Patent Abstract:
A new mounting system for elevating and supporting objects such as solar panels and satellite dishes either upon a roof or above ground.  
     The mounting system utilizes extruded aluminum horizontal members and a means to secure an object upon the horizontal members. This means to secure is an end clamp having a lip for gripping and either having a heeled distal end or one that instead of incorporating a heel, uses a wedge or half-moon washer to perform the same function. The heel, positioned above the horizontal member prevents the end clamp from rotating as it is screwed into frictional engagement with the member. Such rotation is undesirable since it would reduce the area of the lip in gripping contact with an adjacent object.

Full Description:
CLAIM OF PRIORITY  
       [0001]    This is a continuation-in-part application that claims the benefit of U.S. patent application bearing Ser. No. 09/758,407 filed Jan. 10, 2001 which claimed priority to U.S. Provisional Application bearing serial No. 60/176,126 filed Jan. 14, 2000. 
     
    
     
       BACKGROUND OF INVENTION  
         [0002]    The present invention relates to the building industry and specifically to mounting equipment and a method for supporting an object over a roof or above ground.  
           [0003]    Mounting equipment or sometimes referred to herein as a mounting system, is used to attach objects such as solar panels including photovoltaic (PV) modules and solar pool heating panels, solar heating collectors (referred to sometimes as domestic hot water collectors), satellite dishes, air conditioning units, etc. The mounting equipment is typically fastened at its base end to either a foundation, directly to the earth, or to support structures on a building such as roof rafters.  
           [0004]    The roofs of building structures have been used for placement of objects with the primary reason for location upon a roof is the lack of alternative space.  
           [0005]    Air conditioning units, because of their relative heavy weight, provide a downward force upon the roof in any weather condition. However, a problem exists for other objects such as satellite dishes and solar panels, which can, in certain windy conditions, be lifted off the mounting equipment to which they are attached because the force of the wind applied against the surface area on the side or underside of the object creates an uplift condition which is greater than the attachment strength of the mounting equipment.  
           [0006]    Besides the need for compliance with governmental building code requirements, a more time efficient method for installing a mounting system, particularly to a roof, is highly desired by installers. A faster installation reduces the labor costs associated with each install.  
           [0007]    One of the problems with present installations is the fact that more than one lag bolt or other type of fastening bolt is required for each mounting plate that is fastened to the roof. The risk is high that some of the lag bolts will drill at an angle other than perpendicular to the roof rafter. The severity of the angle and the trajectory of the lag bolt penetration into the rafter could cause the rafter to split; further reducing the structural integrity of the mounting system.  
           [0008]    For many years, existing solar mounting systems were installed using a threaded pipe nipple that screwed into a mounting plate commonly called a “floor flange” in the trade. The threaded floor flange has been commercially available as a standard plumbing item for many years. U.S. Pat. No. 5,603,187 issued to Merrin et al. is typical of the prior art.  
           [0009]    The Merrin design, as well as similar prior art, have a common design limitation. They require multiple bolts be installed offset from the threaded vertical support flange or stanchion. Also, because of the floor flange design, it would not permit industry standard flashing to install flat on the roof; primarily due to the base flashing circumference interfering with the height of the floor flange.  
           [0010]    A mounting system based upon the Merrin patent, while appropriate for roof mounting of heavy objects such as air conditioners, is not practical for use with lighter objects such as solar panels or satellite dishes. The Merrin design precludes direct (bolted) attachment to the roof rafter by each of the mounting holes present on the base plate; primarily due to the width of the rafter in relation to the spacing of the mounting holes. Further, Merrin views rafter attachment as a limitation and therefore teaches away from using rafters for structural support. Therefore, Merrin teaches attachment to the roof decking which generally consists of only ½″ plywood or a composite sheeting; either of which do not provide the strength of a bolt mounted to a rafter in an uplift condition.  
         SUMMARY OF INVENTION  
         [0011]    The disclosure contained in U.S. Pat. No. ______ is incorporated herein by reference.  
           [0012]    This invention presents a mounting system for supporting objects such as solar panels and satellite dishes. Also claimed is an end clamp that provides superior frictional engagement of the object to the mounting equipment.  
