Note: Descriptions are shown in the official language in which they were submitted.
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MOLDED SOLAR PANEL RACKING ASSEMBLY
BACKGROUND OF THE INVENTION
Field of Invention
[0001] This invention relates generally to systems for mounting solar
panels or
photovoltaic cells and more specifically to ballasted roof mounted racking
systems for
mounting photovoltaic cells.
Discussion of Related Art
[0002] Solar energy provides the opportunity to generate electricity
without
consumption of fossil fuels and is considered clean technology. In recent
years, the
development of technology for solar thermal systems and photovoltaic systems
has
improved the overall viability of solar energy. Increasing prices of fossil
fuel and the
prospect of expending world oil reserves has created a demand for alternative
energy
sources that can supplement and/or replace some of the energy needs consumed
presently by fossil fuels. Thus, the demand for solar energy has increased.
Because of
the overall accessibility of solar energy, individuals or small businesses can
own and
control all or a significant portion of its energy production free from
dependence upon
the power grid. With the advances of electric powered automobiles, even
transportation
needs can be met by solar generated electricity. Presently, solar power
technology is
one of the most widely-accessible form of alternative fuel to the general
population of
the world. All is needed is access to direct sunlight.
[0003] The cost of solar panel technology includes not only cost of the
photovoltaic panels, but a significant investment installation equipment and
the labor to
construct a solar electric system. Thus, a technology advance that reduces the
cost of
installation of photovoltaic modules (whether through reducing material cost,
shipping
costs, or labor costs) makes photovoltaic technology more viable and
attractive from an
investment perspective. The quality of installation also affects the
efficiency of solar
panel installation. The direction of the solar panels relative to the sun, the
angle of the
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solar panels relative to the horizon, the density of solar panels in a given
area, as well
as position of solar panels relative to other panels can have a positive or
negative effect
on performance of the solar powered system.
[0004] A large percentage of commercial solar panel systems are installed
on
generally flat roofs of office buildings. Generally flat means that the roof
is designed to
be generally horizontal without a predefined pitch. It should be understood
that while
generally flat, flat roofs are often uneven due to settling of the building,
construction
imperfections, etc. A flat roof structure is an attractive place to locate a
solar panel
installation because there is often a large surface area of unused space with
relatively
few obstructions of sunlight. The traffic on a roof is typically restricted.
Because access
is restricted, the likelihood of intentional or accidental damage or theft is
naturally
reduced with relatively inexpensive safety precautions. Consequently, there is
a
significant effort in the solar panel industry to design effective flat roof
mounts or racks
to support arrays of solar panels on flat roofs.
[0005] The ability to assemble with one additional row of solar panels
without
causing overlap of the solar panels in sunlight or compromising optimal
positioning
would be a great advantage. Moreover, it would be advantageous if photovoltaic
panels
could be installed by an unskilled laborer or layperson (do-it-yourselfer)
without a lot of
formal training. It would be further advantageous if the system could be
installed by
hand without tools. It would be further advantageous if the product was light-
weight,
could be stacked or configured in a compact manner to ship a larger number of
system
components per unit of shipping volume and thereby reduce shipping costs. An
additional advantage would be to have a system that can be easily adapted to
avoid
obstructions in the roof such as common rooftop fixtures without having to cut
and
resize parts of the solar panel system. Reducing installation time reduces
labor cost
making solar technology more accessible to the common individual.
[0006] U.S. Patent Publication 2008/0210221 to Genschorek discloses a
relatively compact frame assembly that mounts solar panels at an angle for
mounting on
a flat structure such as a roof or ground. The metal frame system is supported
by
carrier profile elements with feet having holes forming connections to connect
the carrier
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profile elements to the ground or roof surface--presumably by bolt, screw or
penetrating
fastener. The system has multiple parts requiring factory or on site assembly¨
potentially increasing product or installation cost.
[0007] U.S. Patent No. 8,281,524 to Hund is a stackable wire frame design.
