Patent Publication Number: US-2012025042-A1

Title: Apparatus facilitating mounting of solar panels to a rail assembly

Description:
FIELD OF THE INVENTION 
     Embodiments of the invention relate to solar panel installation, and more particularly to mounting structures for enabling a structure supporting one or more solar panels to move along a rail to its desired location. 
     BACKGROUND OF THE INVENTION 
     Solar panel installation traditionally involves installing a foundation system (typically a series of posts or footings), and then mounting individual solar panels to the support frame with brackets or clips. Other, more complicated mounting systems have been proposed with multiple parts and complex assemblies. These mounting structures can be difficult to install and worse, expensive to manufacture. Additional problems can result from the diverse materials used to manufacture such mounting systems. 
     Generally, a common thread with known installation systems is that each solar panel must be installed by moving equipment, materials, and labor along rows of support structures to mount solar panels on the support structures one-at-a-time. This is a time-consuming process, which becomes increasingly inefficient with larger scale systems. 
     With demand for large-scale installations growing, a simplified system for solar panel installation is needed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1C  are cross-sectional, top, and perspective views showing a first embodiment of a slidable apparatus, which may be used in a solar panel mounting system. 
         FIGS. 2A-2B  are cross-sectional and perspective views showing the  FIG. 1A-1C  slidable apparatus mounted to a carrier. 
         FIG. 3A-3C  are cross-sectional, top, and perspective views showing a slidable apparatus in a second embodiment. 
         FIGS. 4A-4B  are cross-sectional and perspective views showing the  FIG. 3A-3C  slidable apparatus mounted to a rail. 
         FIG. 5A-5C  are cross-sectional, top, and perspective views showing a slidable apparatus in a third embodiment. 
         FIGS. 6A-6B  are cross-sectional and perspective views showing the  FIG. 5A-5C  slidable apparatus mounted to a rail. 
         FIGS. 7A-7C  are cross-sectional, top, and perspective views showing a slidable apparatus in a fourth embodiment. 
         FIGS. 8A-8B  are cross-sectional and perspective views showing the  FIG. 7A-7C  slidable apparatus mounted to a rail. 
         FIG. 9  is a cross-sectional view showing a slidable apparatus in a fifth embodiment. 
         FIG. 10  is a cross-sectional view showing the  FIG. 9  slidable apparatus mounted to a rail. 
         FIG. 11A  is a perspective view showing one exemplary solar panel carrier with  FIG. 9  slidable apparatuses attached thereto. 
         FIG. 11B  is an alternate perspective view showing an underside of the  FIG. 11A  carrier. 
         FIG. 12  is a perspective view showing the  FIG. 11A-B  carrier mounted to a  FIG. 10  rail. 
         FIGS. 13A-13B  are perspective views showing another exemplary solar panel carrier with a  FIG. 1A-1C  slidable apparatus attached thereto, mounted on rails. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following detailed description, reference is made to the accompanying drawings which form a part hereof, and which illustrate specific embodiments of the invention. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to make and use them. It is also understood that structural, logical, or procedural changes may be made to the specific embodiments disclosed herein. 
     Described herein is a slidable apparatus for use in a mounting system that supports a simplified installation of solar panels. The apparatus is in the form of a moveable “truck” which may be used with a solar panel carrier of the type described in co-pending application Ser. No. 12/______ entitled “A MOUNTING SYSTEM SUPPORTING SLIDABLE INSTALLATION OF A PLURALITY OF SOLAR PANELS AS A UNIT” by John Bellacicco, John Hartelius, Henry Cabuhay, Tom Kuster, Michael Monaco, and Martin Perkins. (attorney docket no. F4500.1001/P1001), filed concurrently with this application, the disclosure of which is incorporated by reference herein. 
     Generally, the truck (embodiments of which are illustrated in  FIGS. 1 ,  3 ,  5 ,  7  and  9 ) is designed to be attached to an underside of a solar panel carrier (exemplary carriers  1100  and  1300  are shown in  FIGS. 11A-B  and  13 A-B), which is intended to hold multiple solar panels together as a single unit and provide a means for installing the solar panels as a unit onto rails in a manual or semi-automated installation system. The trucks, e.g.,  900   a ,  900   b ,  900   c ,  900   d  shown in  FIGS. 11A-B  and  12 , are intended to slidably support the carrier on a rail system. In general, the sliding rail system is comprised of two parallel rails ( 1040   a ,  1040   b , as shown in  FIG. 12 ) which are mounted one higher than the other from a support surface. When solar panels are installed thereon the rails tilt the panels at a desired angle. Each of rails  1040   a ,  1040   b  is attached to a foundation, e.g.,  1250 . Five examples of rails which can be used are shown in  FIGS. 2A-2B  (rail  240 ),  4 A- 4 B (rail  440 ),  6 A- 6 B (rail  640 ),  8 A- 8 B (rail  840 ), and  FIG. 10  (rail  1040 ). Each carrier, e.g.,  1100 ,  1300  has a plurality of trucks, preferably at least 4, fastened to the bottom side of the carrier. Generally, there are at least two trucks per rail per carrier which are designed to slide along the rails so carriers, e.g., 1100, 1300, can be easily moved to a desired location along the rails. The truck is also constructed in such a way that it prevents the carrier from detaching from the rail. 
