Patent Application
20150183066
The present invention in general relates to solar panel mounting methods, and it more particularly relates to various techniques for mounting solar panels and methods of making apparatus for the mounting of solar panels.
There is no admission that the background art disclosed in this section legally constitutes prior art.
Solar panel array structures are usually constructed by supporting the solar panels on purlins and securing them in place by a group of individually manually installed edge clips. The solar panel array structures may be mounted on a roof of a residential house, carport, garage, storage unit, and others, for generating electrical power to feed the generated power to the electric power grid.
For example, reference may be made to the following patents; U.S. Pat. No. 8,418,983; Germany Patent Publication No. DE202012005671; PCT Patent Publication No. WO10100376; Germany Patent Publication No. DE202009004746; U.S. Pat. No. 8,256,169; PCT Patent Publication No. WO10071085; U.S. Pat. No. 7,766,292; PCT Patent Publication No. WO11154019; PCT Patent Publication No. WO12104455; Germany Patent Publication No. DE202007012570; U.S. Patent Publication No. 2007/084504; U.S. Patent Publication No. 2102/267490; and U.S. Patent Publication No. 2012/175322. Reference is also made to the “Powers” Slide-in Solar Purlin” as shown at the website address http://powersteel.com/solar/solar-purlin.html.
The conventional mounting technique of employing a plurality of individual edge clips for securing each solar panel to a purlin has been less than satisfactory for some applications. An installer must attach individual clips by hand at the job site by typically using a tool to drive fasteners into the clips to hold the solar panel in place on an underlying purlin, which in turn, is fixed on top of a desired support structure. Oftentimes, four or more clips must be used to secure the panel to the purlin. Manipulating the clips by the installer is time consuming and awkward. Therefore, the overall cost of the project increases undesirably as a result.
Prior known solar panel mounting methods have also had other draw backs. Edge clips have been installed from on top of the solar panel arrays. In this regard, the installer usually must be raised up by a lift or standing on the rail of the left to a position above the panels where each panel can be secured in place by the clips. Thus, safety for the installer may be an issue, since installers can sustain serious injuries by falling from the lift. Also, such an unsafe installation technique which places the installer at risk, may be a violation of governmental safety regulations such as the Occupational Safety and Health Administration federal regulations and possibly others.
Further, when an inoperable panel requires replacement in conventional systems, the installer must again position themselves above the array in order to loosen the edge clips, take out the inoperable panel, insert a new panel, and then tighten back down each one of the edge clips. Furthermore, at least some conventional systems require that some or all of the adjacent solar panels be removed during the installation of a single new panel. Additionally, in some situations where the malfunctioning solar panel is located in the center of the array of panels, the installer may have to walk on the array of panels in a very unsafe manner to gain access to the panel to be replaced.
In order to better understand the invention and to see how the same may be carried out in practice, non-limiting preferred embodiments of the invention will now be described with reference to the accompanying drawings, in which:
Certain embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the invention are shown. Indeed, these embodiments of the invention may be in many different forms and thus the invention should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided as illustrative examples only so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.
It will be readily understood that the components of the embodiments as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the certain ones of the embodiments of the apparatus system, components and methods of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, as claimed, but is merely representative examples of one or more of the embodiments of the invention.
Methods of solar panel mounting include a method of making a support apparatus for solar panels. The support apparatus is made by attaching an elongated clamp apparatus to an upper portion of a purlin for supporting a row of adjacent solar panels from below. The clamp apparatus is attached to the purlin by extending fastening devices between the purlin and a clamp rail of the clamp apparatus. A portion of the fastening device is captured to prevent it from rotating, and a rotatable member may be connected to the fastening device to cause the clamp apparatus to move firmly against a continuous line of engagement with upper marginal edges of the row of adjacent solar panel supported on the purlin to secure the solar panels between the clamp rail and the purlin.
Methods of solar panel mounting include a method of making a support apparatus for solar panels. The support apparatus is made by attaching an elongated clamp apparatus to an upper portion of a purlin for supporting at least one solar panel from below. The clamp apparatus is attached by extending fastening devices between the purlin and a clamp rail of the clamp apparatus. A resilient spacer may be disposed at the fastening device to separate the clamp rail from the solar panel. A portion of the fastening device may be captured to prevent it from rotating, and a rotatable member of the fastening device may be disposed below a solar panel support surface of the purlin to cause the clamp apparatus to move downwardly firmly against an upper marginal edge of the solar panel supported on the purlin to secure the at least one solar panel between the clamp rail and the purlin.
According to an embodiment, a stop may be installed so that when the rotatable member is forcibly rotated to move the clamp rail toward the marginal edge of the at least one solar panel against the force of the resilient spacer to compress it, the stop prevents further movement of the clamp member to help stabilize the clamp rail.
