Patent Application
20120145848
The present invention relates to a pier cap for use with a support post, and more particularly, to a pier cap with a mounting cleat for coupling a solar panel support structure to the pier cap, including systems and methods for manufacturing and assembly relating to the same.
Solar energy is typically harvested using an array of photovoltaic panels which collect solar energy and convert it to electricity. Solar arrays often consist of a large number of panels located in proximity to one another. The individual panels are often secured to structures that support a number of panels at once.
Conventional solar panel array support structures often include posts, to which the support structure is secured. The individual solar panels may be mounted to the support structure, which is then secured to the mounting posts. The support structure is often bolted to a number of mounting posts at a number of locations. For example, pier caps may be coupled to the mounting posts, and the support structure may then be bolted to the pier caps.
The assembly of the support structure generally requires a high degree of precision, and as a result, may be labor intensive. Furthermore, the large number of bolts or other fasteners utilized to secure the support structure to the mounting posts and/or pier caps substantially increases the cost of the support structure and associated solar panel system. In addition, the individual panels of the solar array may require maintenance, which may entail at least a partial disassembly of the support structure, for example, by removing a number of bolts from the mounting posts and/or pier caps. As a result, both installation and maintenance of the array may be costly and time consuming.
The complexity of existing solar panel support structures, and the tedious and difficult nature of their assembly, may be seen, for example, by referring to Cusson, U.S. Patent Application Publication No. 2010/0237028.
Therefore, a need exists for a support structure for solar panels that allows for quicker and less expensive coupling to pier caps, mounting posts and/or other structural or support devices. Further, a need exists to reduce installation and maintenance times and the associated labor and material costs for such solar panel support structures.
In accordance with various embodiments, a support structure for a solar panel array comprises a support rail, such as a hat channel, that comprises a mounting flange. A pier cap may be made of light gage steel, and comprises a mounting cleat that is configured to slidably engage with the mounting flange. A post may be coupled to the pier cap to facilitate providing support to the solar panel array. In an embodiment, the support structure comprises a second support rail with a second mounting flange, and the pier cap further comprises a second mounting cleat configured to slidably engage with the second mounting flange. Additionally, in an embodiment, the pier cap comprises a substantially c-shaped channel configuration.
Further, the pier cap may comprise a hold down mechanism positioned proximate the support rail to facilitate securing the support rail to the pier cap. In this manner, the hold down mechanism may engage the support rail in response to the mounting flange being slidably engaged with the mounting cleat. In an embodiment, the mounting flange is configured to slidably engage with the mounting cleat without using a fastener to couple the mounting flange to the mounting cleat.
According to various embodiments, a method for manufacturing a pier cap comprises forming a material into a channel shaped member during a forming process. During the forming process, a mounting cleat shape may be perforated into the channel shaped member, and the mounting cleat shape may be formed to create a mounting cleat. The mounting cleat forms a space and/or a notch between the mounting cleat and the pier cap, such that the mounting cleat may receive a mounting flange associated with a mounting rail. The mounting cleat shape may be formed into the mounting cleat during the forming process. In an embodiment, the mounting cleat shape may be formed into the mounting cleat during a second forming process. Forming processes as disclosed herein may be any forming process suitable to creating the described components, such as roll forming or press brake forming. Further, in an embodiment, the mounting cleat may be attached to the pier cap after the pier cap has been formed.
Additionally, a method of installing a support structure for a solar panel array, in accordance with various embodiments, comprises securing a pier cap to a support post. A mounting flange on a support rail is aligned with a mounting cleat on the pier cap, such that the support rail provides support to the solar panel array. The method further comprises engaging the mounting flange with the mounting cleat to facilitate engaging the support rail with the pier cap. In an embodiment, a hold down mechanism is disposed proximate the support rail to facilitate preventing the mounting cleat from disengaging with the mounting flange, where a fastener is not utilized to secure the mounting cleat to the mounting flange. In an embodiment, the method further comprises aligning a second mounting flange on a second support rail with a second mounting cleat on the pier cap. The second mounting flange engages the second mounting cleat to facilitate engaging the second support rail with the pier cap.
Moreover, according to various embodiments, a pier cap comprise a support rail engaging surface and a mounting cleat disposed on the support rail engaging surface. The mounting cleat comprises a substantially round-shaped section coupled to the support rail engaging surface and a substantially wedge-shaped prong section elevated above the support rail engaging surface. A notched section of the mounting cleat defines a space between the support rail engaging surface and the substantially wedge-shaped prong section. The notched section is configured to receive a mounting flange coupled to a support rail of a support structure. In an embodiment, the mounting cleat is configured to be at least partially formed during a forming process of the pier cap. Further, in an embodiment, the mounting cleat is configured to be affixed to the pier cap after the pier cap has been formed.
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way. The present disclosure will become more fully understood from the detailed description and the accompanying drawings herein:
The detailed description of various embodiments herein makes reference to the accompanying drawing figures, which show various embodiments and implementations thereof by way of illustration and best mode, and not of limitation. While these embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments, it should be understood that other embodiments may be realized and that mechanical and other changes may be made without departing from the spirit and scope of the present disclosure. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option.
The various embodiments of a support structure comprise the features hereinafter described and particularly pointed out in the claims. The following description and the annexed drawings set forth in detail and demonstrate certain illustrative embodiments of the disclosure. However, these embodiments are indicative of but a few of the various ways in which the principles disclosed herein may be employed. Other objects, advantages and novel features will become apparent from the following detailed description when considered in conjunction with the drawings.