           [0013]    Definitions  
           [0014]    Alignment Means—a means to align a roof mount such as a guide tunnel.  
           [0015]    Fastening Means—a means to fasten the base mount portion of the mounting equipment to a roof rafter, or ground racking system.  
           [0016]    Support Means—a term used to collectively refer to the various parts necessary to support an object. Support means includes one or more horizontal members upon which the weight of an object will be supported, and clamps to secure the object to the horizontal member(s).  
           [0017]    Attachment Means—Means by which the support means is attached to the base mount. One example is by the use of a bolt threadably engaging a stanchion located on the opposite side of a horizontal member. The base portion of the stanchion is threaded into the base mount.  
           [0018]    Securing Means—Means to secure the object upon the horizontal member(s). The securing means comprises either a pair of end clamps each having a raised distal heel, or a wedge or half-moon washer and substitute for a heel and used with end clamps having no heel. The securing means is secured to the adjacent horizontal member and, as tightened, it frictionally engages a portion of the object to maintain it in a secure position upon the horizontal member.  
           [0019]    The mounting equipment comprises at least one base mount and associated support clamps and support rails, and are not limited to roof top installations. They can be installed over pipe supports or attached to other support systems or ground racking systems. Types of ground racking systems include, but are not limited to pipe supports, pole mounted installations, building facades and patio covers.  
           [0020]    First Example  
           [0021]    By way of a first example, for new construction or reroofing, a roof mount would be attached prior to installation of the roof flashing. The component parts for supporting a solar panel or satellite dish would be assembled and attached to the roof mount over the flashing. Features of the invention are as follows:  
           [0022]    1. a new base mount (also referred to as a roof mount) having a threadable elongated member or stanchion which requires a single lag bolt positioned directly beneath the stanchion for fastening to a roof rafter. A guide tunnel is also provided on the roof mount for proper drill angle into the rafter.  
           [0023]    2. A support design comprising either a composite or aluminum extruded horizontal members and associated equipment for attachment to a plurality of roof mounts which will support a mounted object such as a solar panel. Although a particular C-shaped design is depicted in the drawings, any design to facilitate the securing means is considered to be part of the support design. The purpose of the horizontal members is to provide: 1) support for the weight of an object positioned upon the member; and, 2) to facilitate the securing means of the object to the member by the use of a pair of end clamps for each member used.  
           [0024]    3. A securing means for securing the end of a supporting object to the support design. One example of the securing means is a pair of cooperating end clamps each having a raised heel which enhances frictional engagement when being secured into position upon a horizontal member with an object to be secured therebetween.  
           [0025]    Second Example  
           [0026]    In a second example, the mounting system, instead of being fastened to a new roof rafter for support, is operatively fastened either: a) upon existing roofs or framework; or, b) over pipe supports or other support systems not necessarily located upon a roof. Here, the roof mount referred to earlier is not utilized although the other features described in paragraphs  2 ,  3 , and  4  above pertain. For this example, the roof mount is replaced as the means to fasten the mounting system with an alternative means such as that described in U.S. Pat. No. 5,746,029 issued to Ullman and which is herein incorporated by reference.  
           [0027]    Roof Mount (For Example 1)  
           [0028]    In order to utilize my mounting system, a roof mount must first be fastened to a rafter. The roof mount can be manufactured from any material commonly used in the building trade to support objects upon a roof. Preferably, the mount is machined from aluminum and comprises a threaded cavity with an insertion opening for threadably receiving a vertical stanchion. Directly below the cavity is an aperture for insertion of a lag bolt for attachment to the rafter. This is a unique feature of my support base. Only one lag bolt or other type of fastening bolt is required. For a one bolt design, having the attachment force positioned directly beneath the stanchion provides the highest level of attachment strength.  
           [0029]    Additionally, a special hollow can be machined at the base of the channel to allow clearance for the bolt head when installed so that it does not contact the bottom surface area of the stanchion. This permits maximum threadable engagement of the stanchion to the base.  
           [0030]    The base section of the roof mount comprises a base for direct contact with the decking surface of a roof and a vertically extending cylindrical member having the threaded cavity and an offset wall having a guide tunnel. It is not necessary that, the guide tunnel be part of the cylindrical member. It is however, preferable to maintain a minimum distance between channel and guide tunnel so that it is easy to use the guide tunnel to drill a pilot hole into a rafter and to thereafter align the pilot hole with the aperture by sliding the base section a minimal distance.  
