WO2014123547A1 - Modular strap mount for solar panels - Google Patents
Modular strap mount for solar panels Download PDFInfo
- Publication number
- WO2014123547A1 WO2014123547A1 PCT/US2013/025622 US2013025622W WO2014123547A1 WO 2014123547 A1 WO2014123547 A1 WO 2014123547A1 US 2013025622 W US2013025622 W US 2013025622W WO 2014123547 A1 WO2014123547 A1 WO 2014123547A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- panel
- frame
- support
- attaching
- straps
- Prior art date
Links
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
- F24S25/634—Clamps; Clips
- F24S25/636—Clamps; Clips clamping by screw-threaded elements
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/10—Arrangement of stationary mountings or supports for solar heat collector modules extending in directions away from a supporting surface
- F24S25/16—Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/30—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors
- F24S25/33—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors forming substantially planar assemblies, e.g. of coplanar or stacked profiles
- F24S25/35—Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors forming substantially planar assemblies, e.g. of coplanar or stacked profiles by means of profiles with a cross-section defining separate supporting portions for adjacent modules
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/50—Arrangement of stationary mountings or supports for solar heat collector modules comprising elongate non-rigid elements, e.g. straps, wires or ropes
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
- F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
- F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
- F24S25/61—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing to the ground or to building structures
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/10—Photovoltaic [PV]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/20—Solar thermal
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/40—Solar thermal energy, e.g. solar towers
- Y02E10/47—Mountings or tracking
Definitions
- the present invention relates to the field of solar panels and more particularly to apparatuses and methods for mounting solar panels on surfaces, including roofs, walls and the ground.
- Solar panels can be of the photovoltaic type of the thermal type or combinations. They can be installed as is or contained within a frame. Solar panels must be mounted correctly in order to maximize power production and to prevent movement of the panels from the force of wind. The proper solar panel mounting provides stability and the proper directional and latitudinal orientation for the solar array.
- ballast mounts For mounting on a roof or the ground there are ballast mounts, flush mounts (such as Modular IronRidge XRS available from IronRidge in Willits, CA) standing seams mounts, and adjustable mounts (such as those available from Unirac in Albuquerque, NM). These usually include a tilted rack, firmly attached to the substrate surface, on which the modules are firmly mounted; or brackets of at least two different heights, firmly attached to the substrate surface, to which the ends of the modules are firmly attached.
- ballast mounts such as Modular IronRidge XRS available from IronRidge in Willits, CA
- adjustable mounts such as those available from Unirac in Albuquerque, NM.
- This invention is an apparatus for mounting a solar collector panel (photovoltaic, thermal or combination), by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface.
- the strap assembly further comprises a plurality of straps attached end to end.
- This invention is also a method of mounting a solar collector panel by itself or supported within a frame, to a surface, comprising the steps of: providing a plurality of straps;
- the first attachment device could be a bolt, a screw, adhesive, etc.
- the support has a top flange and a bottom flange.
- the top flange may be parallel to the surface of at an angle to the surface.
- the length of the support or supports may be wider than the straps and sufficient to span the entire width or length of the solar panel and frame assembly.
- each end of each strap is drilled (and even more preferably pre-drilled) with a hole pattern through which the straps are attached end to end.
- the bottom flange of the support has the same hole pattern drilled into it so that the bottom flange can be attached to two strap ends at the same time and with the same fasteners. Additionally the straps may have different widths.
- the means for attaching the strap assembly to the surface may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these.
- the support may comprise a U shaped channel having a base and an opening opposite the base.
- the base is attached to the strap assembly.
- the solar panel or the panel and frame assembly is clamped to the top of the channel by fastening together with a threaded fastener a plate slidably installed, parallel to the base in the channel; and a clip, adapted to clamp to the frame, placed on the frame, transverse to the frame, over a top edge of the frame at a side of the frame.
- Figure 1 is a perspective view of a strap of this invention.
- Figure 2 is a side view of two straps assembled into a strap pack in accordance with this invention.
- Figures 3A to 3D illustrate different hole patterns that can be made in the ends of the straps.
- Figure 4 is a perspective view of the taller bracket used for flat roof installations of this invention.
- Figure 5 is a perspective view of the shorter bracket used for flat roof installations of this invention.
- Figure 6A is a side view of two units of the embodiment of this invention typically intended for installation on a flat roof.
- Figure 6B is a perspective view of two units of the embodiment of this invention typically intended for installation on a flat roof.
- Figure 6C is a perspective, exploded view of two units of the embodiment of this invention typically intended for installation on a flat roof.
- Figure 7 is a magnified view of the attachment between a bracket and the solar panel and the bracket and a modular straps.
- Figure 8 illustrates in exploded view assembly of a bracket with two modular straps.
- Figure 8A is a magnified view of the assembly of Figure 8 fully assembled.
- Figure 9 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with ballast.
- Figure 10 is a perspective view showing attachment of modular straps used in a flat roof installation with nails, spikes or screws.
- Figure 1 0A is a magnified view of Figure 10 showing the fastener through a hole in the strap assembly.