     Each truck is capable of sliding along the rail while supporting the carrier dead weight and providing the least amount of frictional resistance. The truck is designed to maintain a low coefficient of friction, preferably less than or equal to 0.15 between the body of the truck (or material applied thereon) and a top surface of a head of the rail, to facilitate movement of a carrier along a rail. Low frictional resistance can be obtained by use of rollers, ball bearings, or low friction materials. Once in the desired location, the slide trucks transfer all imposed loads through the rail structure to the foundation. The trucks are designed so as to not impede any ability to stack or nest the carriers for transit. 
     In a first embodiment, shown in  FIGS. 1A-1C , truck  100  comprises a body  102  and a pair of arms  104   a ,  104   b  on opposite sides of the body  102 . The arms  104   a ,  104   b  are designed to hold the truck  100  on a rail  240 , but allow the truck  100  to slide longitudinally along the rail  240 , for example, as shown by rail  240  and truck  100  in  FIGS. 2A-213 . The arms  104   a ,  104   b  can be curved so as to engage the underside of the head  242  of the rail  240  and prevent the truck from moving in any direction except longitudinally. Truck  100  also has a plurality of securing areas  120   a ,  120   b ,  120   c  and  120   d  for attaching the truck  100  to the underside of a panel mounting carrier, such as the carrier  1100  shown in  FIG. 11B  or carrier  1300  shown in  FIG. 13B . The securing areas  120   a ,  120   b ,  120   c  and  120   d  shown in  FIG. 1  may be holes in the body  102  through which a fastener (not shown) can be inserted, however, it should be understood that the holes  120   a ,  120   b ,  120   c  and  120   d  could be threaded (for use with screws), or other attachment means could be used to attach the truck  100  to a carrier, e.g.,  1300 , such as glue, or Velcro®. 
     Truck  100  may be configured with a ball bearing  110  mounted on the underside of body  102 , as shown in  FIG. 1A . The ball bearing  110  is generally partially recessed within body  102  and held in place by a bearing lock  112 . As such, body  102  can be thicker than arms  104   a ,  104   b , to accommodate a portion of ball bearing  110  therein. It should be understood that a roller (such as shown in truck  700  in  FIGS. 7A-7C ) could be used with truck  100  in a similar manner. 
       FIGS. 2A and 2B  show truck  100  mounted on a rail  240  having a head  242 . The rail  240  preferably has a T-shaped cross-section, with rail head  242  comprising a pair of flanges  244   a ,  244   b . Flanges  244   a ,  244   b  in  FIGS. 2A and 2B  have rounded ends, but it should be understood they could be rectangular as well. The arms  104   a ,  104   b  of truck  100  are designed to surround the head  242  of the rail  240 , so as to secure the truck  100  to the rail  240 . Rail  240  can also have a rounded groove  246  on a top surface of rail head  242 , to engage a ball bearing  110  or other means mounted to or within the truck  100 . 
     Though a T-shaped cross-section of rail  240  is illustrated, it should be understood any cross-section could be used. Generally, such a cross-section could correspond with an interior space defined by the body  102  and arms  104   a ,  104   b  of the truck  100 . 
     In another embodiment, shown in  FIGS. 3A-3C , a truck  300  comprises a body of  302  and curved arms  304   a ,  304   b . As shown here, body  302  and arms  304   a ,  304   b  are of the same thickness; truck  300  thus can be made from a single piece of rolled steel. Like truck  100 , truck  300  has a plurality of securing areas  320   a ,  320   b ,  320   c  and  320   d  for securing the truck  300  to the underside of a corresponding carrier  300 . Optionally, as shown by dotted lines  306  in  FIG. 3A , truck  300  can have a low friction surface attached thereon (such as Teflon®) that allows it to slide along a rail, e.g., rail  440  shown in  FIGS. 4A-4B , providing a lower coefficient of friction than if the body  302  contacted the rail  440  directly. 
     The rail  440  of  FIGS. 4A-4B  is similar to rail  240  shown in  FIGS. 2A and 2B , but without a groove. Truck  300  is shown mounted surrounding the rail head  442 , which comprises rounded end flanges  444   a ,  444   b.    
     In yet another embodiment, shown in  FIGS. 5A-5C , truck  500  has a generally rectangular shape. Like truck  100 , truck  500  comprises a body  502  and rectilinear arms  504   a ,  504   b  to engage a rail. Truck  500  has a plurality of securing areas  520   a ,  520   b ,  520   c  and  520   d , which are the same as the securing areas of trucks  100 ,  300 , for securing the truck  500  to a corresponding carrier, e.g.,  1100 ,  1300 . Truck  500  includes a surface  506  of low friction material (such as Teflon®) on the bottom of body  502 . As shown in  FIGS. 6A and 6B , when truck  500  is mounted on rail  640 , surface  506  will contact the head  642  of the rail  640 , which has rectangular shaped flanges  644   a ,  644   b.    