           [0031]    The distance between the cavity and guide tunnel however, must be sufficient so as not to compromise the overall structural integrity of the base section.  
           [0032]    In an alternative design, the guide tunnel is not used and the roof mount base section simply incorporates my single bolt design described above which includes a base and a vertically extending cylindrical member having the threaded cavity.  
           [0033]    The base can be of any geometrical shape such as circular, rectangle or square. All that is required is that the geometrical shape be sized accordingly so that it does not interfere with the alignment or use of commercially available flashing to the roof.  
           [0034]    Once the lag bolt is fastened to the rafter, one end of the stanchion is screwed into the threaded cavity and the roof flashing is thereafter installed. For purposes of this specification, the base section and the stanchion/elongated member are collectively referred to as the roof mount. Although the mounting equipment may be installed days later, it is preferable to install the roof mount at this point.  
           [0035]    Installation of Mounting System Upon Support Means  
           [0036]    At least one horizontal member is provided as a means for supporting an object. The number of horizontal members used will be dependent upon the type of object to be supported.  
           [0037]    The horizontal member is preferably made from extruded aluminum and can be manufactured to any length. Each horizontal member has a track that can be used by either T-nuts or slidable inserts which have been designed to fit within and slide along this track.  
           [0038]    The T-nut has a threaded stem facing upward for engaging a clamp with a nut.  
           [0039]    The slidable inserts can be designed to have: 1) a hole for allowing the threaded stem of a screw or the like to pass upwards while the headed end of the screw can not; or, 2) a female threaded hole for cooperative securement with the clamps as will be discussed now.  
           [0040]    Clamps are used to grip an edge portion of an adjacent object and secure that object in position once the clamp has been fastened to the adjacent horizontal member. The gripping end of the clamp can have a surface which is flat or serrated. One clamp is provided for each slidable insert or T-nut. The clamp has a hole or aperture and is positioned so that either a fastening bolt can be inserted through and secured to the threaded hole of the threadable insert, or it can be secured to the upward facing threaded T-nut stem or, a threaded stem of sufficient length extends upwards through the aperture in the slidable insert and through the aperture in the clamp. Thereafter, a nut is used to threadably engage the threaded stem and fasten the clamp to the horizontal member.  
           [0041]    There are two types of clamps available: end clamps and bi-module clamps.  
           [0042]    Bi-module clamps are primarily used for securement of the sides of adjacent objects such as two solar panel modules.  
           [0043]    A module is a set of photovoltaic cells while a solar panel is a plurality of modules. End clamps would secure the sides of a solar panel. In any case, bi-module clamps are used to secure the sides of two adjoining solar modules to an adjacent horizontal member.  
           [0044]    Each horizontal member uses a pair of end clamps for securement of an object therebetween such as a solar panel. Each end clamp has a section or end referred to as a lip and preferably has a slight rise or heel on its bottom surface distally positioned from the lip end. The lip has a bottom surface that can be described as a gripping surface for engaging an object.  
           [0045]    The slight rise or heel provides functional advantages when securing an object to a horizontal member. First, the slight rise prevents twisting of the end clamp while it is being bolted or secured into position on the horizontal member. Second, when the gripping surface of the lip engages an object, the rise forces the clamp inward at 90 degrees to fully engage the object.  
           [0046]    In the case of a solar panel, this design prevents the end clamp from inadvertently separating the module frame from its glass. Also, the rise provides spring tension against the module frame, providing full engagement as the module laminate glass and frame flex under-extreme stresses caused by weather conditions such as high wind and snow.  
           [0047]    Besides an end clamp having a raised heel portion as described above, an alternative heel means for facilitating the securement of an object between two end clamps can be by more than one piece performing the same function such as a wedge or half-moon shaped washer positioned between an end clamp having no heel and the adjacent horizontal member. The purpose of the wedge or washer would be to angle the end clamp the same as if the end clamp had a raised heel portion. However, the single unitized piece is the preferred embodiment.  