The
wire design is relatively lightweight, compact and stackable. The system is
designed to
have one framework support one panel so the system does not have the benefit
of
interconnectedness. Furthermore, the system is made from a wire grate
connected by
welds at wire intersections. It is pressed into the desired form. The wire is
potentially
vulnerable to damage by bending, corrosion, or breakage at weld points.
[0008] U.S. Patent No. 6,105,316 to Bottger discloses an injection or blow
molded device for supporting solar panels. The device has a bottom wall and a
rear
wall and two side walls integrally joined. Concrete blocks are place in the
interior of the
device. The solar panel is fastened to side edges of the bottom wall and rear
wall.
Each device supports a solar panel individually. There is one vertical member
for each
side. Thus, the panel array is not structurally interconnected.
[0009] U.S. Publ. No. 2006/0196128 to Duke discloses a mounting for solar
panels with fixings on the front and side that enable it to be easily attached
to other
mountings for solar arrays. The devices are interconnected and stackable.
[0010] U.S. Publ. No. 2012/0036799 to Kneip discloses an injection molded
support device that is compact and stackable. The height of the base is
greater than its
width and thus top-heavy relying upon the panels for side-to side stability.
Thus, the
device could have improved stability from side to side. Each device
potentially supports
one side of two adjacent panels.
[0011] U.S. Publ. No. 2012/0223032 to Rothschild discloses a solar panel
mounting system of injection molded bases that are designed to support the
panels at
their respective corners. The bases can be nested like buckets for easy
transport.
Each device potentially supports four panels. Each bucket has four side walls.
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[0012] Additionally, there is a need for systems that are lighter weight,
easier to
install and can be transported and lifted to rooftops with greater efficiency
because a
greater number of units can fit on a similar size pallet.
[0013] Thus, there still exists a need for a system that has many of the
needs
expressed above. The present invention addresses these and other needs.
SUMMARY OF THE INVENTION
[0014] The present invention comprises a stackable, ballasted, roof
mounting unit
integrally formed into a single piece. Each side is formed by two-walls for
extra strength
and stability. The mount unit comprises a plurality of generally elevated side
walls of a
ballast receiving basket. Each of the generally elevated side walls taper
upward and
inward from a generally downward facing peripheral edge to an apex ridge of
the wall to
form the outer face of each of the side walls. The generally elevated side
walls taper
downward and inward from the apex ridge of the wall to form the inner face.
The side
wall further extends inward from the base of the inner face to form a ballast
supporting
basket lip. Each side walls defines a downwardly facing open channel that is
configured
to receive a corresponding side wall from a corresponding solar panel mount in
a
stacking relation.
[0015] The mount unit further comprises a first pair of posts, wherein
each of the
first pair of posts extend upward from the peripheral edge to the top of the
first pair of
posts at a first predetermined height above the generally elevated side wall
to form the
outer side of each of the first pair of posts. Each of the first pair of posts
taper
downwardly and inwardly from the top of each of the first pair of posts to
form the
generally inner side of each of the posts. Each of the first pair of posts
forms a
downwardly facing post receiving first mouth that is configured to receive a
corresponding post from a corresponding first pair of posts of a corresponding
solar
panel mount in a stacking relation.
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[0016] In one embodiment, the mount unit further comprises a second pair
of
posts. Each of the second pair of posts extends upward from the peripheral
edge to a
second predetermined height to form the outer side of a support post. The
support
posts taper downwardly and inwardly from the second predetermined height to
form the
generally inner side of each of the posts. The second predetermined height is
above the
generally elevated side wall. Each of the second pair of posts forms a
downwardly
facing post receiving mouth that is configured to receive a corresponding post
from a
corresponding solar panel mount in a stacking relation.
[0017] The mounting unit of one embodiment where the peripheral edge has
a
plurality of raised gaps around the base to allow water to flow under the base
without
obstruction.
[0018] The mounting unit of another embodiment, wherein the basket has a
large
hollