Rail-less solar panel assembly and installation method

• US 9,647,433 B2
• Filed: 04/27/2016
• Issued: 05/09/2017
• Est. Priority Date: 11/19/2014
• Status: Active Grant

• Current Assignee: Ironridge Incorporated (Esdec B.V.)
• Original Assignee: Ironridge Incorporated (Esdec B.V.)
• Inventors: Meine, Shawn, Ash, Jon, Taggart, Dave, Kim, Willie, Reitz, Clayton Robert, Pereira, William Anthony
• Primary Examiner(s): Herring, Brent W
• Application Number:
  US15/140,399
• Publication Number:
  US 20160268959A1
• Time in Patent Office: 377 Days
• Field of Search: 248237, 126621, 126623, 136244, 521733
• 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 stationary leveling bolt;

e. a barrel nut that extends through the length of the cavity and is rotatably coupled within the cavity, the barrel nut further comprising a top end, a bottom end, and a central aperture wherein;

i. the barrel nut is rotably coupled to the stationary leveling bolt through the central aperture;

ii. the bottom end further comprises a rim that extends outward beneath the bottom portion of the first clamp; and

iii. the top end further comprises a drive head such that when the drive head is rotated, the height of the first clamp is adjusted up or down depending on the direction of the rotation of the drive head.

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

3. The assembly of claim 1 wherein the first mounting plate further comprises a conduit for storing cables that extends beneath a portion of the first mounting plate.

4. 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.

5. The apparatus of claim 4 wherein the raised portion is a pin that is coupled to the first mounting plate.

6. The apparatus of claim 4 wherein the raised portion is a clip that is coupled to the first mounting plate.

7. The assembly of claim 1 wherein the drive head further comprises an allen drive.

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

9. 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.

10. 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, the first mounting plate comprising a pair of raised portions for electrically bonding a first solar panel module to a second solar panel module;

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

d. a first spacer wherein the first spacer is coupled to a middle portion of the first mounting plate for providing parallel separation between a first pair of adjacent solar panel modules; and

e. a cable storage conduit that extends beneath a portion of the first mounting plate.

11. The splice of claim 10 wherein the raised portions are pins that are coupled to the first mounting plate.

12. The splice of claim 10 wherein the raised portion is a clip that is coupled to the first mounting plate.

13. The splice of claim 10 wherein the end of the first mounting plate further comprises a release lever.

14. The splice of claim 10 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; and

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

15. The splice of claim 14 further comprising a second spacer wherein the second spacer is coupled to a middle portion of the second mounting plate for providing separation between a second pair of adjacent solar panel modules.