- Figure 1 1 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with adhesive.
- Figure 1 2 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs.
- Figure 12A is an exploded, magnified, perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs.
- Figure 1 3 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down by welding.
- Figure 14 is a perspective view of an array of multiple solar panels installed on a flat roof with the mounting system of the instant invention.
- Figure 1 5 is a perspective view of a mounting channel used in this invention.
- Figure 16 is an exploded perspective view of attachment of the solar panel to the modular strap via the channel.
- Figure 1 7 is a cross sectional view along the lines 17-17 of Figure 16.
- Figure 1 7A is cross section showing an alternate way of attaching panels directly to the strap assemblies using the clip and bolt clamping assembly.
- Figure 1 7B is cross section showing another alternate way of attaching panels directly to the strap assemblies.
- Figure 1 8 is a plan view of one solar panel installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panel are installed to overlay one half the width of the modular strap and the channels are transverse to the strap assemblies.
- Figure 18A is perspective view of three solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panels are installed to overlay one half the width of the modular strap and the channels are parallel to the strap assemblies.
- Figure 1 9 is an enlarged perspective view of the area shown at 19 on Figure 1 8A.
- Figure 20 is an exploded, perspective view showing a method of attaching a modular strap to a flat or tilted roof using a spike or similar fastener.
- Figure 21 is a perspective view showing a method of attaching a modular strap to a flat or tilted roof using adhesive.
- Figure 22 is a perspective view of a method of attaching a modular strap to a flat or flat or tilted roof using a stud and bolt.
- Figure 22A is an enlarged cross section along the lines 22A-22A of Figure 22
- Figure 23 is an expanded perspective view of a method of attaching a modular strap to a flat or tilted roof using welding.
- Figure 23A is a top view of a method of holding a modular strap to a flat or tilted roof using ballast.
- Figure 24 is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed end to end, and the joints between modular straps are located between the solar panels.
- Figure 25 is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed side to side and the modular straps are under the solar panels.
- Figures 26A-26C illustrate that strap packs can be installed at differing separations.
- Figure 27 is a perspective view of one unit of the instant invention having modular straps of two different widths and in which one bracket extends from one strap to the other.
- Figure 28 is a perspective view of an embodiment of the instant invention having modular straps of two different widths.
- This invention 10 has two major embodiments: one 10a that is intended primarily to be attached to a flat surface 14, such as a roof or wall; and one that is intended to be attached primarily to a tilted surface 18, such as a peaked roof. However, in fact, either embodiment can be attached to a flat 14 or tilted 18 surface. As described in US Patent No. 7,814,899, solar panels 22 may be retained within a frame 24 (as shown in Figure 7), which has a number of holes useful for mounting.
- FIG 1 illustrates the modular strap 28 of this invention. It is made of thin sheet material such as steel or aluminum, preferably 1 /8 inch thick. A number of these straps are attached together end 30a to end 30b as shown in Figure 2 to form a strap assembly 32. Fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc. To facilitate assembly of the straps 28 one to another they are preferably predrilled with a hole pattern 36 at each end as illustrated in Figures 3A through 3C. Since only two holes are needed to produce a secure connection, the pattern 36b shown in 3B allows for the straps 28 to be connected together to make slight adjustment in the total length of the strap assembly 32. As shown in Figure 3D two or more of the holes 40 could actually be slots 44 which allows for some margin of error in assembly.
- two or more of the holes 40 could actually be slots 44 which allows for some margin of error in assembly.
- brackets 52a, 52b attached to the top 48a of the straps are one or two brackets 52a, 52b as shown in Figures 4 and 5. As can be seen they each have a bottom flange 56a, 56b, a top flange 60a, 60b and a central body 64a, 64b. In these brackets 52a, 52b the bodies 64a, 64b have a C shaped cross section but they could be Z shaped or I shaped or any other cross sectional shape. As can be seen, when two brackets 52a, 52b are used, preferably one bracket 52a is taller than the other 52b.
- the taller one 52a is attached to the strap assembly 32 at a point which will be close to the end of the solar panel frame 24 which is intended to be higher and the shorter one 52b is attached to the strap assembly at a point which will be close to the other end of the solar panel frame.
- the brackets 52 are attached to the strap assemblies 32 through their bottom flanges 56. Again fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc. 68. Then the solar panel frame 24 is clamped to the top flange 60 of the brackets 52, preferably using the teachings of US Patent No. 7,814,899.
- Figure 7 illustrates assembly of the clip 76 to the top flange 56 of the bracket 52 except that one panel 22, its frame 24 and the adjustable fastener is not shown.
- bracket 52 and two strap ends 30 can be attached together with the same fasteners 68 at the same time. This is illustrated in Figures 8 and 8A.
- the bottom flange 56 of the bracket 52 must be provided with the same hole pattern 36 as that on the strap ends 30 or at least a hole pattern 36 that will mate with the hole pattern 36 in the strap end 30.
- ballast 80 can be any object made out of a weighty material. Satisfactory objects are bricks, blocks of concrete, blocks of metal, etc.
