Patent Application
20130048815
The disclosure relates generally to installation of photovoltaic modules and more specifically to a mounting system adapted for use in installation of photovoltaic modules.
Photovoltaic systems offer a clean and renewable source of energy. Critical factors in usage and adoption of photovoltaic cells as a supplementary or primary power source include cost to end users and ease of installation. In residential environments, photovoltaic modules are typically installed on house roofs or other suitable surfaces that provide optimal exposure to sunlight.
Installation of photovoltaic modules typically requires elaborate fitting equipment and installation procedures. A significant number of parts are required for complete installation of a residential photovoltaic module array. Typically, mounting equipment is one of the fitting equipment that plays a key role in the installation of photovoltaic modules on a house roof. Conventional mounting equipment or the mounting system is used to support the photovoltaic modules at a top end and a base end is fastened to a mounting surface or rafters of the roof.
One drawback of the installations that use a conventional mounting system is that one lag bolt is required for each mounting plate that is fastened to the mounting surface. As will be appreciated, some of the lag bolts may be disposed at an angle that is not perpendicular to the rafter of the roof. The severity of the angle and the trajectory of the lag bolt that penetrates into the rafter of the roof could cause the rafter to split. This splitting of the rafter unfortunately reduces the structural integrity of the mounting system.
Additionally, the conventional mounting system includes rigid components, which require effective tools to adjust or modify a height of the mounting system on an uneven roof surface/deck. Moreover, since the conventional mounting system typically entails use of a high number of components, installation of the mounting system at a residential site is a time consuming and laborious process. Furthermore, manufacturing costs and installation costs increase significantly as the number of components/parts is increased. Such high costs are a barrier to the widespread usage and adoption of photovoltaic cells as power sources.
It is therefore desirable to develop a mounting system that is less expensive to manufacture and easy to install. Particularly, it is desirable to develop a mounting system with fewer components that facilitates tool-less installation and/or adjustment of the mounting system on any kind of roof surface.
Briefly in accordance with one aspect of the technique, a mounting system is presented. The mounting system includes a support platform configured to fasten the mounting system to a mounting surface. The mounting system further includes a stud operatively coupled to the support platform and disposed substantially perpendicular to the support platform. In addition, the mounting system includes an elevating unit operatively coupled to the stud, wherein the elevating unit includes a fastener operatively coupled to one end of the stud and configured to vary a height of the mounting system, and a rail-clip coupled to the fastener, wherein a rotational motion of the rail-clip is independent of a rotational motion of the fastener. Furthermore, the mounting system includes a rail operatively coupled to the rail-clip and configured to support at least one module.
In accordance with a further aspect of the present technique, a method for assembling a mounting system is presented. The method includes fastening a support platform to a mounting surface. Also, the method includes disposing a stud on the support platform such that the stud is disposed substantially perpendicular to the support platform. The method further includes coupling an elevating unit to one end of the stud, wherein the elevating unit includes a fastener operatively coupled to the stud, and a rail-clip coupled to the fastener, wherein a rotational motion of the rail-clip is independent of a rotational motion of the fastener. The method also includes coupling at least a portion of a rail to the elevating unit. In addition, the method includes adjusting, by the fastener, a height of the mounting system independent of the coupling of the portion of the rail to the elevating unit.
In accordance with another aspect of the present technique, a mounting system for supporting an array of modules on a mounting surface is presented. The mounting system includes a support platform configured to fasten the mounting system to the mounting surface. Further, the mounting system includes a stud having a first end and a second end, wherein the first end is coupled to the support platform such that the stud is disposed substantially perpendicular to the support platform. Also, the mounting system includes an elevating unit coupled to the second end of the stud, wherein the elevating unit includes a fastener operatively coupled to the second end of the stud, and configured to rotate on the stud to vary a height of the mounting system. The elevating unit further includes a rail-clip coupled to the fastener, wherein the rail-clip comprises an aperture that allows the stud to protrude through the elevating unit. The elevating unit also includes a snap ring disposed along the circumference of the aperture in the rail-clip and configured to allow the rotational motion of the rail-clip that is independent of the rotational motion of the fastener. In addition, the method includes a rail operatively coupled to the rail-clip and configured to support the array of modules.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
As will be described in detail hereinafter, various embodiments of an exemplary mounting system for use in installation of photovoltaic modules and methods for assembling the mounting system are presented. By employing the methods and mounting system described hereinafter, manufacturing cost and cost of installing the photovoltaic modules on a mounting surface may be substantially reduced.
