The present disclosure relates to solar panel mounting systems.
In various embodiments, a mounting system may comprise a downslope rail, an upslope rail, a first clamp and a second clamp. The downslope rail may have a first profile and comprising a downslope face and an upslope shelf. The upslope rail may have a second profile and comprising a downslope shelf and an upslope face. The first clamp may be configured to engage the downslope face and accept the installation of a first end of a solar panel. The second clamp may be configured to engage the upslope face and retain a second end of the solar panel against a downslope shelf
The downslope face may comprise a plurality of serrations. The first clamp may be configured to engage the plurality of serrations.
The solar panel may be configured to pivot into or rock into the first clamp. The solar panel may be configured to create an upward load on the first clamp in response to the pivoting or rocking. The solar panel may cause the first clamp to load the serrations in response to the pivoting.
The upslope shelf may include a pivot point or fulcrum. The solar panels may be configured to rock into a channel defined between the first clamp and the up slope shelf. The solar panels may rock on the pivot point or fulcrum.
The downslope rail may include a slot that is configured to receive a fastener. The first clamp may be configured to receive a portion of the fastener. The first clamp may be configured to support an array skirt. The first clamp may comprise a support slot and a support shelf. The array skirt may be configured to engage the support slot and the support shelf
The forgoing features and elements may be combined in various combinations without exclusivity, unless expressly indicated herein otherwise. These features and elements as well as the operation of the disclosed embodiments will become more apparent in light of the following description and accompanying drawings.
The subject matter of the present disclosure is particularly pointed out and distinctly claimed in the concluding portion of the specification. A more complete understanding of the present disclosure, however, may best be obtained by referring to the detailed description and claims when considered in connection with the drawing figures, wherein like numerals denote like elements.
The detailed description of exemplary embodiments herein makes reference to the accompanying drawings, which show exemplary embodiments by way of illustration. While these exemplary embodiments are described in sufficient detail to enable those skilled in the art to practice the inventions, it should be understood that other embodiments may be realized and that logical, chemical and mechanical changes may be made without departing from the spirit and scope of the inventions. Thus, the detailed description herein is presented for purposes of illustration only and not of limitation. For example, the steps recited in any of the method or process descriptions may be executed in any order and are not necessarily limited to the order presented. Furthermore, any reference to singular includes plural embodiments, and any reference to more than one component or step may include a singular embodiment or step. Also, any reference to attached, fixed, connected or the like may include permanent, removable, temporary, partial, full and/or any other possible attachment option. Additionally, any reference to without contact (or similar phrases) may also include reduced contact or minimal contact.
Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “central,” “upper,” “lower,” “front,” “rear,” etc.) are only used to simplify description of embodiments of the present invention and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.
Solar panel mounting systems have generally been provided in two distinct types. These types include rail based systems and rail-less systems. Rail based systems may have a cheaper overall system installation cost. However, rail-less systems are generally considered faster and more efficient to install. As such, there is a need for a solar mounting system that is inexpensive and faster to install.
In various embodiments, the systems, methods, and apparatuses described herein are directed to a hybrid solar panel mounting system. In this regard, the hybrid system can provide a cheaper and more efficient solar mounting system that traditional rail based or rail-less systems.
In various embodiments and with reference to
In various embodiments, downslope rail 102 may comprise one or more teeth 104 (e.g., serrations, notches, steps, and/or the like). First clamp 110 may include teeth 118. Teeth 104 of downslope rail 102 may be configured to interface and interlock with teeth 118. In this regard, teeth 104may couple and/or interlock with teeth 118 thereby coupling downslope rail 102 with first clamp 110. When installed between first clamp 110 and downslope rail 102, solar panel 10 may create an upward force on first clamp 110 causing teeth 104 and teeth 118 to be retained against one another.
In various embodiments, interlocking teeth 104 and 118 of downslope rail 102 and first clamp 110, respectively, may adjustably couple to one another to accommodate solar panels of varying thicknesses (e.g., solar panels with thicknesses from 20 millimeters to 65 millimeters). The teeth 104 or teeth 118 may include one or more indicators (e.g., a symbol, number, color, and/or the like on each tooth) that allow arrangement of the interlocking teeth at specific positions to accommodate the thickness of solar panel 10 being used. In this regard, system 100 may be configured to work with, support, and/or retain any suitable solar panel, photovoltaic module, and/or the like.
