Rail-Less Solar Panel Assembly and Installation Method

• US 20160268959A1
• Filed: 04/27/2016
• Published: 09/15/2016
• Est. Priority Date: 11/19/2014
• Status: Active Grant

• Current Assignee: Ironridge Incorporated (Esdec B.V.)
• Original Assignee: Ironridge Incorporated (Esdec B.V.)
• Inventors: Taggart, Dave, Kim, Willie, Reitz, Clayton Robert, Pereira, William Anthony, Meine, Shawn, Ash, Jon
• Granted Patent: US 9,647,433 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: F24S 2025/019 Means for accommodating irregularities on mounting surface; Tolerance compensation means
• CPC Class Codes: F24S 2025/021 Sealing means between support elements and mounting surface
• CPC Class Codes: F24S 2025/6004 by clipping, e.g. by using snap connectors
• CPC Class Codes: F24S 25/00 Arrangement of stationary mountings or supports for solar heat collector modules
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: F24S 25/634 Clamps; Clips
• CPC Class Codes: F24S 25/65 for coupling adjacent supporting elements, e.g. for connecting profiles together
• CPC Class Codes: F24S 25/70 with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
• CPC Class Codes: H01R 4/26 Connections in which at least one of the connecting parts has projections which bite into or engage the other connecting part in order to improve the contact H01R4/188, H01R4/203, H01R4/5075 take precedence; using shape memory materials H01R4/01
• CPC Class Codes: H01R 4/38 utilising a clamping member acted on by screw or nut H01R4/50 takes precedence
• CPC Class Codes: H02G 3/263 Installation, e.g. suspension, of conduit channels or other supports
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• 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

In various representative aspects, an assembly for securing array skirts and solar panel modules in an array on a roof by providing a leveling system that utilizes a barrel bolt and barrel nut to vertically adjust the assembly. Improved electrical bonding by utilizing bonding pins installed in mounting plates of a support clamp are also provided. Additionally, an improved array skirt design that is installed on the outer row of the array, as well as improved designs in the support clamp and splice mechanisms are also provided. Finally, an improved wire management system is included as well as a method of installation of the array assembly.

Claims

1. An adjustable solar panel mounting assembly comprising:

a. a first clamp further comprising an upper and lower portion wherein the lower portion further comprises a cavity;

b. a first mounting plate extending outward from the lower portion of the first clamp to an end;

c. a first flange extending outward from the upper portion of the first clamp;

d. a barrel nut further comprising a top end and a bottom end wherein the barrel nut is rotatably coupled within the cavity; and

e. a drive head coupled to the top end of the barrel nut.

2. The assembly of claim 1 wherein the barrel nut is independently rotatable within the cavity.

3. The assembly of claim 1 wherein the barrel nut is threaded along an inside surface of the barrel nut for engaging a threaded shank.

4. The assembly of claim 1 wherein the first mounting plate further comprises a conduit extending beneath a portion of the first mounting plate.

5. The apparatus of claim 1 wherein the first mounting plate further comprises a raised portion for electrically bonding a first solar panel module to a second solar panel.

6. The apparatus of claim 5 wherein the raised portion is a pin that is coupled to the first mounting plate.

7. The apparatus of claim 5 wherein the raised portion is a clip that is coupled to the first mounting plate.

8. The assembly of claim 1 wherein the drive head further comprises an alien drive.

9. The assembly of claim 1 wherein the end of the first mounting plate further comprises a release lever.

10. The assembly of claim 1 further comprising:

a. a second clamp further comprising an upper and lower portion such that the lower portion of the second clamp is coupled to the lower portion of the first clamp;

b. a second mounting plate extending outward from the lower portion of the second clamp to an end;

c. a second flange extending outward from the upper portion of the second clamp.

11. A splice for coupling solar panel modules comprising:

a. a first clamp further comprising an upper and lower portion;

b. a first mounting plate extending outward from the lower portion of the first clamp to an end; and

c. a first flange extending outward from the upper portion of the first clamp.

12. The splice of claim 11 wherein the first mounting plate further comprises a conduit extending beneath a portion of the first mounting plate.

13. The splice of claim 11 wherein the first mounting plate further comprises a pair of raised portions for electrically bonding a first solar panel module to a second solar panel.

14. The splice of claim 13 wherein the raised portions are pins that are coupled to the first mounting plate.

15. The splice of claim 13 wherein the raised portion is a clip that is coupled to the first mounting plate.

16. The splice of claim 11 further comprising a first spacer wherein the first spacer is coupled to a middle portion of the mounting plate.

17. The splice of claim 11 wherein the end of the first mounting plate further comprises a release lever.

18. The splice of claim 11 further comprising:

a. a second clamp further comprising an upper and lower portion such that the lower portion of the second clamp is coupled to the lower portion of the first clamp;

b. a second mounting plate extending outward from the lower portion of the second clamp to an end;

c. a second flange extending outward from the upper portion of the second clamp.

19. The splice of claim 18 further comprising a second spacer wherein the second spacer is affixed to a middle portion of the second mounting plate.

20. A wire management system for solar panel arrays comprising:

a. a solar panel mounting assembly;

b. a conduit further comprising an opening wherein the conduit is coupled to, and extends beneath a length of the solar panel mounting assembly; and

c. a tab further comprising a first end and a length that extends to a second end such that;

i. the first end of the tab is pivotally coupled to the solar panel mounting assembly and

ii. the length of the tab is aligned outside of the conduit.

21. The wire management system of claim 20 wherein the tab is resilient such that when the tab is moved upward from a first position and subsequently released, the tab returns to the first position.

22. The wire management system of claim 20 wherein the tab is resilient such that when the tab is moved upward from a first position and subsequently released, the tab returns to the first position and engages a wire so that the wire is secure within the conduit.

23. The wire management system of claim 20 wherein the tab extends around the perimeter of the conduit.