- the ballast 80 can be contained within a container 84 for convenience and to span the distance between strap assemblies 32.
- the objects 80 and/or the container 84 can be just placed on the strap assemblies 32 or can also be fastened to the strap assemblies 32.
- Figures 1 0 and 10A illustrate use of pointed fasteners 88 such as nails, spikes, or screws. They are fastened into the substrate 14, 18 through holes 92 in the strap assemblies 32. The holes 92 may be predrilled for convenience.
- Figure 1 1 illustrates use of adhesive 96 to adhere the strap assemblies 32 to the substrate 14, 18. Any suitable adhesive 96 can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration.
- Figures 1 2 and 12A illustrate the use of threaded studs 100 for fastening down the strap assemblies 32.
- the studs pass through holes 92 in the assemblies 32 and the straps 28 are fastened to the studs 100 with nuts 104.
- the studs 100 must be pre-joined to the substrate 14, 18 such as with inserts or, as illustrated, in Figure 12A by fastening a plate 108 trapped on the stud 1 00 to the substrate 14, 18. Again this plate 108 may be fastened to the substrate via any suitable method such as nails or adhesive.
- Figure 13 illustrates use of welding for fastening down the strap assemblies 32. In this method, a strip of roofing material 1 12 is laid over the strap assembly and bonded to the underlying roof material.
- Figure 14 shows an array of solar panels 22 constructed on a flat surface 14 in accordance with the teachings of this invention.
- Figure 15 shows the channel 1 16 which is used to mount solar panels to strap assemblies 32 on flat or tilted substrates 18, e.g. pitched roofs.
- First the channel 1 1 6 which may be predrilled, is fastened to the strap assembly 32.
- the hole pattern 36c shown in Figure 3C is most useful for this purpose since the channel 1 16 can be mounted parallel with or transverse to the strap assembly 32 as required.
- Figure 16 shows an assembly of solar panels 22 to straps 28 using the channel 1 16 transverse to the strap assembly 32.
- the fasteners are not shown for clarity of understanding.
- Figure 1 7 is a cross section of this assembly showing the fasteners.
- the channel 1 16 is fastened through its bottom 120 to the strap assembly 32.
- a clip 76 goes over the top edge of one or two solar panel frames 24.
- the channel 1 16 has slots or grooves 124 on each side 128 in which a plate 132 can slide.
- a threaded bolt 144 is inserted through the through hole 1 36 and fastened into the threaded hole 140. Tightening the bolt 144 firmly clamps the solar panel frames 24 to the channel 1 16.
- Figure 18 illustrates an assembly of a solar panel 22 to strap assemblies 32 with transverse channels 1 16.
- Figure 18A illustrates assembly of several solar panels 22.
- FIGs 17A and 1 7B show use of a clip and bolt to clamp the panel 22 to the strap 28.
- a threaded insert 1 18 is inserted into the straps and receives the threaded end of the bolt 144. Tightening the bolt 144 into the insert 1 18 clamps the panels 22 to the straps 28.
- Figure 17B shows an alternate method. In this method the straps 28 are bolted or screwed to the underside of the panel 22.
- Figure 19 shows an assembly of solar panels 22 to straps 28 using the channel 1 16 parallel to the strap assembly 32.
- the fasteners are not shown but they are the same as shown on Figure 17.
- Various devices and methods can be used to fasten the strap assemblies of this embodiment to surfaces, depending on the inclination of the surface and the material it is made out of. These are illustrated in Figures 20, 21 , 22, 22A, 23 and 23A.
- Figure 20 illustrates use of pointed fasteners 88 such as nails, spikes or screws. They are fastened into the substrate 1 8 through holes 92 in the strap assemblies 32. The holes 92 may be predrilled for convenience.
- Figure 21 illustrates use of adhesive 96 to adhere the strap assemblies 32 to the substrate 18. Any suitable adhesive 96 can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration.
- Figures 22 and 22A illustrate the use of threaded studs 100 for fastening down the strap assemblies 32. The studs 100 pass through holes 92 in the assemblies 32 and the straps 28 are fastened to the studs 100 with nuts 104. The studs 100 must be pre-joined to the substrate 18 such as with inserts or, as illustrated, in Figure 12A by fastening a plate 108 trapped on the stud 100 to the substrate 1 8. Again this plate 108 may be fastened to the substrate 18 via any suitable method such as nails or adhesive.
- FIG 23 illustrates use of welding for fastening down the strap assemblies 32.
- a strip of roofing material 1 12 is laid over the strap assembly 32 and bonded to the underlying roof material.
- ballast 80 can also be used to hold down the strap assemblies 32. The ballast 80 would have to be inserted between the panels, as shown on Figure 23A.
- the straps 28 can be fastened to each other between solar panels 22, 24. As illustrated on Figures 24 and 25 the solar panels 22, 24 can be assembled end to end or side to side. As illustrated on Figures 26, 26A and 26B, the distance D between strap assemblies 32 can be varied. As illustrated on Figure 27 the brackets 56 can extend all the way across the solar panel 22 from strap assembly 32 to strap assembly. As illustrated on Figures 27 and 28, the straps 28, 28a in an assembly 32 can be of different widths.
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- Life Sciences & Earth Sciences (AREA)
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- Sustainable Energy (AREA)
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Abstract
A method and apparatus for mounting a solar collector panel by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface. The strap assembly comprises a plurality of straps attached end to end. The first attachment device could be a bolt, a screw, adhesive, etc. Alternatively, there could be a support between the panel or frame and the strap assembly. The second attachment means may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these.
Description
MODULAR STRAP MOUNT FOR SOLAR PANELS
Technical Field
The present invention relates to the field of solar panels and more particularly to apparatuses and methods for mounting solar panels on surfaces, including roofs, walls and the ground. Background Art
Solar panels can be of the photovoltaic type of the thermal type or combinations. They can be installed as is or contained within a frame. Solar panels must be mounted correctly in order to maximize power production and to prevent movement of the panels from the force of wind. The proper solar panel mounting provides stability and the proper directional and latitudinal orientation for the solar array.
Different mounting systems are available depending on whether the modules will be mounted on a roof, a wall, the ground, or a pole. For mounting on a roof or the ground there are ballast mounts, flush mounts (such as Modular IronRidge XRS available from IronRidge in Willits, CA) standing seams mounts, and adjustable mounts (such as those available from Unirac in Albuquerque, NM). These usually include a tilted rack, firmly attached to the substrate surface, on which the modules are firmly mounted; or brackets of at least two different heights, firmly attached to the substrate surface, to which the ends of the modules are firmly attached.
Such systems are heavy and expensive to fabricated and time consuming to install. What is needed is a mounting system which is cheaper to fabricate and less time consuming to install. Preferably the improved system can be easily fabricated on site or provided as a kit. The inventor has developed two improvements on the state of the art: US Patent No. 7,814,899 and US Patent Application No. 13/038,286, the entire texts and drawings of which are included in this document by reference.
This inventor has now developed another improvement on the state of the art. Development of a solar panel mounting system which is cheaper to fabricate and less time consuming to install represents a great improvement in the field of solar panel mounting and satisfies a long felt need of the solar panel installer and owner.
Disclosure of Invention
This invention is an apparatus for mounting a solar collector panel (photovoltaic, thermal or combination), by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface. The strap assembly further comprises a plurality of straps attached end to end.
This invention is also a method of mounting a solar collector panel by itself or supported within a frame, to a surface, comprising the steps of: providing a plurality of straps;
attaching the straps together end to end to make a strap assembly; attaching the panel or frame and the strap assembly to each other; and attaching the strap assembly to the surface.
The first attachment device could be a bolt, a screw, adhesive, etc. Alternatively, there could be a support between the panel or frame and the strap assembly. Preferably the support has a top flange and a bottom flange. The top flange may be parallel to the surface of at an angle to the surface. There may be two supports and one may be taller than the other. Furthermore, the length of the support or supports may be wider than the straps and sufficient to span the entire width or length of the solar panel and frame assembly.
Preferably each end of each strap is drilled (and even more preferably pre-drilled) with a hole pattern through which the straps are attached end to end. Also, preferably, the bottom flange of the support has the same hole pattern drilled into it so that the bottom flange can be attached to two strap ends at the same time and with the same fasteners. Additionally the straps may have different widths.
The means for attaching the strap assembly to the surface may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these.
Alternatively, the support may comprise a U shaped channel having a base and an opening opposite the base. In this case the base is attached to the strap assembly. Preferably, the solar panel or the panel and frame assembly is clamped to the top of the channel by
fastening together with a threaded fastener a plate slidably installed, parallel to the base in the channel; and a clip, adapted to clamp to the frame, placed on the frame, transverse to the frame, over a top edge of the frame at a side of the frame.
While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility.
An appreciation of the other aims and objectives of the present invention and a more complete and comprehensive understanding of it may be achieved by referring to the accompanying drawings and studying the following description of the best mode of carrying out the invention.
Brief Description of Drawings
Figure 1 is a perspective view of a strap of this invention.
Figure 2 is a side view of two straps assembled into a strap pack in accordance with this invention.
Figures 3A to 3D illustrate different hole patterns that can be made in the ends of the straps.
Figure 4 is a perspective view of the taller bracket used for flat roof installations of this invention.
Figure 5 is a perspective view of the shorter bracket used for flat roof installations of this invention.
Figure 6A is a side view of two units of the embodiment of this invention typically intended for installation on a flat roof.
Figure 6B is a perspective view of two units of the embodiment of this invention typically intended for installation on a flat roof.
Figure 6C is a perspective, exploded view of two units of the embodiment of this invention typically intended for installation on a flat roof.
Figure 7 is a magnified view of the attachment between a bracket and the solar panel and the bracket and a modular straps. Figure 8 illustrates in exploded view assembly of a bracket with two modular straps.
Figure 8A is a magnified view of the assembly of Figure 8 fully assembled.
Figure 9 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with ballast.
