WO2016200393A1

WO2016200393A1 - Solar panel mounting base and system for solar panel installation

Info

Publication number: WO2016200393A1
Application number: PCT/US2015/035392
Authority: WO
Inventors: Elie Rothschild
Original assignee: Elie Rothschild
Priority date: 2015-06-11
Filing date: 2015-06-11
Publication date: 2016-12-15

Abstract

A solar panel mounting base and system for solar panel installation uses a mounting base that is injection molded to include different connection locations which provide flexibility when installing solar panels to the mounting bases. Attachment clamps are secured to the mounting base using carriage bolts which are secured to the mounting base in an attachment well and allow the installer to attach solar panels from the top which makes installation easy and fast. The attachment clamps have a horizontal and vertical portion that use grooves to adjustably secure the two together when in the desired location. Ballast blocks are used to provide a non-invasive installation. In an array, multiple bases are used to provide the structure to support the solar array. Installers may vary the angle the solar panels form 5 degrees to 10 degrees by selecting the appropriate connection location.

Description

INVENTION TITLE

SOLAR PANEL MOUNTING BASE AND SYSTEM FOR SOLAR PANEL

INSTALLATION

BACKGROUND OF THE INVENTION

[0001 ] As alternative energy sources become more important to the economic and environmental well-being of society, solar energy use will continue to increase. It is becoming more common to see roofs and other structures having solar panels installed to generate electrical energy. In general, these installations require significant rack systems that may be permanent. These kinds of installations can cause exposure problems to the building due to the required structural penetration to secure the solar panels. Additionally, it is difficult to remove if desired. [0002] To solve this problem, some solar systems utilize racking systems that use ballast to secure them rather than permanent installations. Although this helps in removal and minimizing surface penetrations, it is difficult for such installations to meet strength, reliability, environmental and safety standards while also withstanding wind, rain, temperature variations and solar radiation. Additionally, these racking systems tend to be bulky and complex requiring expert installation done on-site. [0003] Often when installing solar panels, the angle at which the panels need to be placed is different depending on the installation and the location of the installation. While many solutions to this problem have been proposed, most involve complicated adjustment components or compromising the best angle for ease in construction. There is a need for a solar racking system that is quick and easy to install and that allows the user to select an angle best suited for the application. It is also desirable to be able to mount the solar panels even where permanent connection to the structure is not desired or practical.

SUMMARY OF THE INVENTION

[0004] A solar panel mounting base and system for solar panel installation uses a mounting base that is injection molded to include different connection locations which provide flexibility when installing solar panels to the mounting bases. Attachment clamps are secured to the mounting base using carriage bolts which are secured to the mounting base in an attachment well and allow the installer to attach solar panels from the top which makes installation easy and fast. The attachment clamps have a horizontal and vertical portion that use grooves to adjustably secure the two together when in the desired location. Ballast blocks are used to provide a non-invasive installation. In an array, multiple bases are used to provide the structure to support the solar array. Installers may vary the angle the solar panels form 5 degrees to 1 0 degrees by selecting the appropriate connection location.

[0005] Other features and advantages of the instant invention will become apparent from the following description of the invention which refers to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective drawing of a solar panel mounting base according to an embodiment of the present invention.

[0007] FIG. 2 is a side view of the solar panel mounting base shown in figure 1 .

[0008] FIG. 3 is a front view of the solar panel mounting base shown in figure 1 .

[0009] FIG. 4 is a perspective drawing showing a plurality of the solar panel mounting bases shown in figure 1 being stacked.

[001 0] FIG. 5 is a perspective view of the solar panel mounting base shown in figure 1 with ballast installed.

[001 1 ] FIG. 6 is a perspective view of a plurality of the solar panel mounting bases shown in figure 1 in an array for mounting solar panels.

[001 2] FIG. 7 is a side view of the solar panel mounting base shown in figure 1 with an attachment clip mounted thereon. [001 3] FIG. 7 A is a detailed view of the attachment clip shown in figure 7.

[001 4] FIG. 8 is a top view of a horizontal clamp portion.

[001 5] FIG. 9 is a top view of the horizontal clamp portion shown in figure 8 along with a vertical clamp portion.

[001 6] FIG. 10 is a perspective view of a plurality of solar panel mounting bases installed using struts.

[001 7] FIG. 1 1 is a side view of the mounting base shown in figure 1 installed using a mechanical anchor.

DETAILED DESCRIPTION OF THE INVENTION

[001 8] In the following detailed description of the invention, reference is made to the drawings in which reference numerals refer to like elements, and which are intended to show by way of illustration specific embodiments in which the invention may be practiced. It is understood that other embodiments may be utilized and that structural changes may be made without departing from the scope and spirit of the invention.

[001 9] Referring to the figures, a solar panel mounting base and system for solar panel installation 100 is shown having a mounting base 1 10. Mounting base 1 1 0 is made of injection molded nylon such as BASF ULTRAMID glass-filled nylon. This material is extremely strong, stable and electrically insulating. Of course other suitable materials may be used to produce mounting base 1 1 0 as long as it can withstand the pressure of the solar panels and the exposure to the elements.

