System and method for mounting PV panels in bracket and/or rail mount design

A modular mounting system for securing a photovoltaic (PV) panel to support structure and a solar array. The mounting system and method configured for flat and pitched surfaces with a minimum of components parts reducing manufacturing and installation costs. The mounting system and method in a rack mount embodiment comprises a base assembly and an elevation assembly each connecting a PV panel via a top plate and mid-clamp assembly. The mounting systems in a rail mount embodiment, the mid-clamp assembly and an end assembly are utilized to ground and secure the PV panel to the rail mount and support structure. The modular mounting system provides a ballast pan, connecting belts for connecting each base bracket to the ballast pan and each other adding rigidity to the system. The modular mounting system provides a reduction in the seismic plates utilized prevent lateral displacement from seismic activity and other environmental factors.

FIELD OF THE INVENTION

The present invention relates to securing a solar and/or photovoltaic (PV) panel(s) to the earth, roof or other building structure and, more particularly, to modular mounting system with improved clamp and grounding of bracket and rail mounts adjustable in angle and height so as reduce manufacturing and installation costs.

BACKGROUND OF THE INVENTION

Roof-mounted solar power systems consist of solar modules secured to frames and the utilizing roof-based mounting systems. Conventional mounting systems typically use a mounting system with numerous parts that increases the cost of manufacture and installation. Mounting systems with numerous parts require assembly resulting in greater manufacturing costs and, if configurable later, numerous parts to assemble in the field. Moreover, typical bracket and rail mount applications may not use all of the features of such complex mounting systems, for example, when mounting a singular panel, or to arrange numerous solar panels in an array, to earth, roof or other building structure. As a result, conventional mounting systems may be overbuilt for the purpose of securing photovoltaic (PV) panel(s) to the earth, roof or other building structure or, alternatively, and extended rows of a solar array.

Examples of bracket mounts in the prior art include supports formed by cutting solid lengths of metal or other supports to order, i.e. the appropriate length. Customized cutting to order of the supports fixed lengths increases the manufacturing cost, results in waste material, results and business losses should an order be canceled having no resale value, and such made to order lengths may not allow configuration during installation in the field. Certain rail mounts in the prior art have multiple parts and pieces also increase the unit manufacturing cost as well as the labor cost to assemble in the field. As a result, there is a long-felt need for a mounting system for both bracket and rail mounts of PV panels and/or solar arrays having interchangeable parts that reduce manufacturing and on-site installation costs.

Installations of PV panels and/or solar array have the PV panels oriented, based on latitude and longitude, for an optimum angle to receive direct solar energy and optimal exposure to the sun, for drainage, and other considerations. Conventional mounting systems with numerous parts allow a user to make angle adjustments through many degrees, for example, adjustments using fasteners securing the panel to the bracket or rail mounts. In certain conventional fixed-length bracket mounts and angle adjustment may be made to a bracket by bending an extended flange or by affixing (e.g. welding) an attachment plate at the desired angle to orient the installed PV panel. Accordingly, such prior art bracket mount systems have has disadvantages as such fixed length brackets may not allow configuration in the field or at the installation as well as bending and/or welding steps tend to increase the manufacturing cost. Attachment plates configured as adjustable also have disadvantages because these require a complex construction and increased the number of individual parts resulting in increased manufacturing cost and labor costs to install. Consequently, there is a long-felt need for an angle plate for PV panels that reduces manufacturing and labor costs.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a modular mounting system and method for securing a solar array and/or photovoltaic (PV) panel(s) to the earth, roof or other building structure.

It is another object of the present invention to provide a modular mounting system and method for securing a solar array and/or photovoltaic (PV) panel(s) with improved grounding clamp useful for both bracket and rail mounts with lower manufacturing and installation costs.

It is yet another object of the present invention to provide a modular mounting system and method of using grounding fasteners to provide a fully grounded system for the electrical connection between electrically charged PV panels and/or multiple PV panels in a solar array.

It is an object of the present invention to provide an apparatus, system and method of utilizing mid- and an end clamp assemblies for PV panels that reduces manufacturing cost, unit cost, and the time of labor to assemble and install on-site.

DESCRIPTION OF THE EMBODIMENTS

Non-limiting embodiments of the present invention will be described below with reference to the accompanying drawings, wherein like reference numerals represent like elements throughout. While the invention has been described in detail with respect to the preferred embodiments thereof, it will be appreciated that upon reading and understanding of the foregoing, certain variations to the preferred embodiments will become apparent, which variations are nonetheless within the spirit and scope of the invention.

Reference throughout this document to “some embodiments”, “one embodiment”, “certain embodiments”, and “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

The drawings featured in the figures are provided for the purposes of illustrating some embodiments of the present invention, and are not to be considered as limitation thereto. Term “means” preceding a present participle of an operation indicates a desired function for which there is one or more embodiments, i.e., one or more methods, devices, or apparatuses for achieving the desired function and that one skilled in the art could select from these or their equivalent in view of the disclosure herein and use of the term “means” is not intended to be limiting.

As used herein the term “Photovoltaic” or “PV” refers or “Solar panel” refers to a photovoltaic module, a solar thermal energy panel, or to a set of solar photovoltaic (PV) modules electrically connected and mounted on a supporting structure. A solar “photovoltaic module” is composed of individual PV solar cells electrically connected, mounted on a supporting structure and arranged in an aluminum frame having glass on the front. A “solar array” is typically composed of a solar panel with24solar modules.

As used herein the term “bracket” refers to a structural member for holding and/or attaching (something) by means of a support, for example, perpendicular, right-angled, or other support arrangement.

As used herein the term “flange” refers to an edge that sticks out from something (e.g. a bracket) and is used for strength, for guiding, or for attachment to another object (e.g. a roof or PV panel).

As used herein the term “splice bar” refers to a metal bar that is bolted to the ends of two rails to join them together in a track.

As used herein the term “track” refers to a surface mount with a recess or channel for receiving a fastener (e.g. a mid-clamp and/or mid-clamp was channel nut) so as to mount a PV module(s) thereto.

As used herein the term “Grounding mid-clamp” refers to a fastener that is utilized to secure two or more PV panels in an array to the channel of a support or track with an action of clamping down on the panels and creating an effective metal to metal connection so as to electrically ground the assembly.

PV panels may be arranged in elongated arrays oriented for optimal exposure to the sun such as, for example, in square or rectangular rows. The installation of the PV panels for exposure to the sun requires adjustments to the height of the bottom and top edges of the PV panel from the support surface that eliminates shadowing between rows and creates the appropriate angle the PV Panel for. For example, the height of the bottom edge is lower than the top edge of an installed PV panel, whereby the flat rectangular panel is positioned at a desired optimal angle to the sun (i.e., for a particular longitude and latitude of the installation). Brackets may be utilized to support bottom edge at a lower height above the roof than the top edge (e.g. utilizing a bracket of a shorter length to support the bottom edge than the length of the top edge). The height adjustment also is important to configure subsequent parallel rows of PV panels in the predetermined arrangement pattern such that the “ahead of” arranged row do not shade the behind row of PV panels.

Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like “central,” “upper,” “lower,” “front,” “rear,” and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as “first” and “second” are used herein for purposes of description and are not intended to indicate or imply relative importance or significance.

As is illustrated inFIGS. 1 through 34B, a mounting system and method100is shown in accordance with an embodiment of the present invention in a roof mounted array of PV panels101as shown inFIGS. 9C and 9D. The mounting system and method100may constructed with an improved bracket assembly with advantages in the manufacture thereof as well as simplifying installation of a solar array in the field. The mounting system and method100of the present invention is described in connection with a flat surface installation, for example, on a roof as is shown inFIGS. 9C and 9E. Additionally, mounting system and method100of the present invention is described in a pitched surface such as the bracket and rail assembly on the roof of a structure as is shown inFIGS. 9B, 9D and 9F. It should be appreciated that the mid-clamp assembly is utilized in both bracket and rail mounting systems hereof. Moreover, the mounting system and method100of the present invention is useful in other installations and surfaces such as, for example, suspended structures and earth anchored installations. As a result, the one or more embodiments illustrating the elements and structures of the present invention should be not be limited to a particular installation as the present invention is adaptable to most known PV panel and solar array designs.

Referring toFIGS. 1A and 1B, the mounting system100can be formed modular as rack mount base assembly110with a base bracket111, operably connected to a top plate120for supporting a front edge or portion of the PV panel101. The top plate120further operably couples to an elevation assembly130for supporting the rear edge or portion of the PV panel101. The elevation assembly130comprises an interleave bracket140operably coupled at openings146,147in side portions141with openings135of a base bracket131, or alternatively, at openings113of the base bracket110. A grounding mid-clamp assembly150is configured to secure the frame of the PV panel101to raised portion122of the top plate120as illustrated inFIGS. 7A and 7B. In this embodiment, the grounding mid-clamp assembly150comprises bolt151, washer152, tabbed-spacer153operably connecting to the raised portion of the top plate120to secure PV panels101. In a rail mount design, the bolt151, washer152and tabbed-spacer153operably connect to a channel nut160and secure between side portions of the PV panels101. In a rail mount design, a panel support assembly170(when the PV Panel is provided without a frame), and end plate180used on the edge of the solar array as shown inFIGS. 1A and 9C. The PV panel101generally is secured in the panel support assembly170and positioned in the appropriate predetermined orientation104of angle105for a particular location (i.e. latitude and longitude). The PV panel101also is secured in the panel support assembly170and positioned in the appropriate predetermined height106orientation104also forming the appropriate angle for a particular location.FIGS. 1A and 1Billustrate the method and mounting system100in an expanded view configured to secure the PV panel101to various roof constructions as shown inFIGS. 9C and 9D.

Referring toFIGS. 1A and 1B, the mounting system100is configured to use the existing panel frame171of the PV panel101, or alternatively to use a panel frame171for custom shaped PV panels. The panel frame171is configured to hold the PV module, glass and the support circuitry in a plane so as to absorb solar energy. An important feature of the design of the mounting system100according to the present invention is the grounding of the panel frame171by way of the grounding mid-clamp assembly150. In a racking system, the grounding mid-clamp assembly150also may secure and ground the panel frame171to the end plate180. It is also important that the panel frame171remains secured during strong winds, seismic events and other environmental conditions (e.g. under loads (heavy snow) without breakage or bending). The mounting system100is configured to utilize advantageously the mid-clamp assembly150for improved securing of the PV panel101to the elements of the base bracket110, top plate120, elevation assembly130top plate120, and interleave bracket140to the structure (e.g. flat or pitched roof) or surface (e.g. earth).

Also as shown inFIGS. 1A and 1B, the mounting system100can be configured with a ballast pan or tray172for ballast179(FIG. 13) for preventing movement of the panel frame171during strong winds, seismic events and other environmental conditions. For example, the ballast pan172may be formed to hold elements of a ballast system, for example, ballast179in the form of cement blocks of appropriate size and weight for prevention of movement (e.g. due to wind forces) as shown inFIG. 13. The ballast pan172reduces and/or prevents direct contact between roofing and cement ballast179that may potentially damage the integrity of the roof as well as maintaining a roof manufacturer's warranty. Accordingly, the mounting system100integral ballast pan172solves problems affecting solar panel installations from during strong winds, seismic events and other environmental factors as well as allowing deflection of the pan under heavy snow loads without breakage or bending.

