Abstract:
In various representative aspects, an assembly for supporting and penetrating metallic solar panel frames to provide a grounding path between the panels, holding ballast of various masses to stabilize the solar panels, and allowing the solar panels to tilt to an adjustable angle is disclosed herein. The assembly has a support member with a pair of vertical components, a ballast holder and a mounting member with at least a raised portion to penetrate a surface of a solar panel and form a grounding path between the assembly and the solar panel. The mass of ballast is adjustable by placing various number of ballast blocks in the ballast holder to stabilize the attached solar panel. The mounting member is pivotally coupled to at least one of the vertical components of the support member so that the angle between the solar panel and the assembly may be adjusted.

Description:
BACKGROUND OF INVENTION 
       [0001]    The present invention relates generally to providing an apparatus that can support and penetrate metallic solar panel frames, providing a grounding path between the panels, holding ballast of various masses to stabilize the solar panels, and allowing the solar panels to tilt to an adjustable angle. 
         [0002]    Solar panels generate electricity from sunrays. Like any electrical power systems, the panels should be grounded. Traditionally, a solar panel has a grounding wire that connects the panel to a grounding device. The more panels in a solar panel array, the more problematic sorting grounding wires becomes. It is preferable that the solar panel mounts provide sufficient grounding between the panels so that some panels may not need grounding wires. 
         [0003]    Solar panels are generally mounted to a support surface at an angle between the panels and the support surface in order to receive more sunlight. The angle between the solar panels and the support surface is preferably adjustable so that the solar panels may be mounted on an uneven support surface with a slope. It is also desirable if the mass of ballast can be adjusted according to the wind lift or any environmental factors that affect the stability of the solar panel array. Moreover, it is desirable that the solar panel mounting apparatuses are easy to manufacture and install to save time and cost. 
         [0004]    Existing solutions are complicated to manufacture or install and are not satisfactory in providing all desired features. For example, US patent publication number US 2009/00242014 A1 (Leary), discloses an apparatus for supporting and ballasting solar panels. The apparatus has a ballast member, a mounting module, and an attachment module to attach to the solar panel(s). The ballast is part of the apparatus, and the weight of the apparatus cannot be adjusted according to the condition of the support surface, e.g. the slope of the rooftop. Although the apparatus may provide a grounding connection between solar panels if the panels&#39; grounding wires are attached to the mounting module, grounding wires are still necessary. 
         [0005]    The PV module assembly taught by US patent publication number US 2009/00320904 A1 (Botkin et al.) has a removable ballast tray adapted to adjust the weight of the ballast. But, the angle between the ballast tray and the solar panel frame is not adjustable. The ballast tray is located under the solar panel, which leaves limited room to place ballast blocks. Moreover, the assembly itself comprises a frame of solar modules and is not merely a solar panel mounting apparatus. It is not designed to be compatible with existing solar panels, and nothing is taught about grounding paths between solar panels. 
         [0006]    US patent publication number US 2008/00230047 (Shugar et al.) teaches a ballasting system that may be used to adjust the angle between a solar panel and the support surface. This system is complicated as it comprises different types of ballast to retain a solar panel and the weights of the ballast are not adjustable at the time of installation. No improvement to the grounding feature is mentioned in this publication. 
         [0007]    In sum, although a solar panel mounting apparatus that comprises ballasting and electrical grounding features that is easy to use and manufacture is desired, such need is not yet satisfied. 
       SUMMARY OF THE INVENTION 
       [0008]    The invention is summarized below only for purposes of introducing embodiments of the invention. The ultimate scope of the invention is to be limited only to the claims that follow the specification. 
         [0009]    It is an object of this invention to provide a solar panel mounting apparatus that is easy to install and manufacture. 
         [0010]    It is a further object of this invention to provide a solar panel mounting apparatus for supporting and stabilizing a solar panel. 
         [0011]    It is also an object of this invention to provide a solar panel mounting apparatus where the angle between the solar panel and its support surface, such as a ground or rooftop, is adjustable. By making the angle adjustable, the solar panel and the apparatus can be mounted on an uneven surface. 
         [0012]    An embodiment of this invention is an assembly comprising at least one support member with a pair of vertical components, a ballast holder, and at least one mounting member. The mounting member is used to couple a solar panel to at least one of the vertical components of the support member. A fastening member, such as a clamp, may be used with the mounting member to secure the solar panel. The mounting member may have one or more raised portions for penetrating the surface of the solar panel. The raised portion may be a tooth or other similar structure as long as it has a sharp ridge, or any kind of configuration that is suitable for penetrating metallic surfaces. An example of a mounting member may be a base with a grounding clip, such as a WEEB-UMC washer. When multiple solar panels are attached to the assembly, the assembly may provide a grounding path between the solar panels. A grounding member, such as a WEEB grounding lug, may be attached to the assembly so that the grounding path from the solar panel to the assembly is further connected to the support surface. 