Figure 10 is a perspective view showing attachment of modular straps used in a flat roof installation with nails, spikes or screws.
Figure 1 0A is a magnified view of Figure 10 showing the fastener through a hole in the strap assembly.
Figure 1 1 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with adhesive. Figure 1 2 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs.
Figure 12A is an exploded, magnified, perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs.
Figure 1 3 is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down by welding.
Figure 14 is a perspective view of an array of multiple solar panels installed on a flat roof with the mounting system of the instant invention.
Figure 1 5 is a perspective view of a mounting channel used in this invention.
Figure 16 is an exploded perspective view of attachment of the solar panel to the modular strap via the channel.
Figure 1 7 is a cross sectional view along the lines 17-17 of Figure 16.
Figure 1 7A is cross section showing an alternate way of attaching panels directly to the strap assemblies using the clip and bolt clamping assembly.
Figure 1 7B is cross section showing another alternate way of attaching panels directly to the strap assemblies.
Figure 1 8 is a plan view of one solar panel installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panel are installed to overlay one half the width of the modular strap and the channels are transverse to the strap assemblies.
Figure 18A is perspective view of three solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panels are installed to overlay one half the width of the modular strap and the channels are parallel to the strap assemblies.
Figure 1 9 is an enlarged perspective view of the area shown at 19 on Figure 1 8A.
Figure 20 is an exploded, perspective view showing a method of attaching a modular strap to a flat or tilted roof using a spike or similar fastener.
Figure 21 is a perspective view showing a method of attaching a modular strap to a flat or tilted roof using adhesive.
Figure 22 is a perspective view of a method of attaching a modular strap to a flat or flat or tilted roof using a stud and bolt.
Figure 22A is an enlarged cross section along the lines 22A-22A of Figure 22
Figure 23 is an expanded perspective view of a method of attaching a modular strap to a flat or tilted roof using welding.
Figure 23A is a top view of a method of holding a modular strap to a flat or tilted roof using ballast.
Figure 24 is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed end to end, and the joints between modular straps are located between the solar panels.
Figure 25 is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed side to side and the modular straps are under the solar panels.
Figures 26A-26C illustrate that strap packs can be installed at differing separations. Figure 27 is a perspective view of one unit of the instant invention having modular straps of two different widths and in which one bracket extends from one strap to the other.
Figure 28 is a perspective view of an embodiment of the instant invention having modular straps of two different widths.
Best Mode for Carrying Out Invention This invention 10 has two major embodiments: one 10a that is intended primarily to be attached to a flat surface 14, such as a roof or wall; and one that is intended to be attached primarily to a tilted surface 18, such as a peaked roof. However, in fact, either embodiment can be attached to a flat 14 or tilted 18 surface. As described in US Patent No. 7,814,899, solar panels 22 may be retained within a frame 24 (as shown in Figure 7), which has a number of holes useful for mounting.
Figure 1 illustrates the modular strap 28 of this invention. It is made of thin sheet material such as steel or aluminum, preferably 1 /8 inch thick. A number of these straps are attached together end 30a to end 30b as shown in Figure 2 to form a strap assembly 32. Fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc. To facilitate assembly of the straps 28 one to another they are preferably predrilled with a hole pattern 36 at each end as illustrated in Figures 3A through 3C. Since only two holes are needed to produce a secure connection, the pattern 36b shown in 3B allows for the straps 28
to be connected together to make slight adjustment in the total length of the strap assembly 32. As shown in Figure 3D two or more of the holes 40 could actually be slots 44 which allows for some margin of error in assembly.
In the flat surface embodiment 10a, attached to the top 48a of the straps are one or two brackets 52a, 52b as shown in Figures 4 and 5. As can be seen they each have a bottom flange 56a, 56b, a top flange 60a, 60b and a central body 64a, 64b. In these brackets 52a, 52b the bodies 64a, 64b have a C shaped cross section but they could be Z shaped or I shaped or any other cross sectional shape. As can be seen, when two brackets 52a, 52b are used, preferably one bracket 52a is taller than the other 52b. As shown in Figures 6A, 6B and 6C, the taller one 52a is attached to the strap assembly 32 at a point which will be close to the end of the solar panel frame 24 which is intended to be higher and the shorter one 52b is attached to the strap assembly at a point which will be close to the other end of the solar panel frame. The brackets 52 are attached to the strap assemblies 32 through their bottom flanges 56. Again fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc. 68. Then the solar panel frame 24 is clamped to the top flange 60 of the brackets 52, preferably using the teachings of US Patent No. 7,814,899. Figure 7 illustrates assembly of the clip 76 to the top flange 56 of the bracket 52 except that one panel 22, its frame 24 and the adjustable fastener is not shown.
In order to simplify assembly and reduce labor and material costs, at least one bracket 52 and two strap ends 30 can be attached together with the same fasteners 68 at the same time. This is illustrated in Figures 8 and 8A. Of course the bottom flange 56 of the bracket 52 must be provided with the same hole pattern 36 as that on the strap ends 30 or at least a hole pattern 36 that will mate with the hole pattern 36 in the strap end 30.