As shown inFIGS. 13 through 15, the mounting system100can be configured with a connect belt185structural component functioning to connect each bracket mount to each other and add rigidity and grounding fully the system. The connect belt185is utilized for connecting rows of PV panels101in a solar array to ground, providing structural connection for environmental factors, and to efficiently create solar arrays giving the array a predetermined orientation so as to eliminate shadows for height given a predetermined length. As shown inFIGS. 14 and 15, the connect belt185may be formed in and elongated panel shape. connection belt formed The connect belt185can be configured to attach to adjacent ballast trays172and to a seismic plate186utilizing a plurality of holes187formed at a midpoint and ends in the elongated panel shape thereof. The ballast tray172and the connect belt185may be secured together by fasteners119to retain rigidity and grounding fully the system for flat roof and/or structure installations.

Similarly, the seismic plate186prevents lateral displacement from seismic activity and may be secured to the connect belt185via fastener119. The seismic plate186may be configured to attach to a stud or other structural element of a roof utilizing fasteners188and lock washers189. As the connection belt185secures to the base assembly110of one row in a solar array and the elevation assembly130in an adjacent row of the solar array, only one seismic plate186will be required reducing the number seismic plates by fifty-percent 50% which is an improvement over the art as typically seismic plates are located at the support, for example, located underneath the base assembly110. Consequently, the connect belt185of the mounting system and method100advantageously provides a secure connection to the structure to withstand environmental conditions, provides grounding of the overall bracket and/or rail mount design of the mounting system100, and the predetermined spacing between rows in a solar panel array, which is an improvement over conventional systems.

Referring toFIGS. 1A and 1B, the mounting system100can be formed with an equipment mount175. The equipment mount175connects necessary solar panel equipment to the mounting systems100so as to continue building the predetermined arrangement102of one or more PV panels101in the system100. For example, according toFIGS. 1A and 1B, an inverter181and any wiring182may be required for each solar panel and may be located at any bracket (e.g. on a rear bracket under the 10 degree tilt or orientation). Conventional systems may not provide equipment mounts for PV panel inverters, micro-inverters, optimizers, wire management, combiner boxes, and other electrical equipment181. In such installations, problems occur as the inverter and other types of electrical equipment may become dislodged and/or disconnected from the PV panel101during strong winds, seismic events and other environmental conditions. Consequently, the design of the mounting system100according to an embodiment of the present invention provides an equipment mount175to secure and support advantageously inverters and other electronic equipment that overcomes the disadvantages of conventional systems.

Referring toFIGS. 2A-2B through 5A-5B, the mounting system100supporting members advantageously can be formed from three (3) main elements according to an embodiment of the present invention. According to an embodiment of the present invention, a front edge of the PV panel101may be supported by two elements: a base bracket110and a top plate120as is shown inFIGS. 1A, 1B, 2A, 2B, and3. Similarly, a rear edge of the PV panel101may be supported by the elevation assembly130consisting essentially of three elements: a base bracket110, a top plate120, and the interleave bracket140as is shown inFIGS. 1A through 5B, including alternative embodiments. Finally, an end plate180may be used for grounding the terminating edges of the panel frame171of a particular PV panel101at each end of a row in a solar array, or alternatively for a single frame171of a PV panel101supported by the mounting system100.

Referring toFIGS. 30-33, the end plate180can be configured for grounding, for example, as an elongated bar with bent angles having spikes125, hole183and slot184at each end, respectively. The spikes125are utilized for grounding the frame171. The hole183and the slot184may be secured to a top plate120using a fastener151and washer152, coupled to the threaded hole123of a top plate120. The hole183is positioned adjacent the spike125such that tightening the fastener bold151exerts sufficient force to drive the spike125into the frame171as shown in more detailFIG. 31B. Similarly, the slot184allows for finer adjustments relative to the frame171. The slot184is positioned adjacent the spike125such that tightening the fastener bold151exerts sufficient force to drive the spike125into the frame171as shown in more detailFIGS. 31A and 33. In this manner, the end plate180may be positioned and secured to the frame171in a bracket mount design to provide grounding as is shown inFIG. 33. Alternatively, the grounding end plate180may be to positioned and secured to the frame171in a rail mount design using the mid-clamp assembly150coordinating with the channel nut assembly160in a track230of a rail mount200configuration to provide grounding as is shown inFIGS. 21 and 33.

Conventional mounting systems designs may involve supports formed from numerous individual parts and/or solid lengths customized by cutting to the appropriate length for the height and angle orientation of the PV panel for the installation that have disadvantages because such fixed length brackets increase the manufacturing cost and may not allow modification during installation in the field. Furthermore, conventional elevation brackets having multiple parts and pieces increase the unit cost of manufacture as well as the labor cost to assemble in the field. In such installations, problems occur as the inverter inverters and other electrical equipment can be dislodged and/or disconnected from the PV panel101during strong winds, seismic events and other environmental conditions.