         [0013]    The mounting member pivots about an axis relative to the vertical component of the support member that the mounting member is coupled to, in order to better conform to the solar panel and to allow the panel to slant to a preferred angle. For an embodiment coupled to multiple solar panels, each mounting member may independently tilt to a different direction in order to accommodate fluctuations of the support surface or the solar panels. 
         [0014]    Various numbers of ballast blocks may be placed in the ballast holder so that the ballasting weight is adjustable. Securing the ballast blocks to the ballast holder may be desired in high wind environments or where seismic conditions may exist. The ballast blocks may be secured using a cover, wire tie, strap, or any other suitable securing mechanism. The ballast holder may also have integrated ballast block retention features to secure the ballast blocks in place. 
         [0015]    Wind deflectors may be used to reduce wind lift and provide stability. The wind deflectors may be attached together to form a beam for assemblies on the same row of a solar array. As such, wind lift is distributed among the assemblies, thus providing more stability and further reducing the number of ballast blocks required. For a better seismic lateral stability, a seismic anchor may be secured to the assembly and the support surface. If the support surface is a rooftop, the seismic anchor may be secured directly to the building structure through roofing material or decking. 
         [0016]    For example, two exemplary assemblies may be used to support a solar panel on a rooftop. Preferably, each assembly may have a pair of support members with a pair of vertical components (although a single support member could be sufficient depending on its shape), a ballast holder, mounting members, and clamps that act as fastening members. Solar panels are generally slanted toward the south to receive more sunlight in the northern hemisphere. One assembly is used to clamp the solar panel on the north side and the other clamps the panel on the south side. The angle between the solar panel and the rooftop can be adjusted by pivoting the mounting members. If each of the support members has two vertical components with different heights, the two mounting members and clamps can be placed on the same vertical component. The mounting members and clamps of the assembly supporting the northern side of the panel are located at the top of each of the longer vertical components of the support members. On the other hand, the mounting members and clamps of the assembly supporting the southern side of the solar panel are located at the top of the shorter vertical component of the support members, which enable the solar panel to slant more towards the south. 
         [0017]    This formation is just one of the ways to use this invention. A person with ordinary skill in the relevant art would know that various formations can be adopted to make use of this invention. Also, any shape or size of the components in this invention, e.g. the support members, the ballast holder, or the mounting member, may be adopted as long as the apparatus can attach to one or more solar panels and provide a grounding path. Any combinations of suitable number, shape, and size of raised portions of a mounting member or the fastening member may be used. The weight that a ballast holder can support depends on the implementation. Also, any materials suitable to achieve the object of the current invention may be chosen, such as stainless steel or metallic materials. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the following illustrative figures. In the following figures, like reference numbers refer to similar elements and steps throughout the figures. 
           [0019]      FIG. 1  illustrates a pair of support members placed on pads and a ballast holder transversely coupled to the support members. 
           [0020]      FIG. 2  illustrates a mounting member and a fastening member of an embodiment. 
           [0021]      FIG. 3  illustrates a grounding clip used in  FIG. 2  as a part of the mounting member. 
           [0022]      FIG. 4  illustrates a side view of an alternative embodiment of the fastening member in  FIG. 2 . 
           [0023]      FIG. 5  illustrates an embodiment coupled to a seismic anchor. 
           [0024]      FIG. 6  illustrates a portion of the embodiment in  FIG. 2  coupled to a solar panel frame. 
           [0025]      FIG. 7  illustrates a method of electrically bonding a mounting member and a support member. 
           [0026]      FIGS. 8   a  &amp;  8   b  illustrate a method of distributing wind lift between or among multiple assemblies. 
           [0027]      FIG. 9  illustrates multiple assemblies of an embodiment used with solar panel arrays. 
       
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
       [0028]    In the following description, and for the purposes of explanation, specific details are provided to thoroughly understand the various aspects of the invention. It will be understood, however, by those skilled in the relevant arts, that the present invention may be practiced without these details. In other instances, known structures and devices are shown or discussed more generally in order to avoid obscuring the invention. In many cases, a description of the operation is sufficient to enable one to implement the various forms of the invention, particularly when the operation is to be implemented in software. It should be noted that there are many different and alternative configurations, devices and technologies to which the disclosed embodiments may be applied. The full scope of the inventions is not limited to the examples that are described below. 