     In a further embodiment, shown in  FIGS. 7A-7C , truck  700  has one or more rollers  710  inset in body  702 . Roller  710  can be, for example, a solid cylindrical structure or hollow wheel. Arms  704   a ,  704   b  are curved like those of trucks  100  and  300 . Also shown in  FIGS. 7A-7C  is an arrangement with 2 securing areas  720   a  and  720   b . Since each roller  710  is configured to be aligned with a rectangular groove  846  on a corresponding rail, as shown in  FIGS. 8A-8B , the securing areas are arranged so as to be located within that groove  846 . Thus, a fastener can be used that is not flush with the bottom surface of the body  702 , and it will not interfere with slidability of the truck  700  along a rail. Although the roller  710  in  FIGS. 7A-7C  is shown to be partially inset into body  702 , rollers  710  could also be housed nearly entirely inside body  702 , so a groove  846  is not required. In such a case, only the very bottom of roller  710  would extend below the bottom surface of body  702 . 
     The rail  840  of  FIGS. 8A-8B  is similar to rail  240  shown in  FIGS. 2A and 2B , but with a rectangular groove  846 . It is understood that the shape of the groove  846  does not have to be rectangular, and can have whatever shape is needed to accommodate truck  700 . Truck  700  is shown mounted surrounding the rail head  842 , which comprises rounded end flanges  844   a ,  844   b.    
     In yet another embodiment, shown in  FIG. 9 , truck  900  comprises a wheel  910  inset in body  902  suspended via an axle  908  which runs through body  902  and is secured in an attachment structure  1130  of a carrier, e.g.,  1100  (as shown in  FIG. 11 ). Wheel  910  can be steel wheel, but it can also be constructed of plastic and rubber. Arms  904   a ,  904   b  are curved like trucks  100 ,  300 . The trucks body  902  extends to a top of attachment structure  1130  so as to engage a screw or locking bolt  912  that extends through the attachment structure  1130  and further secures the truck  900  to the carrier  1100 . 
     The rail  1040  of  FIG. 10  is similar to rail  240 , with rounded groove  846 , but is constructed to mate with the  FIG. 9  truck such that truck  900  surrounds rail head  1042 , which comprises rounded end flanges  1044   a ,  1044   b . 
       FIG. 11A  shows a plurality of  FIG. 9  trucks  900   a ,  900   b ,  900   c  and  900   d  mounted to an exemplary carrier  1100 . Carrier  1100  is comprised of a plurality of elongated members  1110   a ,  1110   b ,  1110   c  and  1110   d , all connected transversely by attachment structures  1130   a ,  1130   b . The trucks  900   a ,  900   b ,  900   c  and  900   d  are attached to the bottoms of attachment structures  1130   a ,  1130   b .  FIG. 11B  is an underside view of the same carrier  1100 , showing truck  900   b , wheel  910  and axle  908 , mounted to attachment structure  1130   a.    
       FIG. 12  shows the  FIGS. 11A-B  carrier  1100  mounted to a pair of  FIG. 10  rails  1040   a  and  1040   b , which are attached to a common foundation  1250 . 
     Another exemplary carrier  1300  with a plurality of solar panels  1320   a - g  mounted thereon is shown in  FIGS. 13A and 13B  being mounted to  FIG. 2  rails  240   a ,  240   b  via attachment structures  1330   a  and  1330   b , which are in the form of grooves in the underside of carrier  1000 .  FIG. 1  trucks  100   a ,  100   b  are shown mounted in attachment structure  1330   b.    
     Mounting carriers, e.g.,  1100 ,  1300 , onto associated rails may be accomplished by manually aligning the trucks, e.g.,  100 ,  300 ,  500 ,  700 ,  900  attached to a carrier with the ends of the rails, e.g.,  240 ,  440 ,  640 ,  840 ,  1040 , and sliding the carriers into position. Alternatively, a semi-automated carrier mounting and delivery system may be used at the end of each solar array row. One such delivery system is described in more detail in co-pending application Ser. No. 12/______, entitled “AUTOMATED INSTALLATION SYSTEM FOR AND METHOD OF DEPLOYMENT OF PHOTOVOLTAIC SOLAR PANELS, to John Bellacicco, Tom Kuster, Michael Monaco and Tom Oshman (attorney docket no. F4500.1002/P1002), filed concurrently with this application, the disclosure of which is incorporated by reference herein. As discussed in this application, each carrier mounts and supports a plurality of solar panels as a unit, is set on the rails by a robotic system and moved along, thereby simplifying installation time and lowering cost. 
     Although trucks  100 ,  300 ,  500 ,  700 ,  900  are shown as being mounted to carriers  1100 ,  1300 , each supporting a plurality of solar panels, trucks can also be mounted to a carrier supporting only one solar panel, or can be mounted directly to the backside of a single solar panel support structure or an individual solar panel, to allow it to be slid along mounting rails. 
     While several embodiments have been described in detail, it should be readily understood that the invention is not limited to the disclosed embodiments. Rather the embodiments can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described. Although certain features have been described with some embodiments of the carrier, such features can be employed in other embodiments of the carrier as well. Accordingly, the invention is not limited by the foregoing description, but is only limited by the scope of the appended claims.