According to an embodiment of the present invention, the base and elevation assemblies110,130of the mounting system100may be formed, assembled and thus manufactured at low-cost. For example, the forward base assembly110for PV panel101may be manufactured by securing the top plate120to the base bracket111such as, for example, aligning holes126and113and operably coupling together using fasteners119or other securing means e.g. rivets, pop rivets, nuts and bolts. Similarly, the elevation bracket134supporting the rear edge of the PV panel101and/or solar array may be manufactured by securing the top plate120to the elevation assembly130comprising the base bracket131operably coupled to the interleave bracket140. The top plate120may be secured to the elevation assembly130by aligning holes126and145formed in flanges124formed from a bend disposed away from an upper surface the raised spacer122so as to form the downwardly extending flanges124, shown inFIGS. 2A and 2B. Thus, aligning the openings126of the top plate120with the corresponding holes or openings145in the elevation assembly130, as shown inFIG. 4, or with the holes or openings113of the base bracket111as shown inFIGS. 3A and 3B, or with the holes or opening135in the embodiment of the base bracket ofFIGS. 5A and 5B, that provides the flanges124operably coupling to the interleave bracket140to join together using fasteners119or other securing means e.g. rivets, pop-rivets, nuts and bolts. Similarly, The base bracket131may be coupled to the interleave bracket140by aligning holes135and one of holes146,147and operably coupling together using fasteners119or other securing means e.g. rivets, pop rivets, nuts and bolts. Consideration is made when selecting a particular hole146or147so as to establish a desired height of the top plate120to support the rear edge the PV panel101, thereby creating the predetermined orientation of the PV panel101to the solar energy. Consequently, the mounting system100satisfies a long-felt need for an integral bracket design for supporting PV panels101that has advantages of reducing costs of manufacturing and installation in the field to overcome these disadvantages found in conventional systems.

Similarly, the mounting system100provides an effective, low-cost cost electrically-grounded solution for terminating each free end of a solar panel array as shown inFIGS. 9C and 9D. The end plate180(shown in detail inFIGS. 1A-1B and 6A-6D) may be secured to the PV panel101using the fastener119and top bracket120hereof to provide grounding thereof. As is shown inFIG. 9C, a bracket mount for elongated solar arrays the end plates180are secured by bolt151, washer152, tabbed-spacer153of the mid-clamp assembly150as these are fastened directly to the top piece120of the base assembly110and the elevation assembly130which are supporting the front and rear edges of the PV panel101, respectively. It should be appreciated that bracket systems typically are arranged on earth and/or relatively flat surfaces such as a roof as is shown inFIG. 9C. Referring toFIG. 9Daccording to another embodiment of the present invention, a bracket system uses the end plates180secured to the track by the assembly150consisting essentially of the bolt151, washer152, tabbed-spacer153, and channel nut160as shown inFIGS. 7A-7B, 9B, 9C and 9F. It is to be appreciated that the bracket system configuration of the present invention is used on pitched roofs, walls and/or surfaces as is shown inFIG. 9D.

Referring again toFIGS. 7A-7B, the mid-clamp assembly150when disposed between PV panels101advantageously couples the mounting system100fully to ground as shown inFIGS. 9C-9D, which is an improvement over conventional systems. The mid-clamp assembly150is adaptable between both bracket and rail mount designs. In a bracket mount design, the mid-clamp assembly150bolts directly to the top plate120without use of the channel nut assembly160. In bracket mount design, mounting system100grounds by the serrated teeth of the tabbed-spacer153forming a ground-based connection with the PV panel101as these are fastened securing the panel to the base and elevation assemblies110,130. In bracket mount design, the full mid-clamp assembly150is used as the teeth165of the channel nut160directly engage the track forming a ground-based connection with the PV panel as these are fastened securing the panel to the end plate180, for example, as is shown inFIGS. 7A-7B, 8A-8D. Accordingly, in operation two mid-clamp assemblies150are used to secure the end plate180to a PV panel101or multiple PV panels101in the solar array as is shown inFIGS. 9C and 9D. It should also be appreciated that, according to an embodiment of the present invention, or more a grounding mid-clamp assembly150may be used between PV the panels101in a solar array. For example, in a bracket mount system, two mid-clamp assemblies150are used to secure to top plates120supporting the front and rear edges of the PV panel101. In a bracket system, the mounting system100utilizes the channel nut assembly160having sufficient strength and grounding such that one mid-clamp assembly150and channel nut160may be used between PV panels101as shown inFIGS. 9B and 9D. The mounting system and method100advantageously provides full grounding of all PV panels101in the solar array with sufficient hold to withstand environmental factors and conditions.

As is illustrated inFIG. 9C, while only one grounding mid-clamp assembly150may be used between PV panels101at mid-points and along an array, two grounding mid-clamp assemblies150are needed at the end of the array as these secure the end plates180formed elongated that can be arranged on and along the entire edge of the PV panel101and secured by clamps at the upper and lower edges of the PV panel101. Accordingly, the mounting system100of the present invention utilizes less component parts thereby reducing costs of manufacturing and installation time which is an improvement over conventional systems. According to the embodiments of the present invention, the two-piece and three-piece construction design of the bracket mount of the mounting system100advantageously reduces manufacturing costs such as, for example, machining costs (i.e. bending, drilling of holes, etc.) the number of parts to be manufactured, inventory requirements, assembly costs (i.e. factory labor cost) and other costs.

Referring toFIGS. 1A-1B, 2A-2B and 3, the manufacture of the base assembly110may be formed by operably coupling the top plate120to the base bracket111at an upper edge115, for example, by joining the top plate120to the base bracket111using fasteners119such as one or more rivet(s) or by aligning holes113on bracket111and holes126on plate120for passing there-through a bolt secured in place a nut. The upper edge115of the base bracket111may be formed at a predetermined angle116(e.g. 5, 10, 15 degrees) as shown inFIG. 3A. The angle116of the base bracket111supports the top plate120and the PV panel101at the predetermined angle116(e.g. 5, 10, 15 degrees) of a particular location for optimum exposure to solar energy.

