Abstract:
A method and apparatus for mounting a solar collector panel by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface. The strap assembly comprises a plurality of straps attached end to end. The first attachment device could be a bolt, a screw, adhesive, etc. Alternatively, there could be a support between the panel or frame and the strap assembly. The second attachment means may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional application of U.S. application Ser. No. 14/811,607, entitled “MODULAR STRAP MOUNT FOR SOLAR PANELS”, filed on Jul. 28, 2015, which is a Continuation of PCT Patent Application No. PCT/US2013/025622 filed 11 Feb. 2013, the entire specification, claims and drawings of which are hereby incorporated by reference. 
     
    
     BACKGROUND OF THE INVENTION 
     (1) Field of the Invention 
       [0002]    The present invention relates to the field of solar panels and more particularly to apparatuses and methods for mounting solar panels on surfaces, including roofs, walls and the ground. 
       (2) Description of the Related Art 
       [0003]    Solar panels can be of the photovoltaic type of the thermal type or combinations. They can be installed as is or contained within a frame. Solar panels must be mounted correctly in order to maximize power production and to prevent movement of the panels from the force of wind. The proper solar panel mounting provides stability and the proper directional and latitudinal orientation for the solar array. 
         [0004]    Different mounting systems are available depending on whether the modules will be mounted on a roof, a wall, the ground, or a pole. For mounting on a roof or the ground there are ballast mounts, flush mounts (such as Modular IronRidge XRS available from IronRidge in Willits, Calif.) standing seams mounts, and adjustable mounts (such as those available from Unirac in Albuquerque, N. Mex.). These usually include a tilted rack, firmly attached to the substrate surface, on which the modules are firmly mounted; or brackets of at least two different heights, firmly attached to the substrate surface, to which the ends of the modules are firmly attached. 
         [0005]    Such systems are heavy and expensive to fabricated and time consuming to install. What is needed is a mounting system which is cheaper to fabricate and less time consuming to install. Preferably the improved system can be easily fabricated on site or provided as a kit. The inventor has developed two improvements on the state of the art: U.S. Pat. No. 7,814,899 and U.S. patent application Ser. No. 13/038,286, the entire texts and drawings of which are included in this document by reference. 
         [0006]    This inventor has now developed another improvement on the state of the art. Development of a solar panel mounting system which is cheaper to fabricate and less time consuming to install represents a great improvement in the field of solar panel mounting and satisfies a long felt need of the solar panel installer and owner. 
       SUMMARY OF THE INVENTION 
       [0007]    This invention is an apparatus for mounting a solar collector panel (photovoltaic, thermal or combination), by itself or supported within a frame, to a surface comprising: a strap assembly, a first attachment device attached to and between the panel or frame and the strap assembly; and a second attachment means for attaching the strap assembly to the surface. The strap assembly further comprises a plurality of straps attached end to end. 
         [0008]    This invention is also a method of mounting a solar collector panel by itself or supported within a frame, to a surface, comprising the steps of: providing a plurality of straps; attaching the straps together end to end to make a strap assembly; attaching the panel or frame and the strap assembly to each other; and attaching the strap assembly to the surface. 
         [0009]    The first attachment device could be a bolt, a screw, adhesive, etc. Alternatively, there could be a support between the panel or frame and the strap assembly. Preferably the support has a top flange and a bottom flange. The top flange may be parallel to the surface of at an angle to the surface. There may be two supports and one may be taller than the other. Furthermore, the length of the support or supports may be wider than the straps and sufficient to span the entire width or length of the solar panel and frame assembly. 
         [0010]    Preferably each end of each strap is drilled (and even more preferably pre-drilled) with a hole pattern through which the straps are attached end to end. Also, preferably, the bottom flange of the support has the same hole pattern drilled into it so that the bottom flange can be attached to two strap ends at the same time and with the same fasteners. Additionally the straps may have different widths. 
         [0011]    The means for attaching the strap assembly to the surface may be: a nail, a spike, adhesive, bolting to a stud attached to the surface, welding, ballast, adhesive tape or combinations of these. 
         [0012]    Alternatively, the support may comprise a U shaped channel having a base and an opening opposite the base. In this case the base is attached to the strap assembly. Preferably, the solar panel or the panel and frame assembly is clamped to the top of the channel by fastening together with a threaded fastener a plate slidably installed, parallel to the base in the channel; and a clip, adapted to clamp to the frame, placed on the frame, transverse to the frame, over a top edge of the frame at a side of the frame. 
