Height Adjustable Solar Panel Mounting Assembly with an Asymmetric Lower Bracket

• US 20170063288A1
• Filed: 11/15/2016
• Published: 03/02/2017
• Est. Priority Date: 08/03/2015
• Status: Active Grant

• Current Assignee: Unirac Incorporated
• Original Assignee: Unirac Incorporated
• Inventors: SCHUIT, Nathan, MAYFIELD, Jason, GALLEGOS, Ernest
• Granted Patent: US 10,819,271 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F16B 2/065 using screw-thread elements F16B2/08 - F16B2/12 take precedence
• CPC Class Codes: F16H 25/20 Screw mechanisms with automatic reversal F16H25/12
• CPC Class Codes: F16M 13/02 for supporting on, or attaching to, an object, e.g. tree, gate, window-frame, cycle
• CPC Class Codes: F24S 25/63 for fixing modules or their peripheral frames to supporting elements
• 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

A height adjustable solar panel mounting assembly with an asymmetric lower bracket is disclosed. The asymmetric lower bracket includes a flat support ledge on a first side of the asymmetric lower bracket and a tilted spring support ledge on a second side of the asymmetric lower bracket, where the first side is opposite from the second side. A central box frame is defined by the asymmetric lower bracket where a helical drive element is receivable in the central box frame.

Claims

1. An asymmetric lower bracket for use in a solar panel mounting assembly, comprising:

a flat support ledge on a first side of the asymmetric lower bracket;

a tilted spring support ledge on a second side of the asymmetric lower bracket, wherein the first side is opposite from the second side; and

a central box frame defined by the asymmetric lower bracket, wherein a helical drive element is receivable in the central box frame.

2. The asymmetric lower bracket of claim 1, wherein the tilted spring support ledge is tilted at an angle ranging from 10-30 degrees to a horizontal plane when a photovoltaic module is not mounted on the tilted spring support ledge.

3. The asymmetric lower bracket of claim 1, wherein the tilted spring support ledge is tilted at an angle of approximately 20 degrees to a horizontal plane when a photovoltaic module is not mounted on the tilted spring support ledge.

4. The asymmetric lower bracket of claim 1, wherein the tilted spring support ledge includes a tilted portion and a horizontal distal portion.

5. The asymmetric lower bracket of claim 1, further comprising an angled web section that is attached to a vertical support wall, wherein the tilted spring support ledge extends horizontally beyond the vertical support wall.

6. The asymmetric lower bracket of claim 1, wherein the tilted spring support ledge has a width (W) and a thickness (t) sufficient to provide an elastic, spring-like force that pushes upward on a photovoltaic module when the photovoltaic module is installed on the tilted spring support ledge.

7. The asymmetric lower bracket of claim 6, wherein a ratio of the width to the thickness (W/t) is greater than 15.

8. A clamping assembly for clamping photovoltaic modules, comprising:

an asymmetric lower bracket, wherein the asymmetric lower bracket includes a flat support ledge on a first side of the asymmetric lower bracket, a tilted spring support ledge on a second side of the asymmetric lower bracket, wherein the first side is opposite from the second side, and a central box frame defined by the asymmetric lower bracket, wherein a helical drive element is receivable in the central box frame; and

an upper bracket, wherein the upper bracket includes a vertical wall that has a lower end that is disposed in a groove of the asymmetric lower bracket and includes a first wing and a second wing.

9. The clamping assembly of claim 8, wherein the tilted spring support ledge is tilted at an angle ranging from 10-30 degrees to a horizontal plane when a photovoltaic module is not mounted on the tilted spring support ledge.

10. The clamping assembly of claim 8, wherein the tilted spring support ledge is tilted at an angle of approximately 20 degrees to a horizontal plane when a photovoltaic module is not mounted on the tilted spring support ledge.

11. The clamping assembly of claim 8, wherein the tilted spring support ledge includes a tilted portion and a horizontal distal portion.

12. The clamping assembly of claim 8, wherein the asymmetric lower bracket further includes an angled web section that is attached to a vertical support wall, wherein the tilted spring support ledge extends horizontally beyond the vertical support wall.

13. The clamping assembly of claim 8 in combination with a first photovoltaic module and a second photovoltaic module, wherein the first photovoltaic module is disposed on a first side of the clamping assembly, wherein the second photovoltaic module is disposed on a second side of the clamping assembly, and wherein the first photovoltaic module and the second photovoltaic module are disposed between the upper bracket and the asymmetric lower bracket.

14. The clamping assembly of claim 13, wherein the tilted spring support ledge is deflected when the second photovoltaic module is inserted between the upper bracket and the asymmetric lower bracket, wherein the deflected tilted spring support ledge provides a vertical force that pushes upward on the second photovoltaic module such that there is essentially no gap between the upper bracket and the second photovoltaic module.

15. The clamping assembly of claim 8, wherein the tilted spring support ledge has a width (W) and a thickness (t) sufficient to provide an elastic, spring-like force that pushes upward on a photovoltaic module when the photovoltaic module is installed on the tilted spring support ledge and wherein a ratio of the width to the thickness (W/t) is greater than 15.

16. A drive, comprising:

a helical drive with a hollow, central core that is surrounded by outer helical threads, wherein the outer helical threads are coated with a coating of a low-noise plastic or elastomer material.

17. The drive of claim 16, wherein the low-noise plastic or elastomer material is nylon.

18. The drive of claim 16, wherein the coating has a thickness ranging from 0.010 to 0.020 inches.

19. The drive of claim 16, wherein the coating is approximately 0.013 inches thick.

20. A method of mounting a photovoltaic module in a solar panel mounting assembly, wherein the solar panel mounting assembly comprises:

an upper bracket; and

an asymmetric lower bracket, wherein the asymmetric lower bracket includes a flat support ledge on a first side of the asymmetric lower bracket, a tilted spring support ledge on a second side of the asymmetric lower bracket, wherein the first side is opposite from the second side, and a central box frame defined by the asymmetric lower bracket, wherein a helical drive element is receivable in the central box frame;

and comprising the steps of;

inserting the photovoltaic module between the upper bracket and the tilted spring support ledge on the second side of the asymmetric lower bracket at an angle with respect to a horizontal plane; and

rotating the photovoltaic module back to the horizontal plane and deflecting the tilted spring support ledge on the second side of the asymmetric lower bracket by the photovoltaic module, wherein the deflecting generates a vertical upward force on the photovoltaic module by the tilted spring support ledge such that there is essentially no gap between the upper bracket and the photovoltaic module.