Various devices and methods can be used to fasten the strap assemblies 32 to surfaces 14, 18, depending on the inclination of the surface 14, 18 and the material it is made out of. These are illustrated in Figures 9, 1 0, 1 0A, 1 1 , 12, 12A and 13.
Figure 9, illustrates ballast 80. The ballast 80 can be any object made out of a weighty material. Satisfactory objects are bricks, blocks of concrete, blocks of metal, etc. The ballast 80 can be contained within a container 84 for convenience and to span the distance between
strap assemblies 32. The objects 80 and/or the container 84 can be just placed on the strap assemblies 32 or can also be fastened to the strap assemblies 32.
Figures 1 0 and 10A illustrate use of pointed fasteners 88such as nails, spikes, or screws. They are fastened into the substrate 14, 18 through holes 92 in the strap assemblies 32. The holes 92 may be predrilled for convenience.
Figure 1 1 illustrates use of adhesive 96 to adhere the strap assemblies 32 to the substrate 14, 18. Any suitable adhesive 96 can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration.
Figures 1 2 and 12A illustrate the use of threaded studs 100 for fastening down the strap assemblies 32. The studs pass through holes 92 in the assemblies 32 and the straps 28 are fastened to the studs 100 with nuts 104. The studs 100 must be pre-joined to the substrate 14, 18 such as with inserts or, as illustrated, in Figure 12A by fastening a plate 108 trapped on the stud 1 00 to the substrate 14, 18. Again this plate 108 may be fastened to the substrate via any suitable method such as nails or adhesive. Figure 13 illustrates use of welding for fastening down the strap assemblies 32. In this method, a strip of roofing material 1 12 is laid over the strap assembly and bonded to the underlying roof material.
Figure 14 shows an array of solar panels 22 constructed on a flat surface 14 in accordance with the teachings of this invention. Figure 15 shows the channel 1 16 which is used to mount solar panels to strap assemblies 32 on flat or tilted substrates 18, e.g. pitched roofs. First the channel 1 1 6 , which may be predrilled, is fastened to the strap assembly 32. The hole pattern 36c shown in Figure 3C is most useful for this purpose since the channel 1 16 can be mounted parallel with or transverse to the strap assembly 32 as required. Figure 16 shows an assembly of solar panels 22 to straps 28 using the channel 1 16 transverse to the strap assembly 32. In Figure 1 6 the fasteners are not shown for clarity of understanding.
Figure 1 7 is a cross section of this assembly showing the fasteners. The channel 1 16 is fastened through its bottom 120 to the strap assembly 32. A clip 76 goes over the top edge of one or two solar panel frames 24. The channel 1 16 has slots or grooves 124 on each side 128 in which a plate 132 can slide. There is a central through hole 136 perpendicularly through the clip 76 and the plate has a threaded hole 140 in its center. A threaded bolt 144 is inserted through the through hole 1 36 and fastened into the threaded hole 140. Tightening the bolt 144 firmly clamps the solar panel frames 24 to the channel 1 16. Figure 18 illustrates an assembly of a solar panel 22 to strap assemblies 32 with transverse channels 1 16. Figure 18A illustrates assembly of several solar panels 22. The solar panels 22 or the frames 24 can be attached directly to the straps 28. Alternate was of doing this are shown in Figures 17A and 1 7B. Figure 17A shows use of a clip and bolt to clamp the panel 22 to the strap 28. A threaded insert 1 18 is inserted into the straps and receives the threaded end of the bolt 144. Tightening the bolt 144 into the insert 1 18 clamps the panels 22 to the straps 28. Figure 17B shows an alternate method. In this method the straps 28 are bolted or screwed to the underside of the panel 22. Those familiar with the art to which this invention applies will realize that other methods can also be used.
Figure 19 shows an assembly of solar panels 22 to straps 28 using the channel 1 16 parallel to the strap assembly 32. In Figure 19 the fasteners are not shown but they are the same as shown on Figure 17. Various devices and methods can be used to fasten the strap assemblies of this embodiment to surfaces, depending on the inclination of the surface and the material it is made out of. These are illustrated in Figures 20, 21 , 22, 22A, 23 and 23A.
Figure 20 illustrates use of pointed fasteners 88 such as nails, spikes or screws. They are fastened into the substrate 1 8 through holes 92 in the strap assemblies 32. The holes 92 may be predrilled for convenience.
Figure 21 illustrates use of adhesive 96 to adhere the strap assemblies 32 to the substrate 18. Any suitable adhesive 96 can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration.
Figures 22 and 22A illustrate the use of threaded studs 100 for fastening down the strap assemblies 32. The studs 100 pass through holes 92 in the assemblies 32 and the straps 28 are fastened to the studs 100 with nuts 104. The studs 100 must be pre-joined to the substrate 18 such as with inserts or, as illustrated, in Figure 12A by fastening a plate 108 trapped on the stud 100 to the substrate 1 8. Again this plate 108 may be fastened to the substrate 18 via any suitable method such as nails or adhesive.