         [0013]    While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility. 
         [0014]    An appreciation of the other aims and objectives of the present invention and a more complete and comprehensive understanding of it may be achieved by referring to the accompanying drawings and studying the following description of the best mode of carrying out the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view of a strap of this invention. 
           [0016]      FIG. 2  is a side view of two straps assembled into a strap pack in accordance with this invention. 
           [0017]      FIGS. 3A to 3D  illustrate different hole patterns that can be made in the ends of the straps. 
           [0018]      FIG. 4  is a perspective view of the taller bracket used for flat roof installations of this invention. 
           [0019]      FIG. 5  is a perspective view of the shorter bracket used for flat roof installations of this invention. 
           [0020]      FIG. 6A  is a side view of two units of the embodiment of this invention typically intended for installation on a flat roof. 
           [0021]      FIG. 6B  is a perspective view of two units of the embodiment of this invention typically intended for installation on a flat roof. 
           [0022]      FIG. 6C  is a perspective, exploded view of two units of the embodiment of this invention typically intended for installation on a flat roof. 
           [0023]      FIG. 7  is a magnified view of the attachment between a bracket and the solar panel and the bracket and a modular straps. 
           [0024]      FIG. 8  illustrates in exploded view assembly of a bracket with two modular straps. 
           [0025]      FIG. 8A  is a magnified view of the assembly of  FIG. 8  fully assembled. 
           [0026]      FIG. 9  is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with ballast. 
           [0027]      FIG. 10  is a perspective view showing attachment of modular straps used in a flat roof installation with nails, spikes or screws. 
           [0028]      FIG. 10A  is a magnified view of  FIG. 10  showing the fastener through a hole in the strap assembly. 
           [0029]      FIG. 11  is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with adhesive. 
           [0030]      FIG. 12  is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs. 
           [0031]      FIG. 12A  is an exploded, magnified, perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down with studs. 
           [0032]      FIG. 13  is a perspective view of a flat roof installation of this invention in which the modular strap assemblies are held down by welding. 
           [0033]      FIG. 14  is a perspective view of an array of multiple solar panels installed on a flat roof with the mounting system of the instant invention. 
           [0034]      FIG. 15  is a perspective view of a mounting channel used in this invention. 
           [0035]      FIG. 16  is an exploded perspective view of attachment of the solar panel to the modular strap via the channel. 
           [0036]      FIG. 17  is a cross sectional view along the lines  17 - 17  of  FIG. 16 . 
           [0037]      FIG. 17A  is cross section showing an alternate way of attaching panels directly to the strap assemblies using the clip and bolt clamping assembly. 
           [0038]      FIG. 17B  is cross section showing another alternate way of attaching panels directly to the strap assemblies. 
           [0039]      FIG. 18  is a plan view of one solar panel installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panel are installed to overlay one half the width of the modular strap and the channels are transverse to the strap assemblies. 
           [0040]      FIG. 18A  is perspective view of three solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the ends of the solar panels are installed to overlay one half the width of the modular strap and the channels are parallel to the strap assemblies. 
           [0041]      FIG. 19  is an enlarged perspective view of the area shown at 19 on  FIG. 18A . 
           [0042]      FIG. 20  is an exploded, perspective view showing a method of attaching a modular strap to a flat or tilted roof using a spike or similar fastener. 
           [0043]      FIG. 21  is a perspective view showing a method of attaching a modular strap to a flat or tilted roof using adhesive. 
           [0044]      FIG. 22  is a perspective view of a method of attaching a modular strap to a flat or flat or tilted roof using a stud and bolt. 
           [0045]      FIG. 22A  is an enlarged cross section along the lines  22 A- 22 A of  FIG. 22   
           [0046]      FIG. 23  is an expanded perspective view of a method of attaching a modular strap to a flat or tilted roof using welding. 
           [0047]      FIG. 23A  is a top view of a method of holding a modular strap to a flat or tilted roof using ballast. 
           [0048]      FIG. 24  is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed end to end, and the joints between modular straps are located between the solar panels. 
           [0049]      FIG. 25  is a plan view of two solar panels installed on modular straps on a flat or tilted roof in accordance with the teachings of this invention in which the solar panels are installed side to side and the modular straps are under the solar panels. 