According to a further embodiment, a method is disclosed of making a clamp apparatus for securing a solar panel to a purlin. The method includes connecting a fastener to the underside of a clamp rail. A resilient spacer is attached to the fastener for providing a sufficient solar panel receiving space between the clamp rail and the purlin. The upper end of the fastener is secured to the clamp rail in a generally non-rotatable manner. The lower end of the fastener is provided with a rotatable member for enabling the resilient member to be compressed when rotating the member mounted on the fastener from below to move the clamp rail into engagement with an upper marginal edge of the solar panel.
According to another embodiment, a method is disclosed of securing a solar panel on a purlin, and includes positioning the solar panel onto the purlin and applying force distributed along one upper marginal edge of the panel to help secure it tightly against the purlin. The applying of the force includes fastening from below the solar panel by moving the clamp rail downwardly firmly into engagement with the solar panel.
A support apparatus for securing at least one solar panel to a support structure is constructed in accordance with an embodiment. The support apparatus may include a fastener attached at its upper end to a clamp rail in a non-rotatable manner and adapted to be installed at its lower end to a purlin. A resilient spacer may hold the clamp rail open to receive a solar panel marginal edge and may be compressed when rotating a rotatable member on the bottom portion of the fastener from below the solar panel to close the clamp rail onto an upper marginal edge of the at least one solar panel along a continuous line of engagement therewith.
According to another embodiment, a clamp apparatus for securing at least one solar panel to a purlin may include a fastener attached at its upper end portion to the underside of a clamp rail in a generally non-rotatable manner and having a rotatable member at its lower end portion. A resilient spacer may be provided to help to position the clamp rail in its opened position to provide a panel receiving opening above a panel receiving surface of the purlin. The resilient spacer may compress responsive to driving the rotatable member of the fastener from below the solar panel to cause the clamp rail to close and thus to engage an upper marginal edge of the at least one solar panel along a continuous line of engagement therewith, to secure it in place on the purlin.
Another embodiment relates to a support apparatus for securing at least one solar panel to a support structure. The support apparatus may include clamp apparatus for mounting above a purlin to secure the at least one solar panel on top of the purlin. The clamp apparatus includes a clamp rail and a series of fastening devices. Each fastening device includes a fastener attached at its upper end to the clamp rail in a generally non-rotatable manner and attached to an upper surface of the purlin. The fastening device may further include a rotatable member at its lower end. A resilient spacer may be provided to help position the clamp rail in its opened position to provide a panel receiving opening above a panel receiving surface of the purlin. The resilient spacer may compress in response to driving the rotatable member of the fastener from below the solar panel to cause the clamp rail to close and thus to engage an upper marginal edge of the at least one solar panel along a continuous line of engagement therewith, to secure the at least one solar panel in place on the purlin.
Therefore, according to at least one embodiment, an installer can safely tighten down an array of solar panels from a safe position such as standing on the ground, in a quick and easy manner. Also, for some applications, the installer can also still be safely positioned in the left (not shown) and be able to tighten from underneath the array of panels. These novel techniques eliminate, or greatly reduce the possibility of endangering the safety of the installer attempting to install conventional edge clips from unsafe heights.
According to an embodiment, there is provided approximately two fastening devices per panel along a clamp rail. The fastening devices can quickly and easily be tightened to secure the clamp rail into a continuous line of engagement with a marginal edge of either one solar panel or two adjacent solar panels. This is in sharp contrast to conventional techniques where the installer must both install and tighten four small individual clips for securing each panel in place. With the present embodiments, no installation of edge clips is required, since the support apparatus may all be assembled in the factor and not at the job site. Also, there may be only about half as many fastening manipulations required, since there are about half as many fastening devices employed per solar panel as compared to conventional edge clips. Thus, the time to assemble the solar panel array at a given job site is dramatically reduced as compared to conventional mounting techniques, and therefore the overall cost of the project is significantly reduced accordingly.
Additionally, by utilizing the solar panel support apparatus, the solar panels are held much more securely in place. According to an embodiment, a pair of clamp rails may be used to secure the opposite marginal edges of each panel along a continuous line of engagement therewith. This technique enables a much more secure attachment of the panels to the underlying purlin, as compared to single points of attachment by edge clips.
Referring now to the drawings, and more particularly to
In other embodiments, the purlins may have other shapes such as a Z-shape purlin (not shown) or any other shape that allows access to the top of the purlin from the side and/or below the purlin. Individual solar panels 18 may be installed between the clamp apparatus 50, 60 and 70 and the purlins 16. The clamp apparatus 50, 60 and 70 including the mounted solar panels 18 may be inclined at an angle to achieve maximum or at least more favorable total energy output for the entire solar panel array purlin assembly 10. This tilt angle may range from about 2 degrees to about 45 degrees, and more particularly from about 10 degrees to about 20 degrees depending upon location and application of the solar panel system 10. One example as indicated in the drawings may be about 15 degrees as shown in the drawings.
The dimensions of one conventional type of solar panel 18 may be approximately 65 inches by about 39 inches by about 2 inches. Other types and sizes of solar panels may also be usable with the support apparatus of the present embodiments. The clamp apparatus 50, 60 and 70 may be prefabricated and preassembled of a metal material such as galvanized steel, aluminum or other suitable materials.