           [0048]    The heel design incorporated into the end clamp can be of any length or shape. It does not have to be continuous across the extrusion so long as it can function to place inward pressure against an object to be secured between an end clamp and another end clamp or bi-module clamp.  
           [0049]    As stated earlier, the securing means, besides using a pair of end clamps having respective heels, can also employ a heel means located between each end clamp not having a heel and the horizontal member. The heel means can be, but should not be considered limited to, the use of a wedge or half-moon shaped washer or other protrusion that, when positioned between the bottom side of the end clamp and the top surface of the horizontal member, will provide the same inward force against the object when tightened to the horizontal support rail.  
           [0050]    The support system includes the horizontal members, slidable inserts or T-nuts, end clamps, optional bi-module clamps and the attachment means. 
       
    
    
     BRIEF DESCRIPTION OF DRAWINGS  
       [0051]    [0051]FIG. 1 is a perspective view and illustrates the position of the base section of the roof mount above a rafter and a drill positioned for drilling a pilot hole.  
         [0052]    [0052]FIG. 2 is a view taken along line  2 - 2  of FIG. 1 and which shows a drilled pilot hole.  
         [0053]    [0053]FIG. 3 indicates the roof mount displaced so that the pilot hole is in alignment with the support channel.  
         [0054]    [0054]FIG. 4 is an exploded view showing the lag bolt and stanchion relationship to the roof mount.  
         [0055]    [0055]FIG. 5 is a perspective view when the lag bolt and stanchion are assembled to the roof mount.  
         [0056]    [0056]FIG. 6 is a view taken along line  6 - 6  of FIG. 5.  
         [0057]    [0057]FIG. 7 is a perspective view illustrating the relationship of the assembled roof mount to flashing material.  
         [0058]    [0058]FIG. 8 is a perspective view of the package comprising a pair of elongated C-shaped members and associated equipment.  
         [0059]    [0059]FIG. 9 is a view taken along line  9 - 9  of FIG. 8.  
         [0060]    [0060]FIG. 9 a  is a end view of an elongated U-shape member depicting a linear positioning groove for a drill bit to make a hole.  
         [0061]    [0061]FIG. 10 is a perspective view illustrating the attachment of an elongated C-shaped member to a plurality of stanchions.  
         [0062]    [0062]FIG. 11 is a perspective view illustrating the slidable relationship of clamps relative to the C-shaped member and the positioning of a solar module.  
         [0063]    [0063]FIG. 12 is an exploded view of the relationship of an end clamp to a slidable insert.  
         [0064]    [0064]FIG. 13 is an exploded view of the relationship of a bi-module clamp to a slidable insert.  
         [0065]    [0065]FIG. 14 is a perspective view of an assembled solar panel having 4 modules.  
         [0066]    [0066]FIG. 15 is a side view showing a secured end clamp in relationship to the side of a solar panel.  
         [0067]    [0067]FIG. 16 is a view taken along line  16 - 16  of FIG. 15.  
         [0068]    [0068]FIG. 17 is a side view showing a secured bi-module clamp in relationship to the adjacent sides of two solar modules.  
         [0069]    [0069]FIG. 18 is a view taken along line  18 - 18  of FIG. 17.  
         [0070]    [0070]FIG. 19 is a perspective partial view of installation of an object and mounting equipment upon an existing roof utilizing the end clamp of my invention.  
         [0071]    [0071]FIG. 20 is a perspective partial view of installation of an object and mounting equipment upon pipe supports.  
         [0072]    [0072]FIG. 21 is a first alternative end clamp to that shown in FIG. 12.  
         [0073]    [0073]FIG. 22 is a second alternative end clamp to that shown in FIG. 12.  
         [0074]    [0074]FIG. 23 is an alternative clamping means utilizing a wedge.  
         [0075]    [0075]FIG. 24 is a first alternative design of a slidable insert to that shown in FIG. 12.  
         [0076]    [0076]FIG. 25 is an alternative means for providing a threaded member to that shown in FIG. 24. 
     
    
     DETAILED DESCRIPTION  
       [0077]    [0077]FIG. 1 through FIG. 6 illustrate the sequence for installing my roof mount to a rafter.  
         [0078]    [0078]FIG. 1 illustrates the general relationship of base section  17  to a roof having decking  12  and rafter  14 .  
