Patent Publication Number: US-2011049322-A1

Title: Novel Design For Mounting Assembly For Photovoltaic Arrays

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates generally to mounting assemblies used for installation of photovoltaic arrays. More particularly, the present invention relates to improved designs of mounting assemblies which allow for their rapid assembly and rapid height adjustment. 
       FIG. 1  shows a conventional mounting assembly  10  used for installation of photovoltaic panels. Assembly  10  includes a base component  12  and a top component  14 . Top component  14  has disposed at one end a supporting plate  16 , and at another end a tube portion  18 . During the assembly of a photovoltaic panel, the appropriate frame and railing are built on supporting plate  16 . A photovoltaic panel (not shown to simplify illustration) is ultimately secured on the railing. 
     Tube portion  18  at one end connects to supporting plate  16  using set screws. At the other end, tube portion  18  connects to base component  12 . Specifically, base component  12  has a cavity which is large enough to receive tube portion  18  as shown in  FIG. 1 . As a result, during assembly of mounting assembly  10 , tube portion  18  is inserted into the cavity of base component  12  to secure at least a portion of the top component inside the base component. 
     Unfortunately, the conventional mounting assembly suffers from several drawbacks. By way of example, installing conventional mounting assemblies is a long and arduous task. It is not enough to assemble conventional mounting assemblies as shown in  FIG. 1 . A significant amount of time is spent leveling the mounting assembly. Typically surfaces are machined (e.g., using a laser for tight tolerances) and/or shims are used to strive for a leveled surface through various stages of component assembly process. 
     As another example, it is difficult to adjust a height of the conventional mounting assembly. Movement of various interconnected components comes into play to adjust the conventional assembly&#39;s height and in some instances, where the amount of adjustment is not significant, shims may be used. Regardless of how a height adjustment is accomplished, it is clear that the above-mentioned drawbacks associated with leveling compound the process of height adjustment in a conventional design. 
     As yet another example, even after enduring such cumbersome efforts, often times the resulting mounting assembly does not have the requisite flatness or is not level. Consequently, subsequent photovoltaic panels installed on conventional mounting assemblies are frequently crooked and/or are bent. Such crooked and bent panels are undesirable as they reduce the efficiency of the panel. 
     As yet another example, the conventional design with all the different interconnecting components involved, represents a complicated design that is expensive to implement. 
     What is therefore needed is a novel system and method of assembly a mounting assembly which does not suffer from the drawbacks encountered by conventional designs. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, this invention provides novel systems and methods for implementing improved designs of mounting assemblies which allow for rapid assembly and rapid adjustment of height. 
     In one aspect, the present invention provides a mounting assembly. The mounting assembly includes: (i) a pipe having a first threaded end and a second threaded end; (ii) a base component having a base portion and a threaded connecting portion; (iii) a top component having a top portion and a threaded portion, the top component is capable of supporting a photovoltaic panel thereon; and (iv) wherein the first threaded end of the pipe and the threaded connecting portion of the base component include threads such that the first threaded end rotatably engages in a first direction with the threaded connecting portion, and the second threaded end of the pipe and the threaded portion of the top component include threads such that the first threaded end rotatably engages in a second direction with the threaded portion of the top component, the first direction is opposite to the second direction, and the first threaded end and the second threaded end are substantially cylindrical. Preferably, the pipe&#39;s cross section between the first threaded end and the second threaded end is a shape that is at least one of circular, triangular, and rectangular. The pipe may be made from an engineered material. The pipe is preferably made from a material that includes one member selected from a group consisting of aluminum, steel, fiberblass, plastic, alloy and treated materials that are galvanized, electrogalvanized and annealed. Preferably, the pipe has a diameter that is between about 1.25 inches and about 3.0 inches. 
     In one embodiment of the present invention, the base component is designed to be secured in concrete. 