[0020] Mounting base 1 1 0 has four connection locations to allow an installer to mount a solar panel 1 95 at the desired angle. The first location 1 65 is the lowest with a second location 1 70 that is above the first. Two upper locations, 1 75 and 1 80 respectively, are located along an upper portion of mounting base 1 1 0 to provide flexibility in both mounting angles and spacing between solar panels 1 95. The connection locations are angled with respect to the horizontal to provide a stable and secure connecting location to secure solar panel 1 95 when solar panel 1 95 is secured between another mounting base 1 1 0 at a connection location that is at a different height than the first mounting base 1 1 0. Various kinds of solar panel installations may attached to these locations such as, but not limited to, struts, channels and frameless panels as is known in the art.

[0021 ] An alignment tab 1 30 is molded into mounting base 1 1 0 to align an attachment clamp 1 25 that is used to quickly and easily allow the installer to attach solar panels 1 95 to mounting base 1 1 0 without having to have access to an underside of solar panel 1 95. This allows the installer to complete the installation from the top down which greatly simplifies and saves installation time. Each alignment clamp fits over an attachment opening 1 20 which is molded into mounting base 1 10 in one of four connection locations 1 65, 1 70, 1 75 and 1 80.

[0022] A plurality of drainage channels 1 85 are located along the bottom portion of mounting base 1 1 0 to allow water to exit and not build up when exposed to the elements such as rain or snow. Mounting base 1 10 has openings along the sides to decrease the amount of material used and to allow air flow. A windscreen (not shown) may be attached to the leading edge of mounting base 1 1 0 to direct the flow of air up and around solar panels 1 95. Four hold down notches 230 are provided along a bottom portion of mounting base 1 1 0 that allow installation struts 240 to fit within.

[0023] Various methods of installing a solar panel array are provided using solar panel mounting base and system for solar panel installation 1 00. It is possible to attach mounting base 1 10 to a roof (not shown) using mechanical fasteners (not shown) that penetrate the structure as is known in the art. If a non-permanent installation or non-intrusive method of installation is desires, ballast blocks 1 90 are stacked within the bottom portion of mounting base 1 10.

[0024] Referring to figures 1 -3 and 1 0, mounting bases 1 1 0 are installed using installation struts 240 that fit within hold down notches 230. Installation struts are used in installations that do not allow anchors to be located under each mounting base 1 1 0. An anchor 250 is attached to strut 240 and then attaches to other struts 240 to hold mounting bases 1 1 0 down. Installation strut 240 is attached to mounting base 1 1 0 using a carriage bolt (not shown) that fits within bottom attachment point 235 that includes a carriage bolt well (not shown) like the one shown in detail in figure 7. In this way mounting bases 1 1 0 are secured using mechanical fasteners even when the fasteners cannot be located beneath the bases.

[0025] Now referring to figure 1 1 , mounting base 1 1 0 is secured to a surface 255 such as a roof where the installation is desired. An anchor plate 260 is attached to surface 255 using bolts, glue, or other fastening devices as known in the art. Anchor plate 260 has carriage bolt 1 35 that is secured within carriage bolt well 21 5 like the one shown in figure 7A and nut 1 40 hold down mounting base 1 1 0. This installation method works in installations where mechanic anchors can be located beneath bottom attachment point 235.

[0026] Referring now to figures 7, 7A, 8 and 9, attachment clamp 1 25 is shown having a horizontal clamp portion 1 50 with a series of grooves 205 on an upper surface. An adjustment slot 225 is used to adjust the position of adjustment clamp 1 25 during installation. In each of the four connection locations 1 65, 1 70, 1 75 and 1 80, an attachment well 220 is molded within mounting base 1 1 0 along with a square shaped carriage bolt well 21 5. Carriage bolt 1 35 fits within a metallic square carriage bolt washer 21 0 and a lower nut 1 40 is secured within an upper portion of attachment well 220. In this way, carriage bolt 1 35 is secured to mounting base 1 1 0 and allows a vertical clamp portion 1 45 to be secured with an upper nut 1 40. Vertical clamp portion 1 45 has a series of grooves 205 on a bottom portion that interacts with grooves 205 on horizontal clamp portion 1 50 to securely hold it in a desired position when clamping down solar panel 1 95. Vertical clamp portion 1 45 also has a second upper horizontal portion with grooves 206 on its underside to frictionally hold solar panel 1 95 in place. Alignment tab 1 30 keeps attachment clamp 1 25 from rotating when clamping down solar panel 1 95.