         [0079]    Base section  17  comprises a base  16  and a cylindrical member  18  integral with and extending away from base  16 . Cylindrical member  18  has an offset wall area.  
         [0080]    As illustrated in FIG. 2, base section  17  has a guide tunnel  20  which extends from the top of cylindrical member  18  to the bottom of base  16 . The purpose of guide tunnel  20  is to provide perpendicular alignment of drill bit  24  to rafter  14  for the drilling of pilot hole  26 . Perpendicular alignment is important because it minimizes the probability of rafter splits, as can occur when a pilot hole is drilled which is not in perpendicular alignment to the rafter.  
         [0081]    Cylindrical member  18  further has a cavity  22 , the top of cavity  22  defining an insertion opening  28 . The walls of cavity  22  are threaded for engaging a stanchion  42  as will be discussed later.  
         [0082]    Defining the bottom of cavity  22  is top surface  30 . A hole  32  extends from top surface  30  through base  16 . Hole  32  has a common axis of symmetry with cavity  22  and is designed to accept the stem  36  of a fastening bolt  34  as shown in FIG. 4.  
         [0083]    With the alignment as shown in FIG. 1, drill bit  24  is inserted into guide tunnel  20  and a pilot hole  26  is drilled into rafter  14  as shown in FIG. 2.  
         [0084]    Base section  17  is then displaced along decking  12  until pilot hole  26  is aligned with hole  32  as shown in FIG. 3.  
         [0085]    [0085]FIG. 4 illustrates the relationship of fastening bolt  34  and stanchion  42  to base section  17 . Once hole  32  is aligned with pilot hole  26 , fastening bolt  34  is inserted through washer  40  and screwed into rafter  14 . Fastening bolt head  38  remains within cavity  22 . Stanchion  42  has a male threaded end  44  and is inserted through insertion opening  28  for threadable engagement within cavity  22 .  
         [0086]    Distal from threaded end  44  is female threaded end  46  for frictional engagement of mounting bolt  48  and washer  50 . FIG. 5 and FIG. 6 illustrate the assembled roof mount  10  fastened to rafter  14 . Roof mount  10  comprises base section  17 , stanchion  42  along with threadably connected mounting bolt  40  and washer  50 .  
         [0087]    In practice, the rafters  14  and decking  12  will be installed prior to the installation of roof mount  10 . A single pilot hole  26  is drilled for each roof mount which, due to my design, will be perpendicular to the roof rafter and minimize the risk of rafter split. The number of roof mounts used will be determined by the size of the object to be mounted.  
         [0088]    Once the pilot hole is drilled, base section  17  is slid a short distance and fastening bolt  34  is inserted to fasten base section to rafter  14 . Again, because only one hole is drilled into the rafter for each roof mount  10 , less labor time is required than with typical floor flanges.  
         [0089]    Once all roof mounts  10  have been fastened to their respective rafters, flashing  52  must be installed to protect the roof from the risk of future water damage. FIG. 7 illustrates the arrangement of multiple flashings  52  over a plurality of roof mounts  10 . Following flashing installation, the decking  12  is typically layered with roofing material (not shown).  
         [0090]    Although my mounting system can be utilized for a variety of objects to be mounted above a roof, the following procedure will address installation of a solar panel having multiple modules.  
         [0091]    Once the roof is in a condition for installing a solar panel, a pair of C-shaped elongated horizontal members  54  are provided. Each horizontal member  54  has a base wall  56  and a pair of side walls  58  and  60 . A linear groove  62  runs along the bottom surface of base wall  56  as can be seen in FIG. 9 a  and FIG. 10.  
         [0092]    [0092]FIG. 9 a  also illustrates a pair of horizontal ledges  64  and  66  extending inward from sidewalls  58  and  60  toward each other. These ledges extend the length of sidewalls  58  and  60 . A pair of protruding lips  68  and  70  extend inward from the distal end of sidewalls  58  and  60  relative to base wall  56 . A track area is defined by the surface area of ledges  64  and  66  which face lips  68  and  70  respectively. The purpose of the track will be discussed below.  