Turning now to the drawings, and referring to
Further, in one embodiment, the support platform 102 is a flat structure that is disposed on a mounting surface 104. The “mounting surface” could be, for example, a roof deck upon which the photovoltaic modules are installed. For example, the surface may be an even and/or uneven roof surface, a building surface, or any concrete surface, suitable for installation of solar or photovoltaic modules. Also, one or more rafters 118 may be employed to provide structural support to the mounting surface 104. The term “rafter” is used to refer to a beam that provides structural support to the mounting surface 104 of a building or a house, for example. The rafter may include a wooden beam or an iron beam. In certain embodiment, the one or more rafters 118 may be disposed or located below the mounting surface 104.
In a presently contemplated configuration, the support platform 102 includes a pair of apertures (shown in
As previously noted, in a conventional mounting system, one lag bolt may be employed to fasten the mounting system to the roof deck. Also, the lag bolt may be drilled at different angles to the roof rafter, which may cause the rafter to split. Moreover, since only one lag bolt is employed, the split in the rafter may unfortunately reduce the structural integrity of the mounting system. Some or all of these shortcomings of the currently available mounting systems may be circumvented via use of embodiments consistent with the example mounting system 100. Particularly, in accordance with aspects of the present technique, the two joints 114, 116 can be employed to fasten the support platform 102 to the mounting surface 104. Moreover, the two joints 114, 116 can be drilled at two ends of the support platform 102 to penetrate into the mounting surface 104 and/or the rafter 118. Also, the joints 114, 116 can be drilled at an angle that is substantially perpendicular to the mounting surface 104 and/or the rafter 118, thereby potentially reducing the likelihood any splitting of the rafter 118 and enhancing the structurally integrity of the coupling of the mounting system 100 with the mounting surface or roof surface 104.
In accordance with exemplary aspects of the present technique, the support platform 102 may be rigidly coupled to the stud 106. Particularly, the center portion of the support platform 102 between the two apertures may be utilized to fasten the stud 106 to the support platform 102. For example, a first end of the stud 106 may be fastened or inserted into the center portion of the support platform 102 such that the stud 106 is rigidly coupled to the support platform 102. Furthermore, the stud 106 can be disposed substantially perpendicular to the support platform 102. In one embodiment, the support platform 102 and the stud 106 may be molded together to form a single entity or component of the mounting system 100.
In one embodiment, the stud 106 includes a cylindrical rod with spiral threads on an outer surface of the stud 106. The stud 106 includes the spiral threads from a first end of the stud 106 to a second end of the stud 106. Also, these spiral threads facilitate rotation of a fastener 110 along the stud 106 from the first end to the second end of the stud 106 and vice versa. It may be noted that the terms “stud” and “threaded stud” may be used interchangeably. In one embodiment, the stud 106 may have a height in a range from about 2 inches to about 4 inches.
Further, the other end of the stud 106 is coupled to the elevating unit 107. Particularly, the second end of the stud 106 is coupled to the elevating unit 107. The elevating unit 107 is configured to support the rail 112. The elevating unit 107 includes a rail-clip 108, the fastener 110, and a snap ring 111. The fastener 110 is coupled to the stud 106. In one example, the fastener 110 is coupled to the second end of the stud 106. Further, the fastener 110 is configured to rotate over the spiral threads of the stud 106 to adjust or vary a height of the mounting system 100 in a Z-direction. For example, by rotating the fastener 110 over the spiral threads of the stud 106, the height of the elevating unit 107 is varied, which in turn varies the height of the rail 112 relative to the mounting surface 104.
Moreover, the rail-clip 108 is coupled to the fastener 110. Specifically, in one embodiment, the rail-clip 108 is coupled to the fastener 110 via the snap ring 111. In one embodiment, the snap ring 111 may be disposed along a circumference of an aperture in the rail-clip 108. The snap ring 111 may include a bearing ring that allows the rotational motion of the fastener 110 to be independent of the rotational motion of the rail-clip 108. For example, the fastener 110 may be rotated on the stud 106 while the rail-clip 108 is maintained at a stationary position. This ability of the fastener 110 to be rotated independent of any rotational motion of the rail-clip 108 aids in adjusting the height of the mounting system 100 even when the rail 112 is mounted over the rail-clip 108. That is, the height of the mounting system 100 may be adjusted regardless of the mounting of the rail 112 over the rail-clip 108.