The base assembly110also can be formed with an upper surface having additional material114(shown inFIGS. 3A-3B) to provide structural support for the top plate120and strength under environmental conditions. In an alternative embodiment, the interleave bracket140is provided with additional material148and the base bracket131may be formed without the additional material114,148, while it is appreciated that the base bracket111may be used nonetheless in the situation. The interleave bracket140can be configured with the additional material148to provide additional support for the top plate120and strength under environmental conditions as is shown inFIG. 4. In this alternative embodiment, the base bracket131is used for establishing height and other adjustment factors supporting the rear edge of the PV panel101as is shown inFIGS. 5A-5B.

The base bracket111can be manufactured from sheet metal utilizing punch-press or other techniques in a pattern for the base bracket111with additional material114to provide additional structural support and (2) the angle116formed at the upper edge115. Further manufacturing of the base bracket(s)111,131consists essentially of drilling holes113, forming a conical hole118by counter-punch and bending the metal sheet into side portions112(i.e. front, left, right sides) and a bottom flange117. The one or more holes113may be formed and located at predetermined locations for securing the top plate120to the base bracket111to form the base assembly110as well as securing the top plate120to the interleave to the elevation assembly130. The base bracket111can have holes113located on an upper edge115to secure the top plate120at a predetermined angle116(e.g. 5, 10, 15 degrees). The base bracket111can have holes113located on a flange117for securing to another structure such as, for example, to posts integral to the ballast pan172(see, e.g.FIGS. 1A and 1B) for securing to the roof103through the conical hole118. Accordingly, manufacturing costs, from inventory to assembly, can be reduced by the two element construction of the base assembly110according to an embodiment of the present invention.

Referring toFIGS. 2A-2B, 4 and 5A-5B, the elevation assembly130for supporting a rear edge of the PV panel101(see, e.g.FIGS. 1A and 1B) can be configured from three elements: a base bracket131, a top plate120, and an interleave bracket140. The top plate120is secured to the interleave bracket140at an upper edge143. The predetermined angle144(e.g. 5, 10, 15 degrees) can be formed by passing a bolt through holes145on bracket140and holes126(e.g. configured to set at 5, 10, 15 degrees) on plate120. As above, the base bracket131can be manufactured from bending a single metal sheet into side portions132(i.e. front, left, right sides) and a bottom flange133. The sheet metal pattern may be punch-press-formed for the base bracket131with (1) additional material148to provide additional structural support and (2) the angle144formed at the upper edge142.

Referring toFIGS. 5A and 5B, the base bracket131can have one or more holes135located at an upper edge136. The base bracket131can have holes135, upper edge of side portion132for securing the interleave bracket140. The base bracket131can have holes135located on a flange134for securing to another structure such as, for example, to posts integral to the ballast pan172(see, e.g.FIGS. 1A and 1B) for securing to the roof103through the conical hole. Similar toFIG. 3, the base bracket131can have holes135located on an upper edge136to secure the top plate120at a predetermined angle (e.g. 5, 10, 15 degrees) if the height of base bracket131is suitable. Otherwise, the height may be formed by securing the interleave bracket140to the base bracket131via aligning the holes135located on the upper edge136two the one or more holes146,147on the side flange(s)141and securely fastening and/or operably coupling together these two elements of the assembly.

Similarly, the base bracket131can be manufactured from sheet metal utilizing punch-press or other techniques using a pattern for the base bracket131without the additional material114to provide additional structural support. Further manufacturing of the base bracket131consists essentially of drilling one or more holes135, forming a conical hole134by counter-punch, and bending the metal sheet into side portions132(i.e. front, left, right sides) and a bottom flange133. The one or more holes135may be formed and located at predetermined locations for securing the top plate120to the base bracket131. The one or more holes145,146,147of the interleave bracket140may be formed and located at predetermined locations for securing the top plate120to the interleave bracket140at holes145, and the base bracket131two the interleave bracket140by selecting from the one or more holes146,147and aligning with hole135on the base bracket131, thereby operably coupling and joining the three elements of the top plate120, the interleave bracket140, and the base bracket131so as to form the elevation assembly130. As has been described herein, the base bracket131may be formed with holes135located on an upper edge136to secure the top plate120at a predetermined angle116(e.g. 5, 10, 15 degrees). Similarly, the interleave bracket140may be formed with holes145located on an upper edge143to secure the top plate120at a predetermined angle116(e.g. 5, 10, 15 degrees). The base bracket131for the rear portion can have one or more holes135located on a flange133for securing to another structure such as, for example, to posts integral to the ballast pan172(see, e.g.FIGS. 1A and 1B) for securing to the roof103through the conical hole134. Accordingly, manufacturing costs, from inventory to assembly, can be reduced by the two element construction of the base bracket131according to an embodiment of the present invention.

Referring toFIG. 4, the interleave bracket140may be formed with one or more holes145,146,147at predetermined locations located side portions141(i.e. left, right sides). The upper hole145is configured to secure a top plate120thereto. The one or more holes146,147(i.e. left, right sides) are adapted to create the appropriate height for the rear edge of PV panel101. The base bracket131may be operably coupled to the interleave bracket140by aligning the hole135on base bracket131to a selected hole146,147establishes a predetermined length of the elevation assembly130. In order to adjust the length, interleave bracket140slides into the base bracket131and hole135would align first with hole147and then hole146so as to adjust the height of the rear edge of PV panel101in the solar array. The upper angle144as well as the predetermined length establishes predetermined angle (e.g. 5, 10, 15 degrees) in the predetermined arrangement102of the solar array of PV panels101at a particular location (i.e., longitude and latitude) for optimal irradiation by solar energy as is shown inFIGS. 6A-6D, and 9C-9D.

