Abstract:
The specification and drawing figures describe and show a low profile mounting system that includes a at least one rail. A plurality of tracks is formed in the rail with opposing jaws. The opposing jaws define a slot. The opposing jaws are disposed in the rail asymmetrically to the longitudinal axis of the rail. At least one ledge monolithically extends from the rail for holding an object such as a solar panel. A coupler is provided for demountably connecting a solar panel to the rail. A cleat also is provided for attaching the system to a surface. A connector connects the rail to the cleat. This abstract is provided to comply with rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure, but this abstract is not to be used to interpret or limit the scope or meaning of any claim.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims benefit of U.S. Provisional Applications for a Low Profile System for Positioning a Module on an Object, filed Feb. 26, 2003, Application No. 60/450,004; an Improved Low Profile System for Positioning a Module on an Object, filed Jun. 12, 2003, Application No. 60/477,985; and an Enhanced Connector Device for a Low Profile System for Positioning a Module on an Object, filed Jun. 12, 2003, Application No. 60/478,036. 
    
    
     FIELD OF TECHNOLOGY 
     The apparatus and methods disclosed in this document pertain generally to mounting energy-producing panels on surfaces. More particularly, the new and useful low profile mounting system claimed in this document pertains to a system for securely, safely, yet quickly mounting in an aesthetically pleasing configuration one or more photovoltaic modules, panels, and arrays (collectively, “solar panels”) to objects that may include, but are not limited to, roof footings, footing grids, roofs, poles, frames, surfaces, or other objects (collectively, “surfaces”). 
     BACKGROUND 
     Numerous technical problems exist in connection with mounting devices such as photovoltaic panels on surfaces that are, or may be, exposed to varying force vectors induced or caused by wind, snow, rain, and other elements of weather. Additional problems are caused by widely diverse materials from which such surfaces are manufactured. The materials include, for example, wood, slate, metal, tar and tile. All such surfaces may have a variety of sub-surfaces constructed of a similar variety of materials, resulting in differing and unique compositions and densities that result in differing holding properties associated with connectors installed to hold mounting devices to the surfaces. The term “connectors” includes at least nails, screws, bolts, nuts, threaded and unthreaded rods, and similar holding devices. Many technical limitations of prior mounting systems have been considered and overcome in pending U.S. patent application for a System for Removably and Adjustably Mounting a Device on a Surface, application Ser. No. 09/910,655, filed Jul. 20, 2001, and U.S. patent application for Apparatus and Method for Positioning a Module on an Object, application Ser. No. 10/116,384, filed Apr. 4, 2002. 
     As the use of solar panels to generate all or part of electrical needs for home and industry increases, demand has escalated for a solar panel mounting system that not only is structurally rigid, weather resistant, and easy to install, but also is aesthetically pleasing in design and presentation when mounted on a surface. One such design criteria requires installed solar panels and mounting system to be functional but inconspicuous. A need exists in the industry, therefore, for a new and useful mounting system that is capable of easily and securely mounting solar panels on a surface that results in the installed system and panels being low profile, and thus comparatively inconspicuous and as indiscernible as possible. 
     SUMMARY 
     The low profile mounting system includes at least one rail. One or more tracks are formed in the rail with opposing jaws. The opposing jaws define a slot. The opposing jaws are disposed in the rail asymmetrically to the longitudinal axis of the rail and to each other. At least one ledge monolithically extends from the rail for holding an object such as frame of a solar panel. A coupler is provided for demountably connecting a solar panel to the rail. A cleat also is provided for attaching the system to a surface. A connector connects the rail to the cleat. 
     It will become apparent to one skilled in the art that the claimed subject matter as a whole, including the structure of the apparatus, and the cooperation of the elements of the apparatus, combine to result in a number of unexpected advantages and utilities. The structure and co-operation of structure of the low profile mounting system will become apparent to those skilled in the art when read in conjunction with the following description, drawing figures, and appended claims. 
