Height adjustable solar panel mounting assembly

• US 10,461,682 B2
• Filed: 04/25/2016
• Issued: 10/29/2019
• Est. Priority Date: 08/03/2015
• Status: Active Grant

• Current Assignee: Unirac Incorporated
• Original Assignee: Unirac Incorporated
• Inventors: Schuit, Nathan, Mayfield, Jason, Nicolaedis, Klaus, Ganshaw, Todd
• Primary Examiner(s): Mekhlin, Eli S
• Assistant Examiner(s): Carlson, Kourtney R S
• Application Number:
  US15/138,018
• Publication Number:
  US 20170040931A1
• Time in Patent Office: 1,282 Days
• Field of Search: 136242-265, 521733
• CPC Class Codes: F24S 2025/019 Means for accommodating irregularities on mounting surface; Tolerance compensation means
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

An apparatus and method for mounting a solar panel in a solar panel mounting assembly is disclosed. The solar panel mounting assembly includes a mounting bracket and a helical drive, where the mounting bracket is vertically adjustable by the helical drive. The helical drive engages with a stanchion that is variably positioned along a base member that is fixed to a roof.

Claims

1. A solar panel mounting assembly, comprising:

a mounting bracket including an upper bracket and a lower bracket, the lower bracket including a first slot and a second slot;

a stanchion including a first vertical arm opposite a second vertical arm, the first vertical arm and the second vertical arm each including teeth protruding from respective inside surfaces thereof, respective outside surfaces thereof being smooth and planar, and the teeth of the first vertical arm facing the teeth of the second vertical arm to define an open central region between the first vertical arm and the second vertical arm; and

a helical drive element disposed inside of the open central region between the first vertical arm and the second vertical arm,

wherein;

the upper and lower brackets are coupled to the helical drive element wherein the mounting bracket is vertically adjustable by rotating the freestanding helical drive element,

the first vertical arm is received by the first slot such that the first vertical arm passes through the first slot when the mounting bracket is vertically adjusted, and

the second vertical arm is received by the second slot such that the second vertical arm passes through the second slot when the mounting bracket is vertically adjusted.

2. The solar panel mounting assembly according to claim 1, wherein the helical drive element includes an external helical thread extending from a bottom of the helical drive element to a top of the helical drive element.

3. The solar panel mounting assembly according to claim 1, wherein the teeth on the first vertical arm are vertically offset with respect to the teeth on the second vertical arm.

4. The solar panel mounting assembly according to claim 3, wherein:

the stanchion comprises an extruded, planar channel section having a selected longitudinal length,

the front and back surfaces of the channel section are defined by a pair of parallel planes that are separated by said selected longitudinal length, and

an outer diameter of the helical drive element extends radially beyond the first pair of parallel planes defining the front and back surfaces of the stanchion.

5. The solar panel mounting assembly according to claim 3, wherein an entirety of the helical drive element is disposed below a top of the stanchion.

6. The solar panel mounting assembly according to claim 1, further comprising:

a tool for rotating the helical drive element,

wherein the helical drive element is rotatable by inserting the tool into a recess in the helical drive element and rotating the tool.

7. The solar panel mounting assembly according to claim 6, further comprising:

a first hole disposed in the upper bracket and vertically aligned with a second hole disposed in the lower bracket, the first hole and the second hole for receiving at least a portion of the tool.

8. The solar panel mounting assembly according to claim 1, wherein the helical drive element is vertically movable before or after the assembly has been mounted to a roof.

9. The solar panel mounting assembly according to claim 1, further comprising;

a base, wherein the stanchion is coupled to the base.

10. The solar panel mounting assembly according to claim 9, wherein the stanchion is variably positionable along a horizontal longitudinal length of the base.

11. The solar panel mounting assembly according to claim 9, wherein the base has a length such that no cutting of shingles is required when installing the base on a composition roof with shingles.

12. The solar panel mounting assembly according to claim 9, wherein the base includes an aperture, and

wherein a lag screw is disposable through the aperture for mounting the base on a roof.

13. The solar panel mounting assembly according to claim 9, wherein the base includes a horizontal hollow channel that is disposed along a longitudinal length of the base.

14. The solar panel mounting assembly of claim 9, wherein the stanchion comprises a hook for locking the stanchion onto a side of the base.

15. The solar panel mounting assembly according to claim 1, wherein the upper bracket is coupled to the lower bracket, and the upper bracket is positioned directly above the lower bracket.

16. The solar panel mounting assembly according to claim 15, wherein an entirety of the helical drive element is disposed below the lower bracket.

17. The solar panel mounting assembly according to claim 15, wherein the lower bracket includes a coupler which couples the helical drive element to the lower bracket.

18. The solar panel mounting assembly according to claim 15, wherein:

a horizontal slot is disposed across a width of the lower bracket, and

a lower end of a vertical wall of the upper bracket is disposed in the horizontal slot.

19. The solar panel mounting assembly according to claim 15, wherein:

the lower bracket includes a first stiffening web and a second stiffening web,

the first stiffening web is attached to a first arm of the lower bracket, and

the second stiffening web is attached to a second arm of the lower bracket.

20. The solar panel mounting assembly of claim 15, wherein the upper bracket and the lower bracket are a single, monolithic, integrated structure.

21. The solar panel mounting assembly of claim 15, wherein the upper and lower brackets are not mirror images of each other.

22. The solar panel mounting assembly according to claim 1, wherein the mounting bracket includes a first panel slot and a second panel slot, and

a first solar panel is mountable in the first panel slot and a second solar panel is mountable in the second panel slot.

23. The solar panel mounting assembly according to claim 1, wherein the helical drive element is vertically movable along a vertical length of the stanchion between the first vertical arm and the second vertical arm, before or after the stanchion has been attached to a base that is mounted to a roof.

24. The solar panel mounting assembly according to claim 1, wherein the helical drive element has an aspect ratio of a vertical height to an outer diameter that ranges from 0.8 to 1.2.

25. The solar panel mounting assembly according to claim 1, wherein the helical drive element has an aspect ratio of an inner diameter to an outer diameter that ranges from 0.5 to 0.9.

26. The solar panel mounting assembly according to claim 1, wherein the helical drive element includes a square thread that has a pitch length ranging from 0.1 to 1.0 inches/thread.

27. The solar panel mounting assembly according to claim 1, wherein the helical drive element has a plurality of circumferential facets on a helical thread of the helical drive element.

28. The solar panel mounting assembly according to claim 1, further comprising:

a bonding pin disposed in the lower bracket of the mounting bracket,

wherein an electrical connection is establishable between a solar panel that is installed in the mounting bracket and the mounting bracket by the bonding pin.

29. The solar panel mounting assembly according to claim 1, wherein the mounting bracket includes an arm and a micro-inverter is mountable on the arm.

30. The solar panel mounting assembly according to claim 1, wherein the stanchion includes a horizontal bridge that extends across from a top of the first vertical arm of the stanchion to a top of the second vertical arm of the stanchion.

31. The solar panel mounting assembly according to claim 1, wherein

the first vertical arm and the second vertical arm are disposed between two parallel planes.

32. The solar panel mounting assembly of claim 1, wherein the helical drive element has an external helical thread that wraps around a cylindrical core.

33. The solar panel mounting assembly of claim 1, wherein the stanchion is an extruded, hollow, U-shaped channel section.