Photovoltaic panel racking system

• US 9,800,201 B1
• Filed: 04/17/2017
• Issued: 10/24/2017
• Est. Priority Date: 09/09/2016
• Status: Active Grant

• Current Assignee: Polar Racking Inc.
• Original Assignee: Polar Racking Inc.
• Inventors: Atcha, Imran, Raileanu, Dorin Lucian, Marentette, Matthew Paul, Yarusevych, Volodymyr
• Primary Examiner(s): Mintz, Rodney
• Application Number:
  US15/488,960
• Time in Patent Office: 190 Days
• Field of Search: 2111811, 211 8531, 211 8517, 211 417, 2111335, 211 74, 211 591
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 25/13 Profile arrangements, e.g. trusses F24S25/12 takes precedence
• CPC Class Codes: F24S 25/16 Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/30 using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors extending in directions away from the supporting surface F24S25/10; peripheral frames for modules F24S25/20
• 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 20/10 Supporting structures directly fixed to the ground H02S20/30 takes precedence
• CPC Class Codes: H02S 20/20 Supporting structures directly fixed to an immovable object H02S20/30 takes precedence
• CPC Class Codes: H02S 20/22 specially adapted for buildings
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• 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 photovoltaic module mounting system may include a right-hand support runner and a left-hand support runner. The support runners collectively define a rooftop contacting plane and a photovoltaic module support plane oriented at a predetermined angle relative to the rooftop contacting plane. The support runners may be interconnected with each other, and with additional support runners, to form an interconnected support structure that can be used to mount an array of photovoltaic modules upon a planar surface such as a building rooftop.

Claims

1. A photovoltaic module mounting system, comprising:

a first plurality of right-hand support runners and a second plurality of left-hand support runners, each support runner including;

first and second separated rooftop contacting portions defining a rooftop contacting plane,

a first curved extension portion extending from one end of the first rooftop contacting portion a first distance away from the rooftop contacting plane,

a first connecting flange disposed at another, terminal end of the first rooftop contacting portion,

a second curved extension portion extending from one end of the second rooftop contacting portion a second distance away from the rooftop contacting plane,

a second connecting flange disposed at another, terminal end of the second rooftop contacting portion,

a transverse module support portion connecting the first curved extension portion to the second curved extension portion and thereby connecting the first and second rooftop contacting portions to each other, and

first and second module clamp assemblies configured to be attached at respective ends of the transverse module support portion and to support a photovoltaic module;

wherein the transverse module support portion of each right-hand support runner and the transverse module support portion of an adjacent left-hand support runner collectively define a photovoltaic module support plane oriented at a predetermined angle relative to the rooftop contacting plane; and

wherein each connecting flange of each right-hand support runner is configured to be brought into mating alignment and joined with one of the connecting flanges of another right-hand support runner and with one of the connecting flanges of each of two left-hand support runners to form an interconnected web of four support runners.

2. The system of claim 1, wherein the first and second rooftop contacting portions, the first and second curved extension portions, and the transverse module support portion of each support runner are all substantially cylindrical in cross section.

3. The system of claim 1, wherein for each support runner, the first rooftop contacting portion defines a first line, the second rooftop contacting portion defines a second line, and the transverse module support portion defines a third line, wherein the first line and the third line intersect at a first obtuse angle when projected into a common plane, and wherein the second line and the third line intersect at a second obtuse angle when projected into a common plane.

4. The system of claim 1, further comprising a plurality of u-shaped cross members, each having a first distal end configured to be joined to the transverse module support portion of one of the right-hand support runners, a second distal end configured to be joined to the transverse module support portion of one of the left-hand support runners, and a central portion configured to be oriented to lie in the rooftop contacting plane.

5. The system of claim 4, further comprising a plurality of ballast pans, each configured to overlay the central portion of one of the u-shaped cross members and to receive one or more ballast stones.