Figure 23 illustrates use of welding for fastening down the strap assemblies 32. In this method, a strip of roofing material 1 12 is laid over the strap assembly 32 and bonded to the underlying roof material. Depending on the exact slope, ballast 80 can also be used to hold down the strap assemblies 32. The ballast 80 would have to be inserted between the panels, as shown on Figure 23A.
There are a number of variations that can be applied to assemblies in accordance with this invention. As shown on Figure 24, the straps 28 can be fastened to each other between solar panels 22, 24. As illustrated on Figures 24 and 25 the solar panels 22, 24 can be assembled end to end or side to side. As illustrated on Figures 26, 26A and 26B, the distance D between strap assemblies 32 can be varied. As illustrated on Figure 27 the brackets 56 can extend all the way across the solar panel 22 from strap assembly 32 to strap assembly. As illustrated on Figures 27 and 28, the straps 28, 28a in an assembly 32 can be of different widths.
The following reference numbers are used on the Figures: 10 this invention
10a embodiment intended to be attached to flat surfaces
10b embodiment intended to be attached to flat or tilted surfaces
14 flat surface
18 flat or tilted surface 22 solar panel
24 solar panel frame
28 modular strap
30a one end of modular strap
30b other end of modular strap 32 strap assembly
36 hole pattern
40 holes in hole pattern
44 slots in hole pattern
48a top of strap
52 bracket
52a taller bracket
52b shorter bracket
56 bottom flange of bracket
56a bottom flange of taller bracket 56b bottom flange of shorter bracket
60 top flange of bracket
60a top flange of taller bracket
60b bottom flange of taller bracket
64 bracket body
64a body of taller bracket
64b body of shorter bracket
68 fastener
76 clip
80 ballast
84 ballast container
88 pointed fastener
92 hole in strap assembly
96 adhesive
100 threaded stud
104 nut
108 fastening plate
1 1 2 strip of roofing material
1 1 6 mounting channel
1 1 8 threaded insert
124 slot or groove in side of channel
128 side of channel
132 plate
136 central through hole in clip
140 threaded hole in center of plate 144 threaded bolt
148 threaded bolt 152 screw
D distance between strap assemblies
This invention has been described with reference to a particular embodiments and variations. However, it should be obvious to those skilled in the art to which this invention pertains that other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow.
Thus, the present invention has been described herein with reference to particular embodiments for particular applications. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof.
It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.
Claims
1 . An apparatus for mounting one of a solar collector panel and a solar collector panel mounted within a frame to a surface comprising: a) a strap assembly comprising a plurality of straps, each having an end, attached end to end, adjacent their ends; b) a first attaching means for attaching one of said panel and said frame to said strap assembly; and c) a second attaching means for attaching said strap assembly to said surface.
2. An apparatus as claimed in claim 1 in which said first attaching means is
selected from the group comprising a fastener and adhesive.
3. An apparatus as claimed in claim 1 in which said first attaching means is a
support attached to and between one of said panel and said frame and said strap assembly.
4. An apparatus as claimed in claim 3 in which said support has a top flange and a bottom flange.
5. A apparatus as claimed in claim 4 in which said top flange is parallel to said
surface.
6. A apparatus as claimed in claim 4 in which said top flange is at an angle to said surface.
7. A apparatus as claimed in claim 3 in which said support comprises a first support and a second support spaced apart from each other.
8. An apparatus as claimed in claim 7 in which a height of said first support is
greater than a height of said second support.
9. A apparatus as claimed in claim 3 in which a length of said support is greater than a width of said strap.
10. An apparatus as claimed in claim 1 in which said straps have different widths.
1 1 . An apparatus as claimed in claim 1 in which said end has a hole pattern through which said straps are attached end to end, adjacent their ends.
12. An apparatus as claimed in claim 3 in which said end has a hole pattern adjacent said end through which said straps are attached end to end.
1 3. An apparatus as claimed in claim 1 2 in which said bottom flange has said hole pattern through which said bottom flange is additionally attached to said ends of two of said straps.
14. An apparatus as claimed in claim 1 in which said means for attaching said strap assembly to said surface is selected from the group comprising: a) a nail; b) a spike; c) adhesive; d) bolting to a stud attached to said surface; e) welding; f) ballast; and g) combinations of these.
15. An apparatus as claimed in claim 3 in which said support comprises a U shaped channel having a base and an opening opposite said base; said base attached to said strap assembly.
16. An apparatus as claimed in claim 1 in which said first fastening means
comprises: a) a clip, adapted to clamp to one of said panel and said frame; b) said clip being placed on one of said panel and said frame, transverse to one of said panel and said frame, over a top edge of one of said panel and said frame, at a side of one of said panel and said frame; c) said clip and said strap assembly being fastened to each other so that one of said panel and said frame is clamped to said strap assembly.
1 7. An apparatus as claimed in claim 1 5 in which said support further comprises a) a plate slidably installed, parallel to said base in said channel; and b) a clip, adapted to clamp to one of said panel and said frame, placed on one of said panel and said frame, transverse to one of said panel and said frame, over a top edge of one of said panel and said frame at a side of one of said panel and said frame; said clip and said plate fastened to each other so that one of said panel and said frame is clamped to said channel.