In various embodiments, downslope rail 102 may include a panel shelf 106. Panel shelf 106 may be configured to receive and support at least a portion of solar panel 10. Moreover, Panel shelf 106 may define a portion of a channel between downslope rail 102 and first clamp 110. The channel may be configured to receive and retain a portion of solar panel 10. Panel shelf 106 may further comprise and/or define a fulcrum or pivot 107. A portion of a frame of solar panel 10 may be configured to contact and/or engage the pivot 107. Panel 10 may be placed on panel shelf 106 at an angle and loaded with downward pressure (e.g., pressure on the panel directed to the roof surface). The downward pressure may cause panel 10 to rotate or rock on pivot 107 into the channel defined by panel shelf 107 and first clamp 110. In this regard, panel 110 may be rocked into and secured between first clamp 110 and panel shelf 107 of downslope rail 102.
In various embodiments, first clamp 110 may also be retained on downslope rail 102. For example, downslope rail 102 may include an attachment point 108 (e.g., a slot, one or more threaded holes, a shelf, a groove and/or the like) that is capable of and/or configured to receive first clamp 110 and/or an attachment device 111 (e.g., a clamp, a shelf, a fastener, such as for example, a nut and bolt, a nut and t-bolt, and/or the like). Attachment device 111 may be integral with and/or be a portion of first clamp 110. Attachment device 111 may also be installable in and/or through first clamp 110 and downslope rail 102.
In various embodiments, first clamp 110 may include an optional array skirt attachment system. The array skirt attachment system may be configured to accept and support an array skirt 126. The array skirt attachment system may be integrally formed on and/or attached to first clamp 110. The array skirt attachment system may comprise a support shelf 114 and/or a support slot 116. For example, array skirt 126 may comprise a corresponding shelf that is installable on support shelf 114. Array skirt 126 may be retained on the array skirt attachment system at support shelf 114. For example, first clamp 110 may comprise an array skirt attachment point (e.g., a slot, one or more threaded holes, and/or the like) that is configured to receive a retention device (e.g., a fastener, a rivet, weld, solder, braze, and/or the like) to capture the shelf of the array skirt on support shelf 114. Array skirt 126 may also comprise a tab that is installable in and/or supported by support slot 116.
In various embodiments, system 100 may comprise a pedestal 124 and a slide 120. Slide 120 may be mountable to a roof surface (e.g., roof decking, a roof truss, and/or the like). Slide 120 may be mountable to the roof surface by one or more suitable fasteners 122 (e.g., a lag bolt, a screw, a nail, an adhesive, and/or the like). Slide 120 may be configured to receive and support pedestal 124. In this regard, pedestal 124 may be positionable along any point of slide 120 to allow for upslope—downslope or north—south adjustability on the roof
In various embodiments, pedestal 124 may be configured to couple to and support shaft 128. Shaft 128 may be a threaded shaft. Shaft 128 may be configured to support and/or adjust other structures in system 100 including, for example, downslope rail 102, first clamp 110, and/or the like. Shaft 128 may be configured to receive and/or be engaged by tie plate 132. Shaft 128 may also be configured to receive and/or be engaged by nut 130. Nut 130 may be a flange nut.
In various embodiments, tie plate 132 may be installed on downslope rail 102. For example, tie plate 132 may be installed in a receivable slot or channel 103 defined in downslope rail 102. Tie plate 132 may include one or more holes that allow shaft 128 to pass through tie plate 132. Tie plate 132 may also comprise one or more engagement flanges for engaging portions of downslope rail 102.
During assembly of the downslope rail of system 100, nut 130 may be positioned through a hole in downslope rail 102. Tie plate 132 may be slide into channel 103 of downslope rail 102. Tie plate 132 may include a hole that may be aligned with the hole in downslope rail 102 and the threaded hole of nut 130. Shaft 128 may be installed through the hole in tie plate 132 into the threaded hole of nut 130 allowing the shaft to pass through downslope rail 102 as nut 130 is advanced down shaft 128. In this regard, shaft 128may be retained and/or captured in downslope rail 102 by nut 130 and tie plate 132.
