Patent Application
20080230108
The present invention relates generally to solar panel arrays and, more particularly, to a solar panel array apparatus and method utilizing vertical supports that may be installed through a pounding action, and that are adapted to rotate during the pounding process to permit a more secure ground installation.
Prior art installation designs and processes for mounting photovoltaic or other types of solar panels to the ground (as opposed to, for example, the roof of a building) are intended to hold the solar panels against wind, hail, rain and snow. In one type of prior art installation, solar panels are mounted at a fixed angle relative to a horizontal support(s), with the horizontal support(s) in turn being secured to two or more vertical supports. In another variation, solar panels are mounted on a platform, which in turn is secured to two or more vertical supports, with the platform being capable of tilting along a single axis to follow the angle of the sun.
In prior art installations, it is often the case that the vertical supports are placed into large holes dug into the ground, which are then filled with reinforced concrete to securely hold the vertical supports in place. Occasionally, reinforced concrete foundations are created and the vertical supports are bolted to the concrete.
Recently, several companies have offered vertical supports that have screw threads, such as those manufactured by American Earth Anchors®. These have a thread much like a wood screw and are often cast or machined to create the thread. As a result, they are relatively expensive to manufacture. Prior art screw-in supports must be rotated as they enter the earth. Machines have been developed that apply a large and steady downward force, and, at the same time, a rotation to “screw” the support into the ground. The rotation enables the support to be screwed into the ground and the steady downward force enables the support to penetrate into dense soils. However, these machines are expensive and the process of screwing in a support is slow. As a consequence, the total cost of installation per support is relatively high.
Prior art designs, as herein described by way of example, are relatively expensive and significantly increase the total cost of a system that uses solar panels to capture energy from the sun, making it more expensive to utilize solar technology. A need exists for apparatuses and methods for more economically installing solar panel arrays in the ground. In particular, a need exists for vertical support components of a solar panel array that are relatively inexpensive to fabricate and that may be installed without the need for a concrete foundation or the use of relatively expensive equipment for screwing supports into the ground. The present invention satisfies this need, and provides other related advantages.
In accordance with an embodiment of the present invention, a solar panel apparatus is disclosed. The apparatus comprises, in combination: first and second vertical supports; wherein the first and second vertical supports are comprised of extruded metal having a twist of sufficient length to permit ground installation utilizing a post pounding device in a manner that permits the first and second vertical supports to rotate during pounding; a horizontal support positioned on the first and second vertical supports; at least one solar panel positioned on the horizontal support.
In accordance with another embodiment of the present invention, a method for installing a solar panel array is disclosed. The method comprises: providing first and second vertical supports; wherein the first and second vertical supports are comprised of extruded metal having a twist of sufficient length to permit ground installation utilizing a post pounding device in a manner that permits the first and second vertical supports to rotate during pounding; providing first and second caps adapted to be positioned on a top portion of each of the first and second vertical supports; providing at least one horizontal support; providing at least one solar panel; positioning the first cap on the top portion of the first vertical support; positioning the second cap on the top portion of the second vertical support; positioning a post pounding device proximate the first vertical support; utilizing the post pounding device to pound the first cap, causing a bottom portion of the first vertical support to enter the ground and further causing the first vertical support to rotate as it penetrates deeper into the ground; utilizing the post pounding device to pound the second cap, causing a bottom portion of the second vertical support to enter the ground and further causing the second vertical support to rotate as it penetrates deeper into the ground; positioning the horizontal support on the first and second vertical supports; and positioning at least one solar panel on the horizontal support.
In accordance with a further embodiment of the present invention, a method for installing a solar panel array is disclosed. The method comprises: providing first and second vertical supports; wherein the first and second vertical supports are comprised of extruded metal having a twist of approximately one rotation per linear foot; providing first and second caps adapted to be positioned on a top portion of each of the first and second vertical supports; wherein the first and second caps further comprise means for permitting them to rotate relative to the first and second vertical supports during pounding of the first and second caps; providing at least one horizontal support; providing at least one solar panel; positioning the first cap on the top portion of the first vertical support; positioning the second cap on the top portion of the second vertical support; positioning a post pounding device proximate the first vertical support; utilizing the post pounding device to pound the first cap, causing a bottom portion of the first vertical support to enter the ground and further causing the first vertical support to rotate as it penetrates deeper into the ground; utilizing the post pounding device to pound the second cap, causing a bottom portion of the second vertical support to enter the ground and further causing the second vertical support to rotate as it penetrates deeper into the ground; positioning the horizontal support on the first and second vertical supports; and positioning at least one solar panel on the horizontal support.
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In one embodiment, a twist 14 of approximately one rotation per linear foot may be provided for the vertical support 12, but some deviation from this length would be permitted without departing from the spirit or scope of the present invention. In determining an appropriate length for the twist 14, the motivation is to provide sufficient twist so as to cause the vertical support 12 to rotate as it is pounded into the ground, as opposed to the twist 14 simply causing the displacement of soil during such an installation. Once the vertical support 12 is in the ground, the twist 14 presents a surface with a horizontal component that resists upward forces which would otherwise pull the vertical support 12 out of the ground. This gives the vertical support 12 the ability to resist the upward forces that can result from high winds hitting the flat surfaces of solar panels.
To emphasize, in contrast to the screw thread of a “screw-in” support, the twist 14 as herein described is mostly vertical, so as to appropriately respond to the entirely vertical force applied by the pounding device. The twist 14 only has a relatively small horizontal component, and only creates a relatively small and slow rotation of the vertical support 12 as it is being pounded into the ground. The guides that are formed in the earth have sufficient strength to convert a small fraction of the applied vertical force into a small horizontal force that rotates the vertical supports 12 as they are pounded. (In comparison, for a screw-in post, the screw threads are mostly horizontal and only have a very small vertical component. They would have to convert most of the vertical force into rotational motion, but the earth is insufficiently rigid and strong to accomplish this conversion.)
In one embodiment of this invention, the vertical support 12 is pounded with a conventional post-pounder of the type that may be used to pound ordinary fence posts, such as the Kinghitter III®. Unlike the machines that rotate screw-in supports into the ground and apply large, steady downward pressure at the same time, post-pounders drop a weight from a large height and ram the post into the ground. These post-pounders are simple, reliable, inexpensive and operate quickly.
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Although particular embodiments of the invention have been described in detail for purposes of illustration, various modifications may be made without departing from the spirit and scope of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.