           [0050]      FIGS. 26A-26C  illustrate that strap packs can be installed at differing separations. 
           [0051]      FIG. 27  is a perspective view of one unit of the instant invention having modular straps of two different widths and in which one bracket extends from one strap to the other. 
           [0052]      FIG. 28  is a perspective view of an embodiment of the instant invention having modular straps of two different widths. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0053]    While the present invention is described herein with reference to illustrative embodiments for particular applications, it should be understood that the invention is not limited thereto. Those having ordinary skill in the art and access to the teachings provided herein will recognize additional modifications, applications, and embodiments within the scope thereof and additional fields in which the present invention would be of significant utility. 
         [0054]    This invention  10  has two major embodiments: one  10   a  that is intended primarily to be attached to a flat surface  14 , such as a roof or wall; and one that is intended to be attached primarily to a tilted surface  18 , such as a peaked roof. However, in fact, either embodiment can be attached to a flat  14  or tilted  18  surface. As described in U.S. Pat. No. 7,814,899, solar panels  22  may be retained within a frame  24  (as shown in  FIG. 7 ), which has a number of holes useful for mounting. 
         [0055]      FIG. 1  illustrates the modular strap  28  of this invention. It is made of thin sheet material such as steel or aluminum, preferably ⅛ inch thick. A number of these straps are attached together end  30   a  to end  30   b  as shown in  FIG. 2  to form a strap assembly  32 . Fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc. To facilitate assembly of the straps  28  one to another they are preferably predrilled with a hole pattern  36  at each end as illustrated in  FIGS. 3A through 3C . Since only two holes are needed to produce a secure connection, the pattern  36   b  shown in  3 B allows for the straps  28  to be connected together to make slight adjustment in the total length of the strap assembly  32 . As shown in  FIG. 3D  two or more of the holes  40  could actually be slots  44  which allows for some margin of error in assembly. 
         [0056]    In the flat surface embodiment  10   a,  attached to the top  48   a  of the straps are one or two brackets  52   a,    52   b  as shown in  FIGS. 4 and 5 . As can be seen they each have a bottom flange  56   a,    56   b,  a top flange  60   a,    60   b  and a central body  64   a,    64   b.  In these brackets  52   a,    52   b  the bodies  64   a,    64   b  have a C shaped cross section but they could be Z shaped or I shaped or any other cross sectional shape. As can be seen, when two brackets  52   a,    52   b  are used, preferably one bracket  52   a  is taller than the other  52   b.  As shown in  FIGS. 6A, 6B and 6C , the taller one  52   a  is attached to the strap assembly  32  at a point which will be close to the end of the solar panel frame  24  which is intended to be higher and the shorter one  52   b  is attached to the strap assembly at a point which will be close to the other end of the solar panel frame. The brackets  52  are attached to the strap assemblies  32  through their bottom flanges  56 . Again fastening can be done by nuts and bolts, screws, rivets or blind fasteners, such as Jo-Bolts, pop rivets, Huck bolts, etc.  68 . Then the solar panel frame  24  is clamped to the top flange  60  of the brackets  52 , preferably using the teachings of U.S. Pat. No. 7,814,899.  FIG. 7  illustrates assembly of the clip  76  to the top flange  56  of the bracket  52  except that one panel  22 , its frame  24  and the adjustable fastener is not shown. 
         [0057]    In order to simplify assembly and reduce labor and material costs, at least one bracket  52  and two strap ends  30  can be attached together with the same fasteners  68  at the same time. This is illustrated in  FIGS. 8 and 8A . Of course the bottom flange  56  of the bracket  52  must be provided with the same hole pattern  36  as that on the strap ends  30  or at least a hole pattern  36  that will mate with the hole pattern  36  in the strap end  30 . 
         [0058]    Various devices and methods can be used to fasten the strap assemblies  32  to surfaces  14 ,  18 , depending on the inclination of the surface  14 ,  18  and the material it is made out of. These are illustrated in  FIGS. 9, 10, 10A, 11, 12, 12A and 13 . 
         [0059]      FIG. 9 , illustrates ballast  80 . The ballast  80  can be any object made out of a weighty material. Satisfactory objects are bricks, blocks of concrete, blocks of metal, etc. The ballast  80  can be contained within a container  84  for convenience and to span the distance between strap assemblies  32 . The objects  80  and/or the container  84  can be just placed on the strap assemblies  32  or can also be fastened to the strap assemblies  32 . 