1 8. A method of mounting one of a solar collector panel and a solar collector panel mounted within a frame to a surface comprising the steps of: a) providing a plurality of straps, each having an end; b) attaching said straps together end to end, adjacent their ends;
c) providing a first attaching means d) attaching said one of said panel and said frame to said strap assembly with said first attaching means e) providing a second attaching means; and f) attaching said strap assembly to said surface with said second attaching means.
19. A method as claimed in claim 18 in which said first attaching means is selected from the group comprising a fastener and adhesive.
20. A method as claimed in claim 18 in which said first attaching means is a support attached to and between one of said panel and said frame and said strap assembly.
21 . A method as claimed in claim 20 in which said support has a top flange and a bottom flange.
22. A method as claimed in claim 21 in which said top flange is parallel to said
surface.
23. A method as claimed in claim 21 in which said top flange is at an angle to said surface.
24. A method as claimed in claim 20 in which said support comprises a first support and a second support spaced apart from each other.
25. A method as claimed in claim 24 in which a height of said first support is greater than a height of said second support.
26. A method as claimed in claim 20 in which a length of said support is greater than the width of said strap.
27. A method as claimed in claim 18 in which said straps have different widths.
28. A method as claimed in claim 18 further comprising the steps of: a) drilling a hole pattern adjacent said end; and b) attaching said straps end to end through said hole pattern.
29. A method as claimed in claim 20 further comprising the steps of: a) drilling a hole pattern adjacent said end; and b) attaching said straps end to end through said hole pattern.
30. A method as claimed in claim 29 further comprising the steps of: a) drilling said hole pattern in said bottom flange; and b) additionally attaching said bottom flange to said ends of two straps through said hole pattern in said bottom flange.
31 . A method as claimed in claim 18 in which said second attaching means is
selected from the group comprising nailing, adhering, bolting, weighing down with ballast, and combinations of these.
32. A method as claimed in claim 20 in which said support comprises a U shaped channel having a base and an opening opposite said base and in which the method further comprises the step of attaching said base to said strap assembly.
33. A method as claimed in claim 18 in which said first attaching means comprises a clip, adapted to clamp to said one of said panel and frame, placed on said one of
said panel and frame, transverse to said one of said panel and frame, over a top edge of said one of said panel and frame at a side of said one of said panel and frame; in which said method further comprises fastening said clip and said strap assembly to each other so that said one of said panel and said frame is clamped to said strap assembly.
34. A method as claimed in claim 32 in which said support further comprises a) a plate adapted to fit slidably in said channel, parallel to said; and b) a clip, adapted to clamp to said one of said panel and frame, placed on said one of said panel and frame, transverse to said one of said panel and frame, over a top edge of said one of said panel and frame at a side of said said one of said panel and frame; in which said method further comprises the step of fastening said clip and said plate to each other so that said one of said panel and said frame is clamped to said channel.
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2013/025622 WO2014123547A1 (en) | 2013-02-11 | 2013-02-11 | Modular strap mount for solar panels |
US14/811,607 US9742347B2 (en) | 2013-02-11 | 2015-07-28 | Modular strap mount for solar panels |
US15/626,080 US9985574B2 (en) | 2013-02-11 | 2017-06-17 | Modular strap mount for solar panels |
US15/682,731 US11067313B2 (en) | 2013-02-11 | 2017-08-22 | Modular floating platform for solar panel straps and ballast tray hold-downs for solar panel straps |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2013/025622 WO2014123547A1 (en) | 2013-02-11 | 2013-02-11 | Modular strap mount for solar panels |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US14/811,607 Continuation-In-Part US9742347B2 (en) | 2013-02-11 | 2015-07-28 | Modular strap mount for solar panels |
US14/811,607 Continuation US9742347B2 (en) | 2013-02-11 | 2015-07-28 | Modular strap mount for solar panels |
Publications (1)
Publication Number | Publication Date |
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WO2014123547A1 true WO2014123547A1 (en) | 2014-08-14 |
Family
ID=51300018
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2013/025622 WO2014123547A1 (en) | 2013-02-11 | 2013-02-11 | Modular strap mount for solar panels |
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WO (1) | WO2014123547A1 (en) |
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WO2016036613A1 (en) * | 2014-09-05 | 2016-03-10 | Port Jonathan | Strap mount for solar panels |
US9587859B1 (en) | 2011-03-01 | 2017-03-07 | Jonathan Port | Strap mount for solar panels |
EP4276380A3 (en) * | 2022-05-10 | 2024-02-21 | Premium Mounting Technologies GmbH & Co. KG | Mounting system for mounting photovoltaic modules on roofs |
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US20070294977A1 (en) * | 2006-06-23 | 2007-12-27 | Mitchell Robert J | System for Securing Roofing Shingles and Underlying Sheeting |
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US9587859B1 (en) | 2011-03-01 | 2017-03-07 | Jonathan Port | Strap mount for solar panels |
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