In various embodiments and in operation, nut 130 may be accessible from above downslope rail 120 and/or solar panel 10 allowing an installer to access and level system 100 and/or one or more solar panels 10 at each nut 130. More specifically, downslope rail 102 may translate up or down on shaft 128 based on or in response to actuation (e.g., spinning) of nut 130 on shaft 128.
In various embodiments and with reference to
In various embodiments and with reference to
In various embodiments, upslope rail 342 may comprise a shelf 343. Shelf 343 may be integrally formed in upslope rail 342. Shelf 343 may be configured to support the face of a solar panel 10. Moreover, shelf 343 may include a slot or channel. The slot or channel may be configured to receive a fastener.
In various embodiments, system 300 may further comprise a slide 320 and a pedestal 324. Slide 320 may be secured, coupled, and/or otherwise fastened to the roof surface with any suitable fastener 322 including, for example, a lag bolt. Pedestal 324 may slidably engage slide 320 and may be positionable along any length of slide 320. Pedestal 324 may be secured on slide 320 with a set screw or other suitable attachment device.
In various embodiments, mounting system may include one or more mounting clips 340. Mounting clip 340 may be operatively coupled to upslope rail 342 at any suitable point along upslope rail 342. For example, mounting clip 340 may be positioned to engage a panel at a point as prescribed by solar panel manufacturer. Moreover, clip 340 may be adjustable along the length of upslope rail 342 which will facilitate the use of mounting system 300 with any solar panel 10. More specifically, clip 340 may be positioned at any point along upslope rail 342 to engage panel 10 at a location defined by anyone of a panel manufacturer, a system designer, an installer, an integrator, a rail manufacturer and/or the like. In this regard, mounting clip 340 is configured to make mounting system 300 customizable and universal. Mounting clip 340 may be configured to support an edge of a solar panel. In this regard, mounting clip 340 may support the trailing edge of the panel (e.g., upslope on array 20).
In various embodiments, clip 340 may comprise a top clamp portion 336 and a bottom clamp portion 334. Top clamp portion 336 and bottom clamp portion 334 may be formed as a single piece. Top clamp portion 336 and bottom clamp portion 334 may also be an assembly held together by a fastener 338. Top clamp portion 336 and bottom clamp portion 334 may be adjustable relative to one another so that they may engage and support a solar panel of any suitable thickness. Bottom clamp portion 334 may comprise an engagement arm 335 that is configured to engage and/or couple to upslope rail 342. In this regard, engagement arm 335 may be configured to engage a slot or channel in upslope rail 342. Engagement arm 335 may also partially wrap around a bottom surface of upslope rail 342. Bottom clamp portion 342 may also include a fulcrum point in the shelf allowing for a solar panel 10 to be rocked in. Top clamp portion 336 may also be removable or adjustable to allow panel 10 to be placed on the shelf defined by bottom clamp portion 334. In this regard, panel 10 may be captured between and/or positively retained by top clamp portion 336 and bottom clamp portion 334. The amount of pressure created between top clamp portion 336 and bottom clamp portion 334 may be adjusted by adjusting the fastener used to retain top clamp portion 336 and bottom clamp portion 334 together as an assembly.
In various embodiments, pedestal 324 may further comprise a support rod 325. Support rod 325 may be configured to engage and support clip 344. Support rod 325 may be operatively coupled to clip 344 with a fastener and/or a leveling system. The leveling system may include a flange nut 330 and/or a tie plate 332. Nut 330 may be installed in a channel or slot defined in clip 322. A portion of nut 330 may also pass through a hole in clip 344. Tie plate 332 may also be installed within the channel or slot of clip 344. Support rod 325 of pedestal 324 may be installable through tie plate 332 and nut 330. Support rod 325 may comprise threads that engage nut 330 and/or tie plate 332. Nut 330 may be accessible from above a solar panel array 20 (e.g., an array comprising 2 or more solar panels including, for example, solar panel 10-1, solar panel 10-1, and/or the like). In operation, nut 330 may be accessible after one or more solar panels 10 are attached to downslope rail 342 to allow the array to be leveled by turning nut 330.