         [0060]      FIGS. 10 and 10A  illustrate use of pointed fasteners  88 such as nails, spikes, or screws. They are fastened into the substrate  14 ,  18  through holes  92  in the strap assemblies  32 . The holes  92  may be predrilled for convenience. 
         [0061]      FIG. 11  illustrates use of adhesive  96  to adhere the strap assemblies  32  to the substrate  14 ,  18 . Any suitable adhesive  96  can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration. 
         [0062]      FIGS. 12 and 12A  illustrate the use of threaded studs  100  for fastening down the strap assemblies  32 . The studs pass through holes  92  in the assemblies  32  and the straps  28  are fastened to the studs  100  with nuts  104 . The studs  100  must be pre-joined to the substrate  14 ,  18  such as with inserts or, as illustrated, in  FIG. 12A  by fastening a plate  108  trapped on the stud  100  to the substrate  14 ,  18 . Again this plate  108  may be fastened to the substrate via any suitable method such as nails or adhesive. 
         [0063]      FIG. 13  illustrates use of welding for fastening down the strap assemblies  32 . In this method, a strip of roofing material  112  is laid over the strap assembly and bonded to the underlying roof material. 
         [0064]      FIG. 14  shows an array of solar panels  22  constructed on a flat surface  14  in accordance with the teachings of this invention. 
         [0065]      FIG. 15  shows the channel  116  which is used to mount solar panels to strap assemblies  32  on flat or tilted substrates  18 , e.g. pitched roofs. First the channel  116 , which may be predrilled, is fastened to the strap assembly  32 . The hole pattern  36   c  shown in  FIG. 3C  is most useful for this purpose since the channel  116  can be mounted parallel with or transverse to the strap assembly  32  as required. 
         [0066]      FIG. 16  shows an assembly of solar panels  22  to straps  28  using the channel  116  transverse to the strap assembly  32 . In  FIG. 16  the fasteners are not shown for clarity of understanding. 
         [0067]      FIG. 17  is a cross section of this assembly showing the fasteners. The channel  116  is fastened through its bottom  120  to the strap assembly  32 . A clip  76  goes over the top edge of one or two solar panel frames  24 . The channel  116  has slots or grooves  124  on each side  128  in which a plate  132  can slide. There is a central through hole  136  perpendicularly through the clip  76  and the plate has a threaded hole  140  in its center. A threaded bolt  144  is inserted through the through hole  136  and fastened into the threaded hole  140 . Tightening the bolt  144  firmly clamps the solar panel frames  24  to the channel  116 .  FIG. 18  illustrates an assembly of a solar panel  22  to strap assemblies  32  with transverse channels  116 .  FIG. 18A  illustrates assembly of several solar panels  22 . 
         [0068]    The solar panels  22  or the frames  24  can be attached directly to the straps  28 . Alternate was of doing this are shown in  FIGS. 17A and 17B .  FIG. 17A  shows use of a clip and bolt to clamp the panel  22  to the strap  28 . A threaded insert  118  is inserted into the straps and receives the threaded end of the bolt  144 . Tightening the bolt  144  into the insert  118  clamps the panels  22  to the straps  28 .  FIG. 17B  shows an alternate method. In this method the straps  28  are bolted or screwed to the underside of the panel  22 . Those familiar with the art to which this invention applies will realize that other methods can also be used. 
         [0069]      FIG. 19  shows an assembly of solar panels  22  to straps  28  using the channel  116  parallel to the strap assembly  32 . In  FIG. 19  the fasteners are not shown but they are the same as shown on  FIG. 17 . 
         [0070]    Various devices and methods can be used to fasten the strap assemblies of this embodiment to surfaces, depending on the inclination of the surface and the material it is made out of. These are illustrated in  FIGS. 20, 21, 22, 22A, 23 and 23A . 
         [0071]      FIG. 20  illustrates use of pointed fasteners  88  such as nails, spikes or screws. They are fastened into the substrate  18  through holes  92  in the strap assemblies  32 . The holes  92  may be predrilled for convenience. 
         [0072]      FIG. 21  illustrates use of adhesive  96  to adhere the strap assemblies  32  to the substrate  18 . Any suitable adhesive  96  can be used. It may be catalyzed, in liquid or tape form or any other suitable configuration. 