As shown in
The middle elongated clamp rail 20 may be a one-piece rail and may include a U-shape section 22 having a short upwardly extending flange 26 and a long downwardly extending flange 24. The flanges extend outwardly in a common plane from the top of U-shape section 22. Both the short flange 26 and a long flange 24 are designed to hold down adjacent solar panels 18 onto the top of the C-shape purlin 16 during final installation to help form an array of solar panels. The flanges 24 and 26 engage upper marginal edges of the adjacent panels along continuous lines of engagement. The U-shaped section 22 may be connected to the C-shape purlin 16 with a series of spaced apart fastening devices 28 for causing the clamp rail 20 to move into engagement with the adjacent panels 18 to secure them in substantially a common plane.
The top clamp rail 30 may include a W-shaped section 32 having a long flange 34 and a leg flange 36. The long flange 34 extends downwardly outwardly in a parallel direction to the panel engaging top surface of the purlin 18, to form one side of the W-shape portion and is designed to press downwardly against an end marginal edge of a top end solar panel 18 of a solar panel array and against the top of the C-shape purlin 16. The leg flange 36 extends downwardly to form the other side of the W-shaped portion and serves to stabilize the clamp rail 20 when it is closed against the panel 18 as shown. The W-shaped section 32 may be connected to the C-shaped purlin 16 with a series of spaced apart fastening devices 28. During final installation, the leg flange 36 is designed to press against the panel engaging upper surface of the C-shape purlin 16 as the fastening device 28 is being tightened from below such that the long flange 34 is forced downward against an upper marginal edge of the solar panel 18 along a continuous line of engagement therewith.
In another embodiment (not shown), the fastening device 28 may be reversed so that the nut 48 is captured within the bottom of the U-shape section 22 and the bolt 41 having a head 49 may be a rotatable member disposed below the C-shape purlin 16. In this embodiment, the nut 48 is designed to be captured so as not to substantially rotate while tightening, when rotating the bolt 41 from below the solar panels. Thus the bold head may be rotated from the ground or other safe location to close the clamp device onto the margin edge of at least one solar panel.
As best seen in
After a solar panel 18 is installed on either or both sides of the fastening device 28, the bolt 48 is tightened by an installer from below the solar panel while standing on the ground or other safe location, to force the middle clamp rail 20 downwardly thus compressing the resilient sleeve 53 until the solar panel 18 is held firmly in place.
Similarly, a top clamp rail apparatus and a bottom clamp rail apparatus may include W-shaped sections and a fastening device 28 that may connect a W-shaped section 32 and a W-shaped section 42 respectively to a C-shape purlin. Also, the C-shaped purlin or other similar purlin (not shown) may be designed to permit easy accessed to the rotatable member such as the bolt 48 by a suitable conventional tool (not shown) used by an installer.
Next, as shown in
As shown in
In this embodiment, the fastening device further includes a stop in the form of a rigid sleeve 45 that surrounds telescopically resilient sleeve 53. The rigid sleeve may be made of a rigid material such as PVC pipe or other suitable rigid load bearing material. After a solar panel 18 is installed on either or both sides of the fastening device 28, nut 42 may be tightened from below by an installer from through opening 47 in the C-shape purlin 16 which forces the middle clamp rail 20 downward thus compressing the resilient sleeve 53 onto the upper marginal edge or edges of solar panel 18. In this embodiment, the downward motion of the middle clamp rail 20 is stopped when contacting the rigid sleeve 45.
The rigid sleeve 45 is designed to provide additional stability to the clamp rail apparatus 31. This embodiment of the clamp rail apparatus 31 may be employed as shown in
Referring now to
Referring now to
Referring now to
Referring to box 131, a portion of the fastening devices may be captured within the clamp rail to prevent the upper portion of the fastening devices from rotating. As indicated in box 133, rotatable members or devices such as nuts 48 may be positioned onto the fastening devices below the purlin solar panel support surfaces. Finally, as indicated in box 135, a stop in the form of a rigid sleeve 45 may be attached to each fastening device to limit the movement of the clamp rail toward the purlin.
Although the invention has been described with reference to the above examples, it will be understood that many modifications and variations are contemplated within the true spirit and scope of the embodiments as disclosed herein. Many modifications and other embodiments will come to mind to one skilled in the art to which the invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. For example, it is contemplated that the clamping devise may be tightened into a closed position from above the panel array for some applications, whereby the clamp rails may be closed tightly against a row of adjacent panels from above, instead of from below the panels. Therefore, it is to be understood that the invention shall not be limited in any way to the specific embodiments disclosed herein or modifications thereof, and that modifications and other embodiments are intended and contemplated to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
The present patent application is related to U.S. patent application entitled SOLAR PANEL SUPPORT APPARATUS, filed Jan. 2, 2014, and assigned application Ser. No. ______, which is incorporated herein by reference as if set forth herein in its entirety.