Similarly, the interleave bracket140can be manufactured from sheet metal utilizing punch-press or other techniques using a pattern for the interleave bracket140with the additional material148portion to provide additional structural support, and angle144located on the upper edge143. Further manufacturing of the interleave bracket140consists essentially of drilling one or more holes145,146,147, and bending the metal sheet into side portions141(i.e. front, left, right sides). The one or more holes145on side portions141may be formed and located at predetermined locations for securing the top plate120to the interleave bracket140. The one or more holes146,147of the interleave bracket140may be formed and located at predetermined locations for securing the top plate120to the interleave bracket140at holes145, and the base bracket131two the interleave bracket140by selecting from the one or more holes146,147and aligning with hole135on the base bracket131thereby operably coupling and joining the three elements of the top plate120, the interleave bracket140, and the base bracket131so as to form the elevation assembly130. Accordingly, manufacturing costs of the elevation bracket assembly130(i.e. top plate120, base bracket131, interleave bracket140) for a predetermined arrangement102of PV panels101can be reduced, from inventory to assembly, can be reduced by the three-piece construction in this embodiment of the present invention. The adjustable mount plate127may be secured to the base bracket110and/or base bracket131according to the design.

Referring toFIGS. 18-20, an adjustable mounting plate127for a bracket mount design of the present invention can provide adjustments in long solar arrays. The adjustable mounting plate127can be configured with a slot128adapted to receive the bolt151and grounding washer153and secured by a nut129as is shown inFIGS. 18 and 19. Referring toFIGS. 16-17 and 20, the slot128provides for travel of the clamping fastener relative to the frame171such as, for example, the tabbed grounding washer153and bolt151using threaded portion151ato engage threads of not nut129and clamp the frame171to the mounting system100. The adjustable mounting plate can use the base bracket111and secures the mounting plate127to an upper portion thereof. The base bracket111may be constructed with sides112and a conical hole118on flange of the base bracket111. Alternatively the base bracket131may be utilized to secure the mounting plate127two an upper portion thereof. Advantageously, the mounting plate127with slot128allows for adjustments in setting the frames171in a long rows of one or more PV panels101in the solar array being installed and secured should alignment be off slightly, for example, to a roof103in accordance with embodiment of the mounting system100of the present invention.

Referring toFIGS. 6A through 6D, and 12, a PV panel101secured in the mounting system100at a predetermined angle (e.g. tilt) is illustrated. Two single base bracket assemblies110comprising the base bracket111with the top plate120secure at a predetermined angle116(e.g. 5, 10, 15 degrees) support the front edge of the PV panel101at a predetermined arrangement102. Similarly, the elevation assembly130may be configured from the base bracket131with the interleave bracket140secured on an inner portion and top plate120secure at a predetermined angle116(e.g. 5, 10, 15 degrees) to the interleave bracket140provide support to the rear edge of the PV panel101. In this manner, the predetermined arrangement102of one or more PV panels101can be secured to a roof103in accordance with embodiment of the mounting system100of the present invention.

Referring toFIGS. 7A and 7B, a grounding mid-clamp assembly150is illustrated according to embodiment of the present invention. The grounding mid-clamp assembly150comprises a bolt151, a lock washer152, a tabbed-spacer153of toothed portion154design, and a channel nut160. The bolt151has a head and elongated threaded shaft configured to be received in a treaded hole163of the channel nut (e.g. tightening and loosening the tabbed-spacer153to a frame171of the PV panel101). The bolt151may be formed from suitable fasteners119and materials such as, for example, zinc coated steel or stainless steel for environmental conditions. The lock washer152provides a locking action between the head of the bolt151and the tabbed-spacer153so that it does not loosen over time. The tabbed-spacer153of toothed portion154design has a tab to provide a predetermined space between PV panels101. The tabbed-spacer153has a rounded shape with a toothed portion154and a flat portion155spaced apart from the tab. The toothed portion154is adapted to form a grounding connection with the metal frame171of the PV panel101. The flat portion155is adapted to not form a grounding connection with the metal frame171of the PV panel101as well as to not puncture the frame or shatter the glass of the PV panel101upon tightening.

Referring toFIGS. 8A and 8D, the channel nut160can be formed with a top portion161configured with a ridge portion162, hole163, side portions164, and serrations165formed at an outer edge. The channel nut160can be formed with opposing angled166face surfaces167forming the channel nut160with a generally polygonal shape that advantageously extends the edges for securing the nut160to the channel of a track230as well as to provide easy insertion when assembling in the field. Finally, the channel nut160can be formed with a sloping168base169thereby creating a triangular shape with one apex at the threaded hole163and to the serrations165at the edges. The triangular shape provides improved tightening and hold by directing the vector forces efficiently through the triangular shape.

Referring toFIGS. 9A and 9B, a grounding mid-clamp assembly150is illustrated in operation with a bracket mount and rail mount system, respectively, according to embodiment of the present invention. In bracket and rail mounts, the mid-clamp assembly150is arranged between two adjoining edges of the frame171spacing each PV panel101predetermined distance apart using advantageously the downwardly extending tab of the tabbed-spacer as is shown inFIG. 10. In a bracket mount design, the lower threads of the bolt151configured to be received by threaded connection123in the top plate120so as to fasten and secure the tabbed-spacer153to the mounting system100and ground PV panel101thereby as shown inFIG. 9A. In a rail mount design, the bolt151of the grounding mid-clamp assembly150is received in a treaded hole163of the channel nut160disposed in the channel of the track180as illustrated inFIG. 9B. By tightening bolt151, threaded shaft of the bolt151engages the threaded hole163of the channel nut160to pull the channel nut160against the channel track180thereby forming a grounding connection between the side portions164, serrations165and the channel track180.