To assist in understanding the context of the present disclosure, a solar panel array configured to utilize a support structure in accordance with various embodiments is illustrated in
Referring to
In accordance with further embodiments, and with reference to
In an embodiment, each support rail 15 has a sufficient number of mounting flanges 22 to interface with the corresponding number of pier caps 20 and mounting cleats 24 with which the mounting flanges 22 interface. For example, each support rail 15 may comprise a plurality of flanges 22 to facilitate coupling support rail 15 to a plurality of pier caps 20. Further, in an embodiment, each support rail 15 may comprise a substantially continuous flange 22 running along the length of support rail 15 to facilitate coupling to mounting cleats 24 on pier caps 20.
Referring to
Various numbers of pier caps 20, mounting cleats 24, support rails 15, and mounting flanges 22 are contemplated in accordance with embodiments of the present disclosure. For example, each pier cap 20 may comprise four mounting cleats 24 configured to interface with four mounting flanges 22 on four support rails 15. Further, depending on the dimensions of solar panel array 5, more or fewer mounting cleats 24, support rails 15, and/or mounting flanges 22 may be employed. In an embodiment, a range of one to four mounting cleats 24 on each pier cap 20 may be utilized. Further, in an embodiment, a range of five to ten mounting cleats 24 on each pier cap 20 may be utilized. In another embodiment, ten or more mounting cleats 24 on each pier cap may be utilized to allow mounting structure 14 to be secured to pier caps 20.
Additionally, a number of pier caps 20 may be advantageously utilized to provide sufficient support to the structure that is mounted to pier caps 20. For example, with reference to
Referring to
With reference again to
With reference again to
The hold down mechanism may comprise any clamp, clip, fastener, or other structure or mechanism configured to facilitate securing support structure 14 and/or support rail 15 to pier cap 20. In a preferred embodiment, the hold down mechanism may comprise a hold down clip 36 that is secured to pier cap 20 and support rail 15 with a bolt 38. Bolt 38 may be configured to pass through a bolt hole 26 in pier cap 20 to facilitate securing panel mounting structure 14 and/or support rail 15 to pier cap 20. With specific reference to
A nut 39 or other fastener may be used to appropriately secure bolt 38 to hold down clip 36. In an embodiment, nut 39 may be stamped or otherwise formed into hold down clip 36. In other embodiments, nut 39 may be a separate component from hold down clip 36. It should be understood that other mechanisms, adhesives, or devices may be utilized to appropriately secure mounting structure 14 to pier cap 20 with or without utilizing bolt hole 26, bolt 38, and/or hold down clip 36, without departing from the scope of the present disclosure.
In various embodiments, one hold down mechanism may be utilized to secure panel mounting structure 14 and/or support rail 15 into pier cap 20, and this one hold down mechanism may sufficiently restrict motion of all support rails 15 and/or mounting flanges 22 with respect to each pier cap 20. In this regard, mounting flanges 22 may not substantially disengage with mounting cleats 24 while the hold down mechanism is in place with respect to support rail 15. In other embodiments, other fasteners may be utilized to secure panel mounting structure 14 to pier caps 20 without using a similar number of fasteners that would be utilized without mounting cleats 24. Further, in certain applications, adhesives, welds, fasteners and/or other devices may be utilized to enhance and/or complement the functionality of cleats 24 and/or the hold down mechanism in securing and providing support to mounting structure 14 and/or other components of solar panel array 5. Accordingly, the use of cleats 24 and/or the hold down mechanism does not necessarily preclude the use of other fasteners.
Various forming processes may be utilized to form the components of pier cap 20 in accordance with embodiments of the present disclosure. For example, pier cap 20 may be created by a metal forming process, and may be formed into a substantially C-shaped channel, into an angle shape, or into other configurations that provide support to mounting structure 14 and/or solar panels 12. In an embodiment, pier cap 20 is formed with a press brake from a sheet of suitable material (such as light gage steel) that has been cut to a suitable size. In another embodiment, pier cap 20 may be roll formed from a sheet of suitable material that has been cut to a suitable size. Any method of forming pier cap 20 which results in a pier cap 20 having characteristics as disclosed herein is contemplated within the scope of the present disclosure.
In various embodiments, mounting cleat 24 may be fabricated concurrently with the forming of pier cap 20. The shape of mounting cleat 24 may be perforated in pier cap 20 during the forming of pier cap 20. Mounting cleat 24 may then be formed to create round shaped rear section 56 coupled to wedge shaped prong 28 in order to form space 30. Such forming may occur during or after the forming of pier cap 20. For example, mounting cleat 24 may be both perforated and formed, creating space 30, during a press brake and/or roll forming process. However, mounting cleat 24 may be formed and/or affixed to pier cap 20 after pier cap 20 has been formed. For example, mounting cleat 24 may be perforated and formed after forming pier cap 20. In an embodiment, mounting cleat 24 may be separately formed and then affixed (e.g., by welding or other adhesion mechanism) to pier cap 20 after pier cap 20 has been formed. Furthermore, it should be understood that any method of forming mounting cleat 24 and affixing it to pier cap 20 to facilitate securing mounting flanges 22 of support rails 15 to pier cap 20 is contemplated within the scope of the present disclosure.
Thus, support structures according to embodiments of the present disclosure facilitate simpler, more efficient, and less expensive installation, removal and/or repair of the support structures. Where such support structures allow for reduced assembly components and labor costs (e.g., where fewer bolts or other fasteners may be utilized), solar panels and other devices that utilize these support structures may be provided and maintained at a reduced cost.
Although this disclosure has been described with respect to certain embodiments, equivalents and modifications will occur to others who are skilled in the art upon reading and understanding of the specification. Various embodiments include all such equivalents and modifications, and are limited only by the scope of the following claims.
Additionally, benefits, other advantages, and solutions to problems have been described herein with regard to various embodiments. However, the benefits, advantages, solutions to problems, and any elements that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as critical, required, or essential features or elements of the inventions. The scope of the disclosure is accordingly to be limited by nothing other than the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more.”