     In preferred embodiments of the present invention, the first threaded end and the second threaded end include threads which extend to a depth that is between about 1 inch and about 3 inches, and more preferably, between about 1 inch and about 2 inches. In further preferred embodiments, the threaded connecting portion of the base component and the threaded portion of the top portion include threads which extend to a depth that is between about 1 inch and about 3 inches, and more preferably, between about 1 inch and about 2 inches. 
     In preferred embodiments of the present invention, the mounting assembly includes a frame that is capable of fastening to the top portion of the pipe. Further, the mounting assembly may include a rail which is secured upon the frame and is capable of having attached thereto a photovoltaic panel. 
     In another aspect, the present invention includes method for assembling a mounting assembly. The method includes: (i) immobilizing a base component on a surface, the base component including a base portion and a threaded connecting portion which includes threads; (ii) obtaining a pipe having first threaded end and a second threaded end, each of the first and the second threaded ends include threads; (iii) rotatably engaging threads of the first threaded end with threads of the threaded connecting portion of the bottom component to connect the bottom component and the pipe and forming a bottom subassembly; and (iv) rotatably engaging threads of the second threaded end with threads of the threaded portion of the top component to connect the bottom subassembly with the top component and forming the mounting assembly. Immobilizing may include securing a bottom part of the base component inside concrete. 
     In preferred embodiments of the present invention, inventive methods may include the further step of adjusting a height of the mounting assembly by rotating the threads of the first threaded end with respect to the threads of the threaded connecting portion. Inventive methods may further include the step of adjusting a height of the mounting assembly by rotating the threads of the second threaded end with respect to the threads of the threaded portion. 
     Preferred embodiments of the present invention may include the further step of leveling a height of the mounting assembly across a radial direction of the mounting assembly by rotating the threads of the first threaded end with respect to the threads of the threaded connecting portion. Inventive methods may further include the step of leveling a height of the mounting assembling across a radial direction of the mounting assembly by rotating the threads of the second threaded end with respect to the threads of the threaded portion. 
     Preferred embodiments may yet include the further step of fastening a frame to the top component using a fastening subassembly. The fastening subassembly may include U-shaped bolts straight bolts, screws, tabs with mounting holes, or other means of secondary attachment. The inventive method may further include the step of communicatively coupling a rail designed to secure a photovoltaic panel on the frame. 
     In another aspect, the present invention provides a mounting assembly. The mounting assembly includes: (i) a means for adjusting height of the mounting assembly, the means of adjusting including a first threaded end and a second threaded end; (ii) a means for immobilizing the mounting assembly including a threaded connecting portion; (iii) means for supporting a frame installed on the mounting assembly, the means for supporting including a threaded portion; and (iv) wherein the first threaded end and the threaded connecting portion include threads such that the first threaded end rotatably engages in a first direction with the threaded connecting portion, and the second threaded end and the threaded portion include threads such that the first threaded end rotatably engages in a second direction with the threaded portion, and the first direction is opposite to the second direction. 
     In preferred embodiments of the present invention, a pitch of threads on first and second threaded end  110  and  112 , threaded portion  114  and threaded connecting portion  116  is a value that is between about 0.03 inches and about 0.11 inches, and is preferably between about 0.06 inches and about 0.11 inches. 
     The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following descriptions of specific embodiments when read in connection with the accompanying figures. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a conventional mounting assembly. 
         FIG. 2A  shows a mounting assembly design, according to one embodiment of the present invention, for installing photovoltaic panels. 
         FIG. 2B  shows an exploded perspective view of the mounting assembly of  FIG. 2A . 
         FIG. 2C  shows a mounting assembly design, according to an alternative embodiment of the present invention, in which a pipe has a rectangular intermediate portion. 
         FIGS. 3A-3E  show a progression of the assembly process, according to one embodiment of the present invention, for the mounting assembly design shown in  FIG. 2A . 
         FIG. 4  shows a photovoltaic panel array installed using mounting assembly design shown in  FIG. 2A . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In the following description numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that the present invention may be practiced without limitation to some or all of these specific details. In other instances, well known process steps have not been described in detail in order to not unnecessarily obscure the invention. 