6. A photovoltaic module mounting system, comprising:

a first plurality of right-hand support runners and a second plurality of left-hand support runners, each support runner including;

first and second separated rooftop contacting portions defining a rooftop contacting plane,

a first curved extension portion extending from one end of the first rooftop contacting portion a first distance away from the rooftop contacting plane,

a first connecting flange disposed at another, terminal end of the first rooftop contacting portion,

a second curved extension portion extending from one end of the second rooftop contacting portion a second distance away from the rooftop contacting plane,

a second connecting flange disposed at another, terminal end of the second rooftop contacting portion,

a transverse module support portion connecting the first curved extension portion to the second curved extension portion and thereby connecting the first and second rooftop contacting portions to each other, and

first and second module clamp assemblies configured to be attached at respective ends of the transverse module support portion and to support a photovoltaic module;

wherein the transverse module support portion of each right-hand support runner and the transverse module support portion of an adjacent left-hand support runner collectively define a photovoltaic module support plane oriented at a predetermined angle relative to the rooftop contacting plane; and

wherein the first and second connecting flanges of each right-hand support runner are configured to be brought into mating alignment and joined with the first and second connecting flanges, respectively, of one of the left-hand support runners to form an interconnected network of support runners.

7. The system of claim 6, wherein the first and second rooftop contacting portions, the first and second curved extension portions, and the transverse module support portion of each support runner are all hollow and substantially cylindrical in cross section.

8. The system of claim 6, further comprising a plurality of wind deflectors, each having a right side configured to attach to a central part of the second curved extension portion of one of the right-hand support runners and to overlie a portion of the second rooftop contacting portion of the same one of the right-hand support runners, and a left side configured to attach to a central part of the second curved extension portion of one of the left-hand support runners and to overlie a portion of the second rooftop contacting portion of the same one of the left-hand support runners.

9. The system of claim 6, wherein for each support runner, the first rooftop contacting portion defines a first line, the second rooftop contacting portion defines a second line, and the transverse module support portion defines a third line, wherein the first line and the third line intersect at a first obtuse angle when projected into a common plane, and wherein the second line and the third line intersect at a second obtuse angle when projected into a common plane.

10. The system of claim 6, further comprising a plurality of u-shaped cross members, each having a first distal end configured to be joined to the transverse module support portion of one of the right-hand support runners, a second distal end configured to be joined to the transverse module support portion of one of the left-hand support runners, and a central portion configured to be oriented to lie in the rooftop contacting plane.

11. The system of claim 10, further comprising a plurality of ballast pans, each configured to overlay the central portion of one of the u-shaped cross members and to receive one or more ballast stones.

12. A photovoltaic module mounting system, comprising:

a right-hand support runner and a left-hand support runner, each support runner including;

first and second separated rooftop contacting portions defining a rooftop contacting plane,

a first curved extension portion extending from one end of the first rooftop contacting portion a first distance away from the rooftop contacting plane,

a first connecting flange disposed at another, terminal end of the first rooftop contacting portion,

a second curved extension portion extending from one end of the second rooftop contacting portion a second distance away from the rooftop contacting plane,

a second connecting flange disposed at another, terminal end of the second rooftop contacting portion,

a transverse module support portion connecting the first curved extension portion to the second curved extension portion and thereby connecting the first and second rooftop contacting portions to each other, and

first and second module clamp assemblies configured to be attached at respective ends of the transverse module support portion and to support a photovoltaic module;

wherein the transverse module support portion of the right-hand support runner and the transverse module support portion of the left-hand support runner collectively define a photovoltaic module support plane oriented at a predetermined angle relative to the rooftop contacting plane.

13. The system of claim 12, wherein the second distance is greater than the first distance, thereby causing the transverse module support portions to be oriented at a non-zero angle relative to the rooftop contacting plane.

14. The system of claim 12, wherein for each support runner, the first rooftop contacting portion defines a first line, the second rooftop contacting portion defines a second line, and the transverse module support portion defines a third line, wherein the first line and the third line intersect at a first obtuse angle when projected into a common plane, and wherein the second line and the third line intersect at a second obtuse angle when projected into a common plane.

15. The system of claim 12, wherein the first and second rooftop contacting portions, the first and second curved extension portions, and the transverse module support portion are all constructed from hollow cylindrical tubing.

16. The system of claim 15, further comprising electrical wiring passing through at least portions of the hollow cylindrical tubing and configured to electrically interconnect the photovoltaic module to an adjacent photovoltaic module.

17. The system of claim 12, further comprising a u-shaped cross member having distal ends configured to be respectively joined to the transverse module support portions of each support runner, and a central portion configured to be oriented to lie in the rooftop contacting plane.

18. The system of claim 17, wherein each distal end of the u-shaped cross member is configured to be attached to a rooftop-facing portion of one of the module clamp assemblies.

19. The system of claim 17, further comprising a ballast pan configured to overlay the central portion of the u-shaped cross member and to receive one or more ballast stones.