         [0073]      FIGS. 22 and 22A  illustrate the use of threaded studs  100  for fastening down the strap assemblies  32 . The studs  100  pass through holes  92  in the assemblies  32  and the straps  28  are fastened to the studs  100  with nuts  104 . The studs  100  must be pre-joined to the substrate  18  such as with inserts or, as illustrated, in  FIG. 12A  by fastening a plate  108  trapped on the stud  100  to the substrate  18 . Again this plate  108  may be fastened to the substrate  18  via any suitable method such as nails or adhesive. 
         [0074]      FIG. 23  illustrates use of welding for fastening down the strap assemblies  32 . In this method, a strip of roofing material  112  is laid over the strap assembly  32  and bonded to the underlying roof material. 
         [0075]    Depending on the exact slope, ballast  80  can also be used to hold down the strap assemblies  32 . The ballast  80  would have to be inserted between the panels, as shown on  FIG. 23A . 
         [0076]    There are a number of variations that can be applied to assemblies in accordance with this invention. As shown on  FIG. 24 , the straps  28  can be fastened to each other between solar panels  22 ,  24 . As illustrated on  FIGS. 24 and 25  the solar panels  22 ,  24  can be assembled end to end or side to side. As illustrated on  FIGS. 26, 26A and 26B , the distance D between strap assemblies  32  can be varied. As illustrated on  FIG. 27  the brackets  56  can extend all the way across the solar panel  22  from strap assembly  32  to strap assembly. As illustrated on  FIGS. 27 and 28 , the straps  28 ,  28   a  in an assembly  32  can be of different widths. 
         [0077]    The following reference numbers are used on the Figures: 
         [0078]      10  this invention 
         [0079]      10   a  embodiment intended to be attached to flat surfaces 
         [0080]      10   b  embodiment intended to be attached to flat or tilted surfaces 
         [0081]      14  flat surface 
         [0082]      18  flat or tilted surface 
         [0083]      22  solar panel 
         [0084]      24  solar panel frame 
         [0085]      28  modular strap 
         [0086]      30   a  one end of modular strap 
         [0087]      30   b  other end of modular strap 
         [0088]      32  strap assembly 
         [0089]      36  hole pattern 
         [0090]      40  holes in hole pattern 
         [0091]      44  slots in hole pattern 
         [0092]      48   a  top of strap 
         [0093]      52  bracket 
         [0094]      52   a  taller bracket 
         [0095]      52   b  shorter bracket 
         [0096]      56  bottom flange of bracket 
         [0097]      56   a  bottom flange of taller bracket 
         [0098]      56   b  bottom flange of shorter bracket 
         [0099]      60  top flange of bracket 
         [0100]      60   a  top flange of taller bracket 
         [0101]      60   b  bottom flange of taller bracket 
         [0102]      64  bracket body 
         [0103]      64   a  body of taller bracket 
         [0104]      64   b  body of shorter bracket 
         [0105]      68  fastener 
         [0106]      76  clip 
         [0107]      80  ballast 
         [0108]      84  ballast container 
         [0109]      88  pointed fastener 
         [0110]      92  hole in strap assembly 
         [0111]      96  adhesive 
         [0112]      100  threaded stud 
         [0113]      104  nut 
         [0114]      108  fastening plate 
         [0115]      112  strip of roofing material 
         [0116]      116  mounting channel 
         [0117]      118  threaded insert 
         [0118]      124  slot or groove in side of channel 
         [0119]      128  side of channel 
         [0120]      132  plate 
         [0121]      136  central through hole in clip 
         [0122]      140  threaded hole in center of plate 
         [0123]      144  threaded bolt 
         [0124]      148  threaded bolt 
         [0125]      152  screw 
         [0126]    D distance between strap assemblies 
         [0127]    This invention has been described with reference to a particular embodiments and variations. However, it should be obvious to those skilled in the art to which this invention pertains that other modifications and enhancements can be made without departing from the spirit and scope of the claims that follow. 
         [0128]    Thus, the present invention has been described herein with reference to particular embodiments for particular applications. Those having ordinary skill in the art and access to the present teachings will recognize additional modifications, applications and embodiments within the scope thereof. 
         [0129]    It is therefore intended by the appended claims to cover any and all such applications, modifications and embodiments within the scope of the present invention.