[0027] Because mounting base 1 1 0 has four different connection locations, the angle that solar panel 1 95 makes can vary from 5 degrees to 1 0 degrees depending on the location chosen to mount solar panel 1 95 to. For example, connecting one edge of solar panel 1 95 to the lowest connection location on the first mounting base 1 1 0 and then connection the opposite edge of solar panel 1 95 to the highest location on a second mounting base 1 1 0 will result in the greatest angle that solar panel 1 95 is installed at. This eliminates the need to measure and set the angle since the angle is set by the selection of connection locations chosen during the installation. Additionally, the spacing between solar panels 1 95 mounted in an array varies from 1 0 inches to 1 3 inches again depending on which location is chosen. Of course other angles could be provided by changing the height of the locations provided or by providing additional attachment locations (not shown). [0028] Referring to figure 6, an array of solar panels 1 95 are installed by placing mounting bases 1 10 in an array and then attaching solar panels 1 95 using attachment clamps 1 25 which are mounted on mounting bases 1 10. Solar panels are mounted at an angle by attaching them to a selected location on one mounting base 1 1 0 to a different location on second mounting base 1 1 0.

[0029] Although the instant invention has been described in relation to particular embodiments thereof, many other variations and

modifications and other uses will become apparent to those skilled in the art.

Claims

WHAT IS CLAIMED IS:

1 . A solar panel mounting base for mounting solar panels comprising:

a mounting base;

said mounting base having a plurality of connection

locations;

said plurality of connection locations being configured to secure a solar panel at a selected connection location;

each of said connection locations having a mechanical connector wherein said solar panel is secured using said mechanical connector;

said mounting base having a lower portion adapted to hold ballast; and

said mounting base having sides that narrow from a

maximum at a top portion to a minimum at a lower portion wherein each mounting base is stackable when placed in another mounting base.

2. The solar panel mounting base according to claim 1 wherein each of said plurality of connection locations having a carriage bolt well disposed around an attachment opening;

said carriage bolt well holding a carriage bolt washer therein; a carriage bolt disposed in said attachment opening; a nut securing said carriage bolt therein wherein said carriage bolt is securely held therein by a nut wherein said mechanical connector is secured therein.

3. The solar panel mounting base of claim 2 further comprising an alignment tab disposed along a side of said connection location wherein said mechanical connector is aligned when secured thereon.

4. The solar panel mounting base of claim 1 wherein said mechanical connector comprises:

a horizontal clamp portion;

said horizontal clamp portion having a plurality of horizontal clamp grooves along an upper surface thereon;

said horizontal clamp portion having a first end that bends back around defining a generally v-shaped portion with a first end defining an angle of less than 90 degrees with the horizontal and an oppositely disposed second end defining a generally v-shaped portion with a second end defining an angle less than 90 degrees with the horizontal;

an adjustment slot disposed in said horizontal clamp portion wherein a bolt adjustably slides therein;

a vertical clamp portion;

said vertical clamp portion being generally step-shaped; said vertical clamp portion having a vertical clamp top portion 90 degrees from said vertical clamp portion and terminating in a top end;

said vertical clamp portion having a vertical clamp bottom portion 90 degrees from said vertical clamp portion and terminating in a bottom end extending in a direction opposite said top end;

said vertical clamp top portion having a plurality of grooves on a bottom surface thereon wherein said top portion frictionally engages with a frame portion of said solar panel; and

said vertical clamp bottom portion having a plurality of vertical clamp grooves disposed on a lower surface wherein said plurality of vertical clamp grooves interact with said horizontal clamp grooves wherein said vertical clamp is locked down when said vertical clamp portion is forced against said horizontal clamp portion using said bolt and a nut.

5. The solar panel mounting base of claim 1 further comprising a bottom attachment point disposed in a bottom portion of said mounting base wherein a bolt is attached therein to secure said mounting base to a surface.

6. The solar panel mounting base of claim 1 having a plurality of hold down notches disposed in a lower portion of each of said sides wherein an installation strut is secured therein.

7. The solar panel mounting base of claim 1 further comprising a plurality of drainage channels disposed in a bottom portion of said mounting base wherein water is directed away from said bottom portion.

8. A system for installing solar panels to a surface using a plurality of solar panel mounting bases comprising:

each of said plurality of solar panel mounting bases comprises a mounting base;

said mounting base having a plurality of connection locations;

said mounting base having a lower portion adapted to hold ballast;

said mounting base having sides that narrow as from a maximum at a top portion to a minimum at a lower portion wherein each mounting base is stackable when placed in another mounting base;

at least one solar panel having a leading edge and a trailing edge; said leading edge secured using said mechanical connector at a selected connection location on a pair of mounting bases disposed thereon;

said trailing edge secured at a second selected connection location disposed on a second pair of mounting bases wherein said solar panel is securely held in place.

9. The system for installing solar panels to a surface using a plurality of solar panel mounting bases according to claim 8 wherein each of said mounting bases is secured to said surface using ballast disposed therein.

1 0. The system for installing solar panels to a surface using a plurality of solar panel mounting bases according to claim 8 wherein each of said mounting bases is secured to said surface using mechanical connectors.

1 1 . The system for installing solar panels to a surface using a plurality of solar panel mounting bases according to claim 8 wherein each of said mounting bases has a plurality of hold down notches disposed in a lower portion therein.

1 2. The system for installing solar panels to a surface using a plurality of solar panel mounting bases according to claim 8 wherein each of said mounting bases having sides that narrow from a maximum at a top portion to a minimum at a lower portion wherein each mounting base is stackable when placed in another mounting base during transport.