In accordance with aspects of the present technique, the rail-clip 108 includes a base-wall 120 and a pair of side walls 122, 124. The base-wall 120 and the side walls 122, 124 are molded together to form a C-shaped structure in certain embodiments. Further, a first end of the base-wall 120 is coupled to the fastener 110, as depicted in
In a presently contemplated configuration, the pair of side walls, such as a first side wall 122 and a second side wall 124, is disposed on a second end of the base-wall 120 to form the C-shaped structure. Furthermore, the first side wall 122 includes a first protruding portion 126 and a first ridged portion 148. The first protruding portion 126 extends inward from a distal end of the first side wall 122 relative to the base-wall 120. The term “distal end” may be used to refer to an end of the side wall 12 that is farther from the base-wall. Further, the first ridged portion 148 extends inward from the first side wall 122 at a determined distance below the first protruding portion 126, as depicted in
In addition to the lateral movement of the rail 112, the rail-clip 108 also allows a longitudinal movement or Z-axis movement of the rail 112. This longitudinal movement of the rail 112 is obtained by rotating the fastener 110 of the elevating unit 107 on the threaded stud 106. As previously noted, rotating the fastener 110 on the threaded stud 106 results in the longitudinal movement of the rail-clip 108 in the Z-direction. The movement of the rail-clip 108 in the Z-direction in turn causes a similar movement of the rail 112 relative to the support platform 102 since the rail-clip 108 is coupled to the rail 112. Particularly, the fastener 110 coupled to the rail-clip 108 is rotated on the stud 106 to adjust the height of the rail 112 from the support platform 102. Thus, the exemplary mounting system 100 facilitates both the lateral movement and the longitudinal movement of the rail 112.
In accordance with aspects of the present technique, the rail-clip 108 is configured to couple at least a portion of the rail 112 to the rail-clip 108. In one example, the rail-clip 108 is configured to mechanically snap at least a portion of the rail 112 into the rail-clip 108. Particularly, the rail 112 includes a pair of parallel beams and an I-beam. The I-beam is disposed at a first end of the rail 112 and the pair of parallel beams is disposed at a second end of the rail 112. These parallel beams, such as a first beam 130 and a second beam 132 are configured to mate with the rail-clip 108 when the rail 112 is inserted or snapped into the rail-clip 108. More specifically, the first beam 130 includes a first wedge 136 that extends outward at a distal end of the first beam 130, as depicted in
As will be appreciated, in a conventional mounting system, a strut may typically be positioned at a top end of the mounting system for supporting or holding the photovoltaic modules, for example. This strut may be coupled to the base of the mounting system by inserting a lag bolt through the strut and tightening the lag bolt by a fastener. Since the strut is coupled to the base by employing the bolt and fastener, the time and the labor cost for installation of photovoltaic modules may be substantial. Some or all of these shortcomings of the currently available mounting system may be circumvented via use of the exemplary mounting system 100. Particularly, in accordance with aspects of the present technique, the rail 112 can be simply snapped into the rail-clip 108 without intervention of a fastener and a bolt. This may advantageously reduce the labor cost and installation time of the mounting system 100.
Furthermore, the I-beam 140 may be formed by coupling two C-channels back-to-back. The I-beam 140 is configured to support the photovoltaic modules 144, 146. Each of the C-channels in the I-beam 140 is employed to support one or more photovoltaic modules. Also, a rail pin 142 is coupled to one end of the I-beam 140. This rail pin 142 aids in tightening the C-channels of the I-beam 140 that supports the photovoltaic modules, such as a first photovoltaic module 144 and a second photovoltaic module 146. Although, the mounting system 100 of
By employing the exemplary mounting system 100, the installation time and the installation cost of the photovoltaic modules 144, 146 may be substantially reduced relative to conventional mounting systems. Also, since relatively fewer components are used for assembling the mounting system 100, the mounting system 100 may be easily adjusted or modified with minimal labor cost. For example, on an uneven surface of the roof, the height of the mounting system 100 may be easily adjusted by rotating the fastener 110 of the elevating unit 107 on the threaded stud 106. Moreover, the exemplary mounting system 100 facilitates adjustment of the mounting system 100 without the use of tools or with use of relatively fewer tools. For example, an installer may easily rotate the fastener 110 or nut with his hand to adjust the height of the mounting system 100. In particular, the mounting system 100 may be adjusted without dismantling the rail 112 and/or photovoltaic modules 144, 146 from the mounting system 100.