       FIG. 2A  shows a perspective view of a mounting assembly, according to one embodiment of the present invention, used for installation of photovoltaic panels. Details of the various components involved in the manufacture of assembly  100  are shown in greater detail in  FIG. 2B  discussed below. 
       FIG. 2B  shows an exploded front view of mounting assembly  100 . Mounting assembly  100  includes a pipe  108  disposed between a top component  104  and a base component  102 . Pipe  108 , top component  104 , a base component  102  may be, but are not necessarily, made from similar material, which includes any engineered material. Preferably, however, pipe  108 , top component  104  and base component  102  are made from at least one member selected from a group consisting of aluminum, steel, fiberglass, plastic, alloy, and treated materials that are galvanized, electrogalvanized and annealed. 
     Pipe  108  has a first threaded end  110  and a second threaded end  112 . Each threaded end includes threads thereon. Base component  102  includes a threaded connecting portion  116  and a base portion  122 . During installation of a photovoltaic panel, at least a bottom part of base portion  122  is preferably designed to be submerged in concrete. Threaded connecting portion  116  includes threads such that first threaded end  110  rotatably engages in a first direction with threaded connecting portion  116 . In other words, the threads of first threaded end  110  are capable of rotating around the threads of threaded connecting portion  116  in a particular direction. 
     Top component  104  includes a threaded portion  114  and a top portion  106 . Disposed on top portion  106  are cross-bars  120  using a pair of U-bolts  118 , as shown in  FIG. 2B . Threaded portion  114  includes threads such that threaded portion  114  rotatably engages in second direction with second threaded end  112 —i.e., threads of threaded component  114  are capable of rotating around the threads of second threaded end  112 . It is possible that the first direction and second direction are the same direction. However, for effective leveling of the partial or full mounting assembly, the second direction is preferably opposite to the first direction. 
     In accordance with one embodiment of the present invention, the threads on first and second threaded end  110  and  112 , threaded portion  114  and threaded connecting portion  116  extend to a depth that is between about 1 inch and about 3 inches, preferably extend to a depth that is between about 1 inch and about 2 inches, and more preferably extend to a depth that is about 1.5 inches. 
     In preferred embodiments of the present invention, the pitch of threads on first and second threaded end  110  and  112 , threaded portion  114  and threaded connecting portion  116  is a value that is between about 0.03 inches and about 0.11 inches, and is preferably between about 0.06 inches and about 0.11 inches. 
     Although according to  FIG. 2B  the interior of threaded connecting portion  116  and threaded portion  114  are threaded and the exterior of first threaded end  110  and second threaded end  112  are threaded, vice versa is also possible—i.e., exterior of threaded connecting portion  116  and threaded portion  114  are threaded and that interior of first threaded end  110  and second threaded  112  end are threaded. 
     Pipe  108  may be any shape, so long as first threaded end  110  and second threaded end  112  are cylindrical to effect rotational displacement. Moreover, an intermediate portion of pipe  108  that is located between first threaded end  110  and second threaded end  112  can have any shape. By way of example, the intermediate portion of pipe  108  has a cross-section that has a shape selected from a group consisting of circular, triangular and rectangular. The intermediate portion, which may well be a non-cylindrically shaped, is either welded to the cylindrically-shaped first and second threaded ends or is fastened using well known fastening hardware to the threaded ends. In the event pipe  108  is fabricated using a mold, then the intermediate portion is contiguous to the cylindrical threaded ends, and neither welds nor fastening assemblies are required. 
       FIG. 2C  shows a mounting design assembly  200  having a pipe  208  with a rectangular shaped intermediate portion. Other components (e.g., base component  202  and top component  204  of assembly  200 ) are substantially similar to their counterparts (i.e., base component  102  and top component  104 ) shown in  FIG. 2B . 