     The foregoing has outlined broadly the more important features of the invention to better understand the detailed description that follows, and to better understand the contributions to the art. The low profile mounting system is not limited in application to the details of construction, and to the arrangements of the components, provided in the following description or drawing figures, but is capable of other embodiments, and of being practiced and carried out in various ways. The phraseology and terminology employed in this disclosure are for purpose of description, and therefore should not be regarded as limiting. As those skilled in the art will appreciate, the conception on which this disclosure is based readily may be used as a basis for designing other structures, methods, and systems. The claims, therefore, include equivalent constructions. Further, the abstract associated with this disclosure is intended neither to define the low profile mounting system, which is measured by the claims, nor intended to limit the scope of the claims. The novel features of the low profile mounting system are best understood from the accompanying drawing, considered in connection with the accompanying description of the drawing, in which similar reference characters refer to similar parts, and in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWING 
         FIG. 1  of the drawing is a perspective view of a mounting system located on a roof; 
         FIG. 2  is a perspective view of a first embodiment of the low profile mounting system in an operative environment; 
         FIG. 3  is an exploded end view of the first embodiment of the first embodiment of the low profile mounting system; 
         FIG. 4  is a perspective view of a second embodiment of the low profile mounting system in an operative environment; 
         FIG. 5  is an exploded end view of a second embodiment of the low profile mounting system; 
         FIG. 6  is a perspective view of a third embodiment of the low profile mounting system in an operative environment; 
         FIG. 7  is an exploded end view of the third embodiment of the low profile mounting system; 
         FIG. 8  is a perspective view of a fourth embodiment of the low profile mounting system in an operative environment; 
         FIG. 9  is an exploded end view of the fourth embodiment of the low profile mounting system; 
         FIG. 10  is a perspective view of a fifth embodiment of the low profile mounting system in an operative environment; 
         FIG. 11  is an exploded end view of the fifth embodiment of the low profile mounting system; 
         FIG. 12  is a perspective view of a sixth embodiment of the low profile mounting system in an operative environment; and 
         FIG. 13  is an exploded end view of the sixth embodiment of the low profile mounting system. 
     
    
    
     DETAILED DESCRIPTION 
     As shown in  FIGS. 1 through 13 , a low profile mounting system  10  is provided that in its broadest context includes at least one rail  12 . At least one track  14  is formed in rail  12  with opposing jaws  16   a, b . Opposing jaws  16   a, b  define a slot  18 . Opposing jaws  16   a, b  are disposed in rail  12  asymmetrically to the longitudinal axis of rail  12  and to each other. At least one ledge  20   a  monolithically extends from rail  12  for holding an object such as the frame  22  of a solar panel  24 . A coupler  26  is provided for demountably connecting solar panel  24  to rail  12 . A cleat  28  also is provided for attaching low profile mounting system  10  to a surface  30 . A connector  32  connects rail  12  to cleat  28 . 
     As shown in  FIG. 1 , rails  12   a, b  are mounted on a surface  30 . Surface  30  is a roof  34 .  FIG. 1  also shows solar panels  24   a, b  bounded by frames  22   a, b . During installation of Frames  22   a, b  are connected to rails  12   a, b . Rails  12   a, b  are secured to roof  34 . In general, rails  12   a, b  are secured to roof  34  in part using footers or footings (in this document, a “footing  36 ”). A number of footings  36   a, b  traditionally have been used to secure rails  12   a, b  to roof  34 . Footings  36   a, b  may be L-shaped and constructed of metal or other materials. Footings  36   a, b  may be attached to roof  34  by inserting lag bolts (not shown) through passages (not shown) in footings  34   a, b  into rafters  38  beneath roof  34 . 
     As also shown in  FIG. 1 , in a conventional mounting configuration, solar panels  24   a, b  are mounted top-down onto rails  12   a, b . This may present an aesthetically displeasing appearance because solar panels  24   a, b  and rails  12   a, b  present an undesirably excessive elevation. What is desirable is to easily, quickly, and securely mount solar panels  24   a, b  on a surface  30  that produces a low profile that is comparatively inconspicuous and as indiscernible as possible. 
     Low profile mounting system  10 , as shown in different embodiments in  FIGS. 2 through 13 , allows an installer to achieve a low profile that is comparatively inconspicuous and as indiscernible as possible. 