         [0093]    [0093]FIG. 10 illustrates the attachment of horizontal members  54  to roof mounts  10 . Initially, mounting bolts  48  and washers  50  are removed from stanchions  42 . Horizontal member  54  is positioned along each flashing cone. As shown in FIG. 9 a,  a drill is used to drill mounting holes  72  along groove  62  on base wall  56  for each roof mount. Once the first mounting hole  72  is drilled, additional mounting holes can be drilled by simply measuring the distance from the last hole drilled when the spacing between the rafters is known.  
         [0094]    The support means can also be modified to be fastened to an existing roof by use of base mounts  810  as shown in FIG. 19. The attachment means comprises base mount  810  which joins to member  54 . An insert is used to threadably sandwich member  54  between the insert and base mount  810  for additional structural support. Alternatively, base mount  810  can be directly bolted to member  54  but this configuration would not provide the structural support as if base mount  810  were bolted to the insert.  
         [0095]    The support means can also be modified to be fastened to ground raking system  700  as shown in FIG. 20. The attachment means comprises a U-shaped member  710  which joins to member  54  having a pipe member therebetween. The ends of U-shaped member  710  are operatively attached to member  54  by the use of an insert (not shown) which essentially serves as the base mount although located within member  54 . Alternatively, U-shaped member  710  can be directly bolted to member  54  but this configuration would not provide the structural support as if U-shaped member  710  were bolted to the insert.  
         [0096]    Once all mounting holes  72  have been drilled, horizontal member  54 , is positioned the above flashing cones with mounting holes  72  aligned with female threaded end  46 . Mounting bolts  48  and washers  50  are then used to frictionally engage horizontal members  54  to respective roof mounts  10 . FIG. 11 shows horizontal members  54  assembled to roof mounts  10 .  
         [0097]    At least two slidable inserts  74  are provided for each horizontal member  54  and a general configuration is illustrated in FIG. 12 and FIG. 13. Insert  74  has a female threaded hole  80 . The outer configuration of insert  74  is designed to be slidably received within track area of horizontal member  54 . The required number of inserts  74  is dependent upon the number of clamps needed to secure the solar panel. There are two types of clamps available: end clamps  76  and bi-module clamps  78 .  
         [0098]    End clamp  76  is illustrated in FIG. 12 and has a hole  82  for alignment with threaded hole  80  on insert  74 . End clamp  76  has a notched surface  84  for frictionally engaging the solar panel and securing it between notched surface  84  and horizontal member  54  when end clamp bolt  86  has its threaded stem  88  passed through washer  90  and hole  82  for engagement with threaded hole  80  on insert  74 . FIG. 15 and FIG. 16 show the solar panel in frictional engagement between notched surface  84  and horizontal member  54 .  
         [0099]    Two end clamps  76  are used to secure a solar panel therebetween and along each horizontal member  54  when each end clamp  76  is threadably fastened to insert  74  using bolt  86 . A solar panel is defined as at least one solar module and can be a number of modules in series as illustrated in FIG. 14. Therefore, four end clamps  76  are used to secure a solar panel to two horizontal members  54 .  
         [0100]    A bi-module clamp  78  is illustrated FIG. 13. They are used to secure the sides of two adjoining solar panel modules and to a horizontal member  54  when bi-module clamp  78  is threadably fastened to insert  74  using a bolt  104 . The use of bi-module clamps  78  and end clamps  76  in my mounting system is best illustrated in FIG. 14.  
         [0101]    The number of bi-module clamps required for each horizontal member  54  is determined by the formula:  
         [0102]    number of bi-module clamps=(number of modules −1).  
         [0103]    Each bi-module clamp  78  has a top side  92 , a bottom side  94 , a pair of side walls  96 . Holes  98  located on top side  92  and bottom side  94  have a common axis of symmetry and are for alignment with threaded hole  80  on insert  74 . Top side  92  extends perpendicularly away from side walls  96  in either direction forming overhangs  100  having notched surfaces  102 . Notched surfaces  102  are for frictionally engaging the solar module and securing it between notched surface  102  and horizontal member  54  when bolt  104  has its threaded stem  106  passed through washer  90  and holes  98  for engagement with threaded hole  80  on insert  74 . FIG. 17 and FIG. 18 show a pair of solar modules in frictional engagement between notched surfaces  102  and horizontal member  54 .  