       FIG. 3A-3E  shows a progression of the assembly process, according to one embodiment of the present invention, of the inventive mounting assemblies. According to  FIG. 3A , a base component  102 , in its upright vertical position, is immobilized. This may be accomplished by submerging a bottom part of base component  102  in concrete, which subsequently hardens and as a result, secures base component  102  in the concrete. Before the concrete hardens, however, base component  102  is leveled using techniques well known to those skilled in the art. Alternatively, before leveling, the base may be secured by well known fastening hardware to a supporting surface (e.g., a concrete slab or a rooftop). 
     Next, as shown in  FIG. 3B , a pipe  108  is communicatively coupled to base component  102  by engaging their respective threads and form a bottom subassembly  130 . In its engaged position, first threaded end  110  of pipe  108  rotates around a radial direction of threaded connecting portion  116  and also moves down along its axis, i.e., a length of threaded connecting portion  116 . 
     At the other end of pipe  108 , a top component  104  is similarly connected. Specifically, as shown in  FIG. 3C , threaded portion  114  of top component  104  is communicatively coupled to a second threaded end  112  by engaging their respective threads. As a result, top component  104  connects to bottom subassembly  130  to form an adjustable subassembly  132 . In its engaged position, threaded portion  114  of top component  104  rotates around a radial direction of second threaded end  112  and also moves down along its axis, i.e., a length of second threaded end  112 . 
     The above-mentioned threaded connections between various components allow the present invention to rapidly and easily adjust the height of the inventive mounting assemblies. As shown in  FIG. 3D , by rotating first threaded end  110  relative to base component  102  in a clockwise and/or counter-clockwise direction and/or rotating threaded portion  114  of top component  104  relative to pipe  106  in a counter-clockwise and/or clockwise direction, the present inventions provide the advantages of rapidly leveling the inventive mounting assemblies during installation of a photovoltaic panel. This feature of the present invention represents a marked improvement over the conventional design. Specifically, the present invention reduces the number of interconnecting components required to assemble the inventive mounting assemblies. By reducing the number of components and offering simple connecting designs, the present invention realizes an increased throughput and a decreased cost of assembly that is not realized by the conventional design of mounting assembly. 
       FIG. 3E  is a front view of the mounting assembly  100  resulting after implementing the various steps mentioned above and presents a different view of mounting assembly  100  shown in  FIG. 2A .  FIGS. 2A and 2B  shows plates (not specifically denoted by a reference numeral to simplify illustration) which attach by welding to base component  102  and top component  104 . 
     After mounting assemblies are assembled according to the above-mentioned inventive processes, preferably a frame is built on cross-bars  120  (of  FIG. 2B ). Next, a rail (e.g., about 20 feet long) is installed above the frame and is designed to secure photovoltaic panels thereon. In preferred embodiments of the present invention, two mounting assemblies combine to form a structure upon which frames and rails are built so that a photovoltaic panel having a length that is between about 2 feet and about 8 feet is installed. It is noteworthy that when two mounting assemblies, according to the present invention are used to install a photovoltaic panel, the tasks of adjusting height and leveling are significantly easy over the conventional design. Both height adjustment and leveling of the inventive mounting assemblies is accomplished by simply rotating threads on first threaded end  110  relative to threads on threaded connecting portion  116  and/or by rotating threads on second threaded end  112  relative to threads on threaded portion  114 . 
       FIG. 4  shows a photovoltaic panel array  400  installed using mounting assembly design shown in  FIG. 2A . By way of example,  FIG. 4  shows three rows of mounting assemblies— 450 ,  460  and  470 , for array  400 . Array  400 , however, may consist of more or less than three rows of mounting assemblies. Furthermore, more or less than two mounting assemblies may be used to secure a single photovoltaic panel, as shown in  FIG. 4 . However, it is preferable to use two mounting assemblies (such as the one shown in  FIG. 2A ) to secure a single photovoltaic panel. 
     Although illustrative embodiments of this invention have been shown and described, other modifications, changes, and substitutions are intended. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the disclosure, as set forth in the following claims.