In the example depicted in
In a similar fashion, the second joint 116 is inserted into the second aperture 204 of the support platform 102 with a head portion 208 that settles above or in line with the support platform 102 and a tail portion 212 protruding from the support platform 102. Further, the protruding tail portion 212 of the second joint 116 is inserted into the mounting surface 104 to fasten the second joint 116 to the mounting surface 104 and/or the rafter 118 that is positioned beneath the mounting surface 104. Thus, the second joint 116 fastens the other side of the support platform 102 to the mounting surface 104. In one embodiment, the support platform 102 may be a mounting plate that is fastened to the mounting surface 104 at regular intervals for supporting an array of photovoltaic modules.
As previously noted with respect to
The surface area of the side walls 122, 124 below the protruding portions 126, 128 may act as a channel for guiding the rail 112 along a Y-axis or in a direction that is substantially perpendicular to the threaded stud 106. Moreover, the surface area of the side walls 122, 124 below the protruding portions 126, 128 and the surface area of the ridged portions 148, 150 facing the protruding portions 126, 128 may together form the track area that allows for a lateral movement (Y-axis) of the rail 112, as depicted in
In addition, a portion 304 of the protruding portions 126, 128 may be tapered, as depicted in
Turning now to
In a presently contemplated configuration, the I-beam 140 at the other end of the rail 112 is configured to support photovoltaic modules 144, 146. The I-beam 140 is formed by two C-channels connected back-to-back, as depicted in
Referring now to
Subsequently, at step 604, the stud 106 is coupled to the support platform 102. The stud 106 may be a long cylindrical rod that is disposed substantially perpendicular to the support platform 102. The height of the cylindrical rod may be in a range from about 2 inches to about 4 inches. In one embodiment, the stud 106 may have spiral threads on the surface of the stud 106. These spiral threads on the stud 106 may be employed to translate the elevating unit 107 in a Z-direction.
Also, at step 606, the elevating unit 107 is coupled to one end of the stud 106. The elevating unit 107 includes the fastener 110 and the rail-clip 108. The fastener is rotated over the stud 106 to allow the elevating unit 107 to translate in the Z-direction. Moreover, the fastener 110 is coupled to the stud 106 at an end that is farther from the support platform 102. In addition, the rail-clip 108 is coupled to the fastener 110 through the snap ring 111. The snap ring 111 may be coupled to the circumference of the aperture of the rail-clip 108 and the fastener 110 may be coupled to the snap ring 111. The snap ring 111 allows a rotational motion of the rail-clip 108 that is independent of the rotational motion of the fastener 110. More specifically, the snap ring 111 may include a ball bearing ring that allows the fastener 110 to rotate on the stud 106 without disturbing or rotating the rail-clip 108.
Further, at step 608, a portion of the rail 112 is coupled to the elevating unit 107. The rail 112 includes two parallel beams 130, 132 that are snapped into the rail-clip 108. The wedges 136, 138 of the parallel beams 130, 132 slip or slide over the protruding portions 126, 128 of the rail-clip 108 and thereafter the parallel beams 130, 132 are mounted on the ridged portions 148, 150 of the rail-clip 108. It may also be noted that in certain embodiments, the parallel beams 130, 132 may be mounted on the base-wall 120 of the rail-clip 108.
Upon assembling the mounting system 100, at step 610, the fastener 110 is used to adjust the height of the mounting system 100. The fastener 110 is rotated and translated along the stud 106. This consequently varies the height of the rail-clip 108 and the rail 112 mounted on the rail-clip 108 relative to the mounting surface 102. Thus, by rotating the fastener 110, the photovoltaic modules 144, 146 disposed on the rail 112 may be laterally moved in the Z-direction.
The mounting system and the method for assembling the mounting system described hereinabove aid in reducing the manufacture cost and the labor cost for the installation of photovoltaic modules. Also, by employing fewer components in the mounting system, the installation time may be substantially reduced. Moreover, the mounting system facilitates tool-less adjustment of height of photovoltaic modules from a mounting surface, thereby allowing leveling of the photovoltaic modules and easy installation of the photovoltaic modules on an uneven roof surface.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