     In the embodiment of low profile mounting system  10  illustrated by cross-reference between  FIGS. 2 and 3 , rail  12  is shown to be mountable on a surface  30  known as a stanchion or stand-off (in this document, a “stanchion  40 ”) rather than on roof  34 . Stanchion  40  is useful because of the aforementioned variety of materials used to manufacture a roof  34  and coverings for roof  34 . For example, if the covering for roof  34  is made of tile, bolting a rail  12  directly to a tile on roof  34 , through a tile (not shown), is undesirable because the tiles may crack or break. To avoid that problem, one or more tiles are removed, stanchion  40  is installed on roof  34 , and solar panel  24  is attached to stanchion  40 . 
     To achieve a lower profile than conventional installation apparatus allow, in the embodiment of low profile mounting system  10  illustrated by cross-reference between  FIGS. 2 and 3 , rail  12  is shown to include at least one ledge  42 . As shown, rail  12  is formed with an upper surface  44 , a lower surface  46 , and opposing walls  48   a, b  monolithically connected to upper surface  44  and a lower surface  46 . At least one ledge  42  extends at a substantially right angle from opposing walls  48   a, b  in opposite directions from the longitudinal axis through rail  12 . Rather than mount solar panel  24  top-down, thus raising the total elevation of an installed mounting system, at least one ledge  42   b  allows installation of frame  22  of solar panel  24  closer to surface  30 . 
     As also shown in the embodiment shown in  FIGS. 2 and 3 , rail  12  includes plurality of tracks  14   a, b . Plurality of tracks  14   a, b  is formed in rail  12  with opposing jaws  16   a - d  defining slots  18   a, b . In addition, in the embodiment shown in  FIGS. 2 and 3 , opposing jaws  16   a, b  and opposing jaws  16   c, d  are disposed in rail  12  asymmetrically to each other and to the longitudinal axis of rail  12 . The term “asymmetrically” as used in this document means that slot  18   a  is directionally disposed differently than slot  18   b . As indicated, at least one coupler  26  is provided. Coupler  26  includes an attachment device  50 . In the embodiment shown in  FIGS. 2 and 3 , attachment device  50  is a first bolt  52  and a first nut  54 . Coupler  26  also includes a clamp  56 . Clamp  56 , as shown in  FIGS. 2 and 3 , is substantially a U-shaped gutter  56   a  formed with an orifice  58  and opposing fins  60 . The head  62  of first bolt  52  is slidably insertable into slot  18   a  of track  14  to extend through opposing jaws  16   a, b  and, by deploying first nut  54  on first bolt  52 , U-shaped gutter  56   a  may be clamped into ducts  64   a, b  formed on a conventional frame  22  of solar panel  24 . Clamp  56  as shown in all embodiments of low profile mounting system  10  may be a short segment, or may extend the entire length of rail  12  to enhance the aesthetic appearance of an installed low profile mounting system  10 , and to aid in resisting wind and rain penetration into the components of low profile mounting system  10 . 
       FIGS. 2 and 3  also show that a second bolt  66  and a second nut  68  are included. Head  70  of second bolt  66  is slidably insertable into track  14   b  to extend through slot  18   b . An opening  72  is provided in an extension  74  of stanchion  40 . Second bolt  66  is inserted through opening  72 , second nut  68  is inserted on second bolt  66 , and the embodiment of low profile mounting system  10  as shown in  FIGS. 2 and 3  is securely attached to stanchion  40 , which in turn has been attached to roof  34 . Solar panel  24  thus provides a low visual profile. 
     In the embodiment low profile mounting system  10  illustrated by cross-reference to  FIGS. 4 and 5 , low profile mounting system  10  is shown to include a plurality of ledges  20   a, b  on rail  12 .  FIGS. 4 and 5  also show an embodiment of low profile mounting system  10  that includes at least one cleat  28 . Further, the embodiment shown in  FIGS. 4 and 5  shows a clamp  56   b  in the form of a substantially flat planar surface or plate  76 . Clamp  56   b  is another embodiment of clamp  56  useful in providing a pleasing configuration to an assembled low profile mounting system  10  and for securing ducts  64   a, b  of a plurality of frames  22   a, b  on plurality of ledges  20   a, b  on rail  12 . Further, cleat  28  includes at least one hole  78 . As shown, cleat  28  includes holes  78   a, b, c . Holes  78   a, b  are used to attach cleat  28  to roof  34  using lag bolts or similar connectors. Hole  78   a  is used to attach cleat  28  to rail  12  by inserting second bolt  66  into slot  18   b  and through hole  78   c , and attaching second nut  68  to second bolt  66 . As a result, a secure, easily installable, and aesthetically pleasing installation of low profile mounting system  10  is achieved. 