         [0104]    As a slidable insert  74  is threadably engaged and frictionally positions either bi-module clamp  78  or end clamp  76  along member  54 , insert  74  also frictionally engages an area of member  54 . This relationship is illustrated in FIG. 16 and FIG. 18. This engagement changes the structural properties of member  54  to that of a structural square for enhanced strength. In addition, when engaged to the module or solar panel frame, the structural properties of the module frame combine with horizontal member  54  and form a rigid inter-locking trussed cross-section.  
         [0105]    Alternatives to that shown in FIG. 12 are shown in FIG. 24 and FIG. 25. Rather than having a bolt with a threaded stem which threads downward into insert  74 , FIG. 24 shows a slidable insert  274  having an upward rising threaded stem  288 . FIG. 25 shows insert  74  where bolt  390  having male stem  388  is screwed into from below to have the same final configuration as that shown in FIG. 24.  
         [0106]    Each end clamp  76  has a heal means, or slight rise  108  on its bottom surface distally positioned from its clamping surface and is illustrated in FIG. 12 and FIG. 15. Rise  108  prevents end clamp  76  from twisting while fastening bolt  86  to insert  74 .  
         [0107]    Alternative designs to end clamp  76  shown in FIG. 12 are presented in FIG. 21 and FIG. 22. Rather than having an aperture located on the portion of the clamp which contacts member  54  as is the case for clamp  76 , apertures  172  and  272  for end clamps  176  and  276  shown respectively in FIG. 21 and FIG. 22 are located on the horizontal portion which includes notched surface  184  and  284 . Alternative end clamps  176  and  276  also incorporate a heel means, or raised heels  186  and  286  respectively.  
         [0108]    Besides the heel means of the end clamp designs mentioned which incorporate a heel, an alternative heel means, which performs the same function as a unitized heel, i.e. preventing the twisting of the end clamp while being secured to horizontal member  54  and forcing the clamp inward at 90 degrees to fully engage the object by the notched surface can be accomplished with the combination shown in FIG. 23. Here, end clamp  376  can be the same design as for end clamp  76  but excluding heel portion  108 . The function of the heel is performed by a second item, denoted as wedge  386 . The width of wedge  386  must be sufficient so it will contact both top sides of member  54 . Alternatively, a pair of smaller wedges can be positioned on each top side of member  54  directly below end clamp  376  to provide the proper inward angle toward the object to grip.  
         [0109]    As stated earlier, the securing means, besides being an end clamp having a heel, can also be an end clamp not having a heel used in combination with a wedge or half-moon shaped washer or other protrusion that, when positioned between the bottom side of the end clamp and the top surface of the horizontal member, will provide the same inward force against the object when tightened to the horizontal support rail.  
         [0110]    As best illustrated in FIG. 14, horizontal members  54  along with the associated component parts, namely slidable inserts  74 , end clamps  76  and bi-module clamps  78  and the attachment means to roof mount  10  comprise a solar panel support structure.  
         [0111]    [0111]FIG. 8 illustrates the unitized packaging for the mounting components, namely a pair of horizontal members  54  and the associated number of inserts  74 , bi-module clamps  78 , and a pair of end clamps  76 . The ends of the horizontal members  54  are secured by tape or other packaging material  110 . Packaging material  110  not only maintains the relationship of horizontal members  54  to one another, it also prevents the inserts and clamps from escaping.  
         [0112]    As can be best seen in FIG. 9 a,  the outward facing surface  112  of the open side of horizontal member  54  has ridges. These ridges extend the length of each member  54  and form mating or interlocking surfaces when the open sides of two horizontal members  54  are aligned and contacted with one another. FIG. 9 illustrates two horizontal members  54  mated to one another and show a bi-module clamp  78  and an end clamp  76  in view.  
         [0113]    During assembly, the inserts and clamps are placed into a horizontal member  54 . Packing such as paper (not shown) is also inserted to prevent the inserts and clamps from excessive movement and potential wear and damage. The second horizontal member  54  is thereafter mated to the other member by cooperatively engaging along surfaces  112 . Outside packaging is thereafter used to seal the open ends.

Technology Classification (CPC): 5