In various embodiments and with reference to
In various embodiments, the leading edge of solar panel 10-2 may be supported by a portion upslope rail 442-1. For example, the leading or downslope edge of solar panel 10-2 may directly engage a portion of upslope rail 442-1. Solar panel 10-2 may also be configured to engage and/or, otherwise, rock into one of more clamps that are operatively coupled to upslope rail 442-1. The upslope edge of solar panel 10-2 may be supported by, configured to engage and/or operatively coupled to upslope rail 442-2. Upslope rail 442-1 and upslope rail 442-2 may have the same general cross sectional profile. Moreover, upslope rail 442 (e.g., upslope rail 342 as shown in
In various embodiments and with reference to
In various embodiments and with specific reference to
In various embodiments, columns A and B, as show in
In various embodiments, the mounting systems described herein may be coupled to a roof my any suitable mount system. The mount system may include a slide 520. Slide 520 may be coupled to a roof with a fastener 522. Fastener 522 may be any suitable fastener including, for example, a screw, a law screw, a bolt, a nail, and/or the like. Fastener 522 may be sealed with seal 521. Seal 521 may be any suitable washer including, for example, an EPDM washer, a rubber washer, a metal washer, and/or the like. Slide 520 may also comprise a slot or channel 523. The mounting system may also comprise support shaft 528. Support shaft 528 may be receivable within channel 523. Moreover, support shaft 528 may be secured at any position along slot 523 of slide 520 by attachment mechanism 529 (e.g., a nut).
In various embodiments and with reference to
In various embodiments, each mounting point may include leveling features. In this regard, an installer may access nut 630 from above the panels (e.g., panel 10 as shown in
In various embodiments, the mounting system described herein may be provided with the ability to employ an array skirt. The mounting system described herein may also be provided without the ability to install an array skirt. For example, and with reference to
In various embodiments and with reference to
In various embodiments, downslope rail 802 may also be installed in standard lengths (e.g., 72 inch lengths, 48 lengths, and/or any other suitable length). Standard lengths may be defined by an installation region, environmental loads the panels may be subjected to, requirements of an authority having jurisdiction, requirements or preferences of an installer or integrator, as defined by the engineer designing a solar system, and/or any other standard defining entity or authority.
In various embodiments and with reference to
In various embodiments and with reference to
In various embodiments and with reference again to
The systems, methods, and apparatuses described herein may be used with any suitable roof mounted structure including, for example, a solar panel array or system, and/or the like. The systems may also be used with any suitable roof system, including for example, shingle roofing systems, metal roofing systems, slate roofing systems, concrete or ceramic tile roofing systems, and/or the like.
Benefits, other advantages, and solutions to problems have been described herein with regard to specific embodiments. Furthermore, the connecting lines shown in the various figures contained herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical system. 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 disclosure. 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.” Moreover, where a phrase similar to “at least one of A, B, or C” is used in the claims, it is intended that the phrase be interpreted to mean that A alone may be present in an embodiment, B alone may be present in an embodiment, C alone may be present in an embodiment, or that any combination of the elements A, B and C may be present in a single embodiment; for example, A and B, A and C, B and C, or A and B and C.
Systems, methods and apparatus are provided herein. In the detailed description herein, references to “one embodiment”, “an embodiment”, “various embodiments”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. After reading the description, it will be apparent to one skilled in the relevant art(s) how to implement the disclosure in alternative embodiments.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 104(f), unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
The present application claims priority to and the benefit of U.S. Provisional Patent Application Nos. 62/352,953, filed Jun. 21, 2016, the entire contents of which is herein incorporated by reference for any purpose. The present application also claims priority to and the benefit of U.S. Provisional Patent Application Nos. 62/369,303, filed Aug. 1, 2016, the entire contents of which is herein incorporated by reference for any purpose. The present application also claims priority to and the benefit of U.S. Provisional Patent Application Nos. 62/378,608, filed Aug. 23, 2016, the entire contents of which is herein incorporated by reference for any purpose.
Number | Date | Country | |
---|---|---|---|
62352953 | Jun 2016 | US | |
62369303 | Aug 2016 | US | |
62378608 | Aug 2016 | US |