     In another embodiment of low profile mounting system  10 , as shown in  FIGS. 6 and 7 , an alternative clamp  56  is provided as clamp  56   c . Clamp  56   c  is useful in connection with variations of frame  22  formed with a plurality of ducts  64   a, b  as shown best in  FIG. 7 . Clamp  56   c  also is formed as a gutter, but with opposing arms  80   a, b  long enough to be removably insertable into ducts  64   a, b  to hold frame  22  of solar panel  24  tightly against ledge  20   a, b  when locked into position using attachment device  50 . 
     In the embodiment of low profile mounting system  10  illustrated in  FIGS. 8 and 9 , clamp  56   a , as shown by cross-reference between  FIGS. 2 and 3  in connection with a single frame  22  of solar panel  24  being attached to stanchion  40 , is shown to be equally useful when disposed in a configuration in which a plurality of opposing frames  22   c, d  are mounted on a rail  12  that in turn is mounted on cleat  28  for attachment to roof  34 . 
     In another embodiment of low profile mounting system  10 , as shown by cross-reference between  FIGS. 10 and 11 , rail  12  is shown with a track  14   b  and a longitudinal cavity  82  formed in upper surface  44  of rail  12   c . As shown, longitudinal cavity  82  is shaped to receive an attachment device  50 . Attachment device  50 , as shown in  FIG. 11 , includes first bolt  52 . A receptor body  84  also is monolithically formed adjacent longitudinal cavity  82 . As shown in  FIG. 11 , first threads  86  are formed in receptor body  84  for matable connection with second threads  88  formed on first bolt  52 . Further, as also shown in  FIG. 11 , clamp  56   d  is formed with a contoured cross-sectional configuration for both aesthetics and for gripping frame  22  of solar panel  24   a, b , and includes parallel nubs  90   a, b . Parallel nubs  90   a, b  are designed to fit tightly along exterior surfaces  92   a, b  of longitudinal cavity  82 . 
     In the embodiment of low profile mounting system  10  illustrated in  FIGS. 12 and 13 , longitudinal cavity  82   a  is shown to be useful as a scribe guide  94  for inserting into rail  12  an attachment device  50  in the form of a screw  50   e . As shown, receptor body  84  also includes a groove  96 . As also shown, two detents  98   a, b  are formed in receptor body  84 . A variation of clamp  56   d , namely  56   e , is provided with comparatively longer parallel nubs  90   c, d  that are insertable into two detents  98   a, b  in receptor body  84 . Receptor body  84  also includes opposing fins  100   a, b . Screw  50   e  is removably insertable through clamp  56   e  into receptor body  84 . Screw  50   e  extends into the chamber  102  formed in rail  12 . Screw  50   e  is held in place in part by opposing fins  100   a, b.    
     In all embodiments shown in  FIGS. 1 through 13 , end plates  104 , as best shown in  FIG. 10 , may be placed across low profile mounting system  10  to further add to the aesthetic appearance of an assembled low profile mounting system  10 , and to preclude entry of water, wind, and other elements into low profile mounting system  10 . 
     Although  FIGS. 1 through 13  shows embodiments of low profile mounting system  10  in which components of low profile mounting system  10  are in certain positions in relationship to one another, the components may be located in any number of other positions. Although the a number of alternative attachment devices and connectors are shown, other fasteners may be used. The low profile mounting system shown in drawing  FIGS. 1 through 13  includes a number of non-exclusive embodiments that are merely illustrative of the disclosed low profile mounting system  10 . In addition, claim elements and steps in the following appended claims in this document have been numbered solely as an aid in readability and understanding. The numbering is not intended to, and should not be considered as intending to, indicate the ordering of elements and steps in the claims. Means-plus-function clauses in the claims are intended to cover the structures described as performing the recited function that include not only structural equivalents, but also equivalent structures. Thus, although a nail and screw may not be structural equivalents, in the environment of the subject matter of this document a nail and a screw may be equivalent structures.