         [0029]      FIG. 1  illustrates an embodiment of the support member  210  with pads  500  and the ballast holder  220 . In this embodiment, the U-Shaped bars  210   a  &amp;  210   b  together constitute the support member  210  which comprises two vertical components and one of the vertical components is longer than the other. The U-Shaped bars  210   a  &amp;  210   b  each have vertical arms of different heights. The longer arms of the U-shaped bars  210   a  &amp;  210   b  are located at a rear side, forming the longer vertical component of the support member  210 . The shorter arms of the U-Shaped bars  210   a  &amp;  210   b  at the front form the shorter vertical component of the support member  210 . 
         [0030]    The ballast holder  220  includes two angle bars,  220   a  &amp;  220   b . The angle bars  220   a  &amp;  220   b  of the ballast holder  220  have vertical portions  221   a  &amp;  221   b  and horizontal portions  222   a  &amp;  222   b . The vertical portions  221   a  &amp;  221   b  of the angle bars  220   a  &amp;  220   b  may prevent the ballast blocks from moving toward the front or rear sides while the horizontal portions  222   a  &amp;  222   b  support the ballast blocks. 
         [0031]    The vertical portions  221   a  &amp;  221   b  of the angle bars  220   a  &amp;  220   b  in this embodiment may include tabs  223   a ,  223   b ,  224   a  &amp;  224   b  to prevent the ballast blocks from moving laterally. The tabs  223   a ,  223   b ,  224   a  &amp;  224   b  are located on both sides and protrude in the direction where the ballast blocks are placed so when they are placed within the area surrounded by the tabs  223   a ,  223   b ,  224   a  &amp;  224   b , they can be retained when an external force, resulting for example from an earthquake, is applied. The tabs  223   a ,  223   b ,  224   a  &amp;  224   b  may also be located on the horizontal portions  222   a  &amp;  222   b  and protrude upward or anywhere in the ballast holder suitable for retaining ballast blocks. 
         [0032]    Pads  500  may protect the support surface from possible damage over time. They may also help distribute loading on the support surface. Pads  500  may be rubber or any suitable material. Pads  500  may be configured to surround a portion of the support member  210 . The pads  500  of this embodiment conform to the shape of the bottom of the U-Shaped bars  210   a  &amp;  210   b . As such, they can be secured onto the bottom of the U-Shaped bars  210   a  &amp;  210   b  before being installed with the solar modules, thus saving time for installation. 
         [0033]      FIG. 2  depicts the relative positions of an exemplary mounting member  300  and a clamp  400  before they are assembled. The mounting member  300  comprises a grounding clip  310 , a base  320 , and a bolt  330 . The grounding clip  310  has multiple raised portions  311  and spring retention tabs  312 . The spring retention tabs  312  are disposed through the holes  322  to engage the grounding clip  310  to the base  320 . 
         [0034]    The mounting member  300  is attached to at least one of the vertical components of the support member  210  with the bolt  330 . The bolt  330  forms an axis for the mounting member  300  to pivot, relative to the support member  210 , in order to better conform to the solar panel and to allow the solar panel to slant to a preferred angle. Each mounting member  300  in an embodiment may independently tilt to a different direction. 
         [0035]    A clamp  400 , which acts as a fastening member of the embodiment, has a fastener  410  and an elongated washer  420 . The washer  420  has several tabs. One of the tabs  421  may be bent to engage the base  320  through a void  321  for stabilizing the to-be-attached solar panel frame  011  as shown in  FIG. 5 . An alternate embodiment of the washer  420  may also have raised portions to penetrate the surface of the solar panels in order to have a better grip and provide better grounding capability. 
         [0036]      FIG. 3  shows a closer view of the grounding clip  310  in  FIG. 2 . The grounding clip  310  has raised portions  311  and spring retention tabs  312 . The raised portions  311  have sharp edges that may penetrate the coating of solar panels to provide better electrical bonding capabilities. 