As is illustrated inFIGS. 21 through 27, a rail mount200is configured to implement the features and advantages of the mounting system100of the present invention. The rail mount200comprises a base assembly210that can be configured as a shoe base201connected to a host or stand202. The shoe base201of the base assembly210may be formed with one or more holes203for securing to the support structure so as to anchor the rail mount200thereto. The stand202is a fixed to the base201at a lower and at an upper end the stand202may be configured to secure an L-foot204thereto by a threaded hole207four receiving a fastener205. The shoe base201and stand202may be formed in various dimensions such as, for example, different lengths to provide different height dimensions. The L-foot204operably couples to an L-bracket206that couples to the track230of the rail mount200so as to provide angular adjustments such as, for example to accommodate the rail at a proper angle to orient the PV panel101for optimal solar energy exposure. A full ground G of the frame171of the PV panels101is accomplished utilizing toothed portion154of the mid-clamp assembly150as is illustrated inFIGS. 21 and 29. The base assembly210is configured to secure a frontal portion of the PV panel101to the support structure.

Similarly, the rail mount200orients a rear portion of the PV panel101utilizing an elevation assembly220connected to the track230. The elevation assembly220may be configured with an elevation assembly220coupled to the base assembly210to secure the elevation assembly220to the track230and the base assembly210to the support structure. The similar component parts of the base assembly210are utilized including the shoe base201with holes203for securing to the structure, the stand202for securing the L-foot204thereto utilizing the one or more fasteners205and threaded hole207, a telescopic leg assembly221with an integral adjustment arm222, and the L-bracket206configured to attach the elevation assembly to the track230utilizing fasteners205. In operation, frame171the PV panel101is attached to the track230which is secured to and supported by elevation assembly220and base assembly210of the rail mount200. The mid-clamp assembly150is utilized to secure between adjacent frames171of PV panels101utilizing the channel nut assembly160secured in the track230. A full ground G of the frame171of the PV panels101is accomplished utilizing toothed portion154of the mid-clamp assembly150as is illustrated inFIGS. 21 and 29. An end clamp assembly240and or the grounding end plate180may be utilized on the terminating edge of the frame171of the PV panel101in a solar array as is shown inFIG. 29. Accordingly, the frame171may be secured to the rack mount200according to an embodiment of the present invention so as to elevate and orient one or more PV panels101in a row of a solar array. The design of the rack mount200provides a mounting system100advantageously that minimizes component parts, supports panels above the surface, simplifies installation thereof, provides improved maintenance as installed component parts are made easily accessible, which is an improvement over the art.

Referring toFIG. 25, the rail mount200of the mounting system100can comprise a composite shingle with a flashing208and secured by a sealing fastener209utilizing a large nut. The L-foot204is disposed on the post between the flashing208and sealing fastener209. The track230may be secured to the L-Foot204by fastener205and a channel nut assembly160mounting to the track230in the horizontal plane. The frame171of the PV panel101may be mounted on the track230and secured thereto by the channel nut assembly150with the channel nut assembly160as shown inFIG. 21. Consequently, the rack mount200provides a mounting system100for post on structures advantageously that minimizes component parts, supports panels above the surface, simplifies installation thereof, provides improved maintenance as installed component parts are made easily accessible, which is an improvement over the art.

Referring toFIGS. 26, 34A, and 34B, the rail mount200of the mounting system100may further utilize a tab157with the mid-clamp assembly150to provide additional spacing and securing from environmental factors when the frame171of the PV panel101are mounted on the track230. Referring toFIG. 27, the rail mount200of the mounting system100may be formed to utilize a grounding splice bar assembly250to join sections of track230of the rail mount200for a solar array. The splice bar assembly250comprises an inner bar241and an outer bar252secured by fasteners205. For example, the fasteners205on the inner bar251are tightened which urges the inner bar against the inner wall of the slot in the horizontal opening in track230. Similarly, the fasteners join with holes in the inner bar251so as to operably join inner bar251and outer bar252to ground the track230and secure from environmental factors when the frame171of the PV panel101are mounted on the track230.

As is illustrated in the rail mount design inFIG. 10, tightening threads151aof the bolt151urges the channel nut160against the track thereby compressing and securing the metal frame171of the PV panel101to the rail mount. The washer153of the mid-clamp assembly150is arranged between metal frames171of the PV panels101. The toothed portion154and flat portion155are arranged on and upper surface of the metal frames171so that the toothed portion155forms to form a grounding connection with the metal frame171of the PV panel101such as, for example, forming a ground by biting through layers of anodization, paint and the like on the metal frame171when the bolt151is tightened. The flat portion155remains close to the PV panel101and functions to distribute the tightening force so that the glass of the PV panel101does not break when secured. The flat portion155is adapted to not form a grounding connection with the metal frame171of the PV panel101. Similarly, upon tightening, the locking washer152is positioned between the bolt151and tab154of the tabbed-spacer153and provides distribution of a locking force so as not to crack or damage a PV panel101when securing to the frame of the mounting system100.

The lock washer152also is adapted to compress providing a locking force so that the bolt151does loosen under environmental conditions (i.e. does not back out over time). The locking force of the lock washer152is useful in maintaining the grounding circuit under various environmental factors such as, for example, seismic, winds and other forces. Similarly, the locking force of the lock washer152also functions with the flat portion156of the tabbed-spacer153with tab154to maintain the securing force against the metal frame171so as not to puncture the frame171or shatter the glass of the PV panel101under various environmental factors. Accordingly, the flat portion156of the tabbed-spacer153operates advantageously to distribute compression force and hold the PV panel101thereby preventing potential damage to the solar panel as may result in conventional systems from loosening under environmental conditions. Similarly, in a bracket mount design shown inFIG. 11, the top plate120is configured with solar panel portions121and raised spacer122formed integrally in the top plate120maintain separation between frame(s)171in a solar array. Supplemental, separation between frame(s)171in a solar array may be maintained by tab(s)151of the tabbed-spacer153with grounding teeth154, without use of the channel nut160, as the threads151aof the bolt151as shown inFIGS. 10 and 11.

As is shown inFIG. 28, according to the embodiment of the present invention, the mounting system100may include an equipment plate190that may be arranged in-line with other PV panels101of an solar array. For example, the equipment plate190may have a generally square and/or rectangular shape similar in size and dimension to an frame171of the PV panel101. The equipment plate may have and elongated face191and flange192forming an edge overhang as shown inFIG. 28. The equipment plate190may be arranged anywhere along an array of PV panels101. In one embodiment, the equipment plate190is arranged at the end of an array of PV panels101of the solar array. The last PV panel101secures the frame171by end plate180utilizing fasteners151that secure to the underlying top plate120. The equipment plate190is arranged adjacent the end plate180and lies flat across and between two bracket mounts: (1) one bracket mount supporting and edge of the equipment plate190terminating the solar array as well as (2) another bracket mount supporting and edge of the equipment plate190and the PV panel101(e.g. the assembly of the base bracket110and top bracket120, the elevation assembly130formed by base bracket131, interleave bracket140and top bracket120, which are secured to the ballast plate172for ballast179(FIG. 13)). The equipment plate190may be secured to the top plate120by one or more suitable fasteners193such as, for example, corrosion resistant self-tapping sheet metal screws. Securing the equipment plate190takes into consideration that the overhang flange192may be flush with the base bracket110, which can also be secured using suitable fasteners to provide additional structure for withstanding environmental conditions. Inverters or other electrical equipment181and accompanying wires182four such electrical equipment181may be secured directly to the equipment plate190utilizing one or more fasteners193. Accordingly, the electrical equipment181and wires182are elevated advantageously above the surface, installation thereof is simplified, maintenance and replacement is improved, and any such equipment installed is made easily accessible, which is an improvement over the art.

Referring toFIG. 29, according to the various embodiments of the present invention, the mounting system and method100can provide a complete and full ground of the PV panel(s)101in a solar array whether using a bracket and/or rail mount designs. The grounding diagram ofFIG. 29illustrates a ground, represented by element G, and the connection and by dashed line thereof. For simplicity, a bracket mount design using the base bracket110attached to the top plate120can illustrate the methodology of fully grounding. An absolute ground G is made to the earth and electrically secured to the base bracket110. As the bracket mount design of the mounting system100is assembled, certain components continue the ground by making connections to electrical equipment181and the frames171of the PV panels101. For example, a ground G is formed at a termination end during the installation of an end plate180because the threads151aof bolt151engage threaded aperture123of the top plate120forcing the spike125into the frame171. At the end of the solar array, the end plate180the ground G passes through the contact between the spike125in the frame171, the threads151ato the bracket base assembly110to the system ground. A lock washer152or other non-grounding washer158may be used as grounding is formed by the spike125biting into the frame171. At central locations in the solar array, grounds are formed between panel frames171(i.e. a panel-to-panel grounding path) using the tabbed-spacer153of the mid-clamp assembly150. The ground continues along the metal frame171to the mid-clamp assembly150. At any of the numerous mid-points between PV panels101and a solar array, the mid-clamp assembly150can be utilized to create a ground. At the opposite end, as is represented by an open circuit in the dashed ground-line ofFIG. 29, no ground G is formed in the bracket mount because no spikes125integral to a top plate120and/or an end plate180, or the teeth portion155of the tabbed-spacer153, dig into the metal of frame171to create a ground G.

According to one embodiment of the present invention, a ground is formed utilizing the top plate120formed with spikes125as is shown inFIG. 2B. The threads151aof bolt151and the non-grounding washer158can force the metal frame171of the PV panel101into the spikes125of the top plate120thereby creating a ground G. The grounding path continues from absolute ground through each of the frames171of adjacent PV panels101.

According to another embodiment of the present invention, a ground is formed utilizing the tabbed-spacer153and top plate120as is shown inFIG. 2A. The threads151aof bolt151and tabbed-spacer153can force the toothed portion155into the metal frame171of the PV panel101thereby creating a ground G. as discussed herein, the bolt151, washer152, tabs of the tabbed-spacer153, toothed portion154, flat portion156of the tabbed-spacer153coordinate with the raised portion122of the top plate120two maintain spacing between the metal frames171of adjacent PV panels101. The grounding path continues from absolute ground through each of the frames171of adjacent PV panels101.

According to the embodiment of the present invention, the mounting system100may be used and assembled in a cost efficient manner such as, for example, the layout for a solar array in a rail mount design can be established portrait and/or landscape on a roof such as, for example, the frame can be set with rails parallel to the rafters (i.e. portrait) or horizontal to the rafters (i.e. landscape). Each of the base bracket111,131may be secured to the roof103, for example, base bracket111may be secured through the conical hole118with a seal so that the installation does not require a flashing (or filling the hole with approved roofing sealant), whereby inserting a fastener119to secure to the roof engages the hole and seal thereby sealing the connection through the roof.

While certain configurations of structures have been illustrated for the purposes of presenting the basic structures of the present invention, one of ordinary skill in the art will appreciate that other variations are possible which would still fall within the scope of the appended claims. Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.