 24, the mount/rail
configuration of the outside row (designated S) requires only one
rail 86S extended between the front row mounting unit 82S and a
medial row mounting unit 86S and fastened preferably by a fastener
85. Space apart just less than three-fourths of a panel length from
the outside rail 86S, is a second set of a front row mounting unit
82, a medial row mounting unit 81 and a pair of rails 86 extending
from each of the pair of posts of the front row mounting unit 82 to
the tall posts of the medial row mounting unit. Likewise, in one
embodiment, the rails are fastened by a tool-less pin fastener
85.
[0075] With further reference to FIG. 25, a panel 90 is placed over
rail 86S and the adjacent rail 86S. The medial facing edge of each
panel should be positioned equidistance between the legs of the
respective baskets.
[0076] Turning now to FIG. 27, the first row 100A of basket is
continued in the same manner illustrated in FIG. 25, by placing an
additional set of supports including a front row mounting unit 82,
a medial row mounting unit 81 connected by a pair of rails 86
fastened in one embodiment by tool-less pin fastener 85.
[0077] As shown in FIG. 28, a second panel 90 is positioned
adjacent the first panel 90 and fastened to a pair of rails 86 as
hereinbefore described in one embodiment. FIG. 29 illustrates that
the first row 100 A continues by following the pattern described
above with reference to FIGS. 24 through 27 until the last set of a
first row mounting unit 82S connected to a medial row mounting unit
81 by a single rail 86S on the outside edge. The last panel 90 is
affixed as shown in FIG. 30. In each instance, the baskets of any
mounting unit are filled with ballasts prior to attaching the
panel.
[0078] The second row 100B is altered due to a rooftop obstruction
96 that will interfere with the placement of the third row. A row
of medial row mounting units 81 are placed behind the previous row
of medial row mounting units 81 in row 100B with the long legs
positioned towards the previous row. Two mounting units 98 are
turned in opposite direction with the small legs positioned towards
the previous row, but the long legs these reverse position mounting
units 98 are aligned with the long legs of the other medial row
mounting units 81 in the second row 100B. Rails 86 are
fastened--preferably by tool less fasteners 85--to the mounting
units 81 or 98. The side mounting units 81S are attached with only
one rail 86S. A row of panels are added as shown in FIG. 32 after
ballasts are placed in the basket of the mounting units 81 or
98.
[0079] With reference to FIG. 33, a third row 100C is started by
placing an additional row of medial mounting units 81 behind the
preceding row of mounting units 81. Any time that the mounting unit
(81 or 82) cannot be connected to a preceding row, a front row
mounting unit 82 is placed in position. Any time, the mounting unit
(81 or 82) is connected to a unit in front of it and behind it, a
medial row mounting unit 81 is used with the tall legs positioned
towards the preceding row so that the basket will be positioned
behind the solar panels 91 when fully assembled. Any time the
mounting unit (81 or 82) is expected to be connected to a mounting
unit the previous row, but not expected to be connected to mounting
unit behind it, then the mounting unit 91 with four legs is
selected and positioned with the small legs adjacent the front of
the array so that the basket of the mounting unit 91 is positioned
under the solar panel 90 when fully assembled.
[0080] Then, rails are attached between the small posts in front
and the tall posts behind. Then, as shown in FIG. 34, ballasts
weights can be placed in the basket and the panels 90 can be
fastened to the rails to complete the third row 100C.
[0081] The fourth row 100D is added with reference to FIGS. 35 and
36. The mounting units 91 in the last row is positioned with the
small legs forward so that the basket is oriented under the panel
91. If the basket cannot connect to the previous row, then a first
row mounting unit 82 can be used in front of the mounting unit 91
to accommodate attachment of the panel. Once the panels are in
place, ballasts can be placed in the basket and the solar panels 92
can be connected to complete the row 100D.
[0082] The system also has a plurality of ground wires and related
fasteners explained with reference to FIGS. 17-22. The ground wire
180 is formed with two wire terminals. In one embodiment the wire
terminals are ring wire terminals 181 that are affixed to
respective ends of the ground wires by a crimp fitting. The ground
wires are clamped by a ground wire clamp apparatus 182 having a
C-clamp housing 179 defining a first clamping surface 183 and a
second clamping surface 185. The first clamping surface of one
embodiment is flat. The first clamping surface of another
embodiment is knurled or otherwise textured. In one embodiment the
first clamping surface 183 is formed with teeth 184. The second
clamping surface 185 has a hole 186 that receives a nut 187 and
bolt 188 through the hole 186. The bolt 188 extends through the
ring wire terminal 181 and the ring wire terminal 181 is placed
between the second clamping surface 185 and the nut 187. The bolt
188 is freely rotatable and slidable along the axis of the bolt 188
in the C-clamp housing 179. The nut 187 is slidably but not
rotatably received in the C-clamp housing 179 so that rotation of
the bolt 188 relative to the C-clamp housing 179 and the nut 187 in
a tightening direction causes the nut 187 to impinge against and
clamp the ring wire terminals 181 to clamp the terminal and cause
an electrical connection between the terminal and the C-clamp
housing.
[0083] Likewise rotation of the bolt 188 relative to the nut 187
and the C-clamp housing 179 causes the end of the bolt to move
towards the first clamping surface 183. When an edge of the solar
panel frame 189 is placed between the end of the bolt 188 and the
first clamping surface 183, the bolt forces the first clamping
surface 183 and the respective teeth 184 against the side of the
panel frame 189. The teeth 184 penetrate the annealing surface of
the frame 189 to form a reliable electrical connection between the
panel frame and the C-clamp. Thus, by use of the ground wire and
clamping mechanism, a plurality of solar panel frames can be
adequately grounded together.
* * * * *