         [0037]      FIG. 4  illustrates the side view of a clamp  400 ′, an alternative embodiment of the clamp  400  in  FIG. 2 , without side tabs on the washer  420 ′. After this embodiment is installed, a solar panel frame will rest against the fastener  410 ′ and be secured between the top of the washer  420 ′ and the mounting member  300 . It is more difficult to accomplish this task without lifting the washer  420 ′ upward and putting the solar panel between the washer  420 ′ and the mounting member  300 . To save this trouble, the clamp  400 ′ may further comprise a packing  430 ′ such as an O-ring that engages the fastener  410 ′ in order to hold the washer  420 ′ in place. The fastener  410 ′ is first loosely fastened to the mounting member  300 , and the packing  430 ′ supports the washer  420 ′ at the top of the shaft of the fastener  410 ′, thus leaving extra room for installing the solar panel frame before fastening the clamp  400 ′ to firmly secure the solar panel. The packing  430 ′ can be made of rubber, plastic or any material suitable for holding the washer  420 ′ in place before clamping the solar panel. 
         [0038]      FIG. 5  illustrates an exemplary assembly  100  having two fastening members  400 , two mounting members  300 , support member  210 , and a ballast holder  220 . The assembly  100  is placed on pads  500  and coupled with a seismic anchor  600 . A seismic anchor  600  may provide lateral stability to the assembly  100  when the anchor  600  is secured directly to a support surface, such as a ground or a building structure. 
         [0039]      FIG. 6  shows the embodiment in  FIG. 2  with a clamp  400 , a mounting member  300 , and a vertical component of the support member  210  coupled to a solar panel frame  011 . The frame  011  is fastened by the clamp  400  and the mounting member  300 . The raised portions  311  as shown in  FIG. 2  of the mounting member  300  penetrate the contacting surface of the frame  011 , thus forming a grounding path from the panel frame  011 , through the mounting member  300 , and finally to the support member  210 . If a grounding member is used, the solar panel is electrically bonded to a support surface such as a ground or a roof of a building. 
         [0040]      FIG. 7  illustrates how a mounting member  300  and a support member  210  can be electrically bonded together without a grounding strap. A bolt  330  and a nut  350  are used to couple the base  320  of the mounting member  300  to at least one of the vertical components of the support member  210  in this embodiment. A sufficient force is applied to secure the bolt  330  and the nut  350  to compress the base  320  and the vertical component of the support member  210  together so that they become electrically bonded. Another nut with internal threads  340 , such as a PEM® nut, may also be used if there are at least two contact areas between the base  320  and the support member  210  to reinforce the force to compress the base  320  and the support member  210  together. Any person skilled in the relevant art would likely know that electrical bonding can be achieved with a sufficient force to increase the contact area between the base  320  and the support member  210  no matter how they are coupled together. 
         [0041]      FIGS. 8   a  &amp;  8   b  illustrate a method of distributing uplift forces among multiple assemblies  100   a ,  100   b , &amp;  100   c , and thus providing more stability to the solar array. In  FIG. 8   a , a first wind deflector  030   a  is attached to the assemblies  100   a  &amp;  100   b . In  FIG. 8   b , a second wind deflector  030   b  is attached to assemblies  100   b  &amp;  100   c  and slightly overlaps with the first wind deflector  030   a . As shown in  FIG. 8   a , the right end of the wind deflector  030   a  aligns with the right end of the solar panel  010   a  for illustration purposes. Comparing  FIG. 8   a  and  FIG. 8   b , the overlapped portion  031  starts from the left end of the second wind deflector  030   b  to the right end of the solar panel  010   a . The overlapping wind deflectors  030   a  &amp;  030   b  form a “beam” and distribute uplift forces among the assemblies  100   a ,  100   b , &amp;  100   c . Therefore, less ballast blocks are needed. A person skilled in the relevant art would likely know that the length of the wind deflector and the distance between the assemblies may vary, thus the number of wind deflectors needed and the size of the area overlapped to achieve the same feature may be different. 
         [0042]      FIG. 9  shows how multiple assemblies  100  of an exemplary embodiment are coupled to three rows of solar panels  010 . The assemblies  100  are aligned between adjacent rows of the solar panels  010 . The assemblies  100  support the solar panels  010  and allow them to slant, by having different heights on different sides of the assemblies  100 . As shown in the figure, an assembly  100  may connect to one or more panels. Some assemblies  100  are coupled to panels  010  on the same row. Some assemblies  100  are coupled to panels  010  on different rows while others connect panels  010  both on the same row and on adjacent rows. Therefore, the assemblies  100  provide grounding paths among the solar panels  010  not only on the same row but also on adjacent rows. In addition, various numbers of ballast blocks  020  are placed in the ballast holders  220  of the assemblies  100  to secure the solar panels  010  in place. Some of the assemblies  100  have wind deflectors  030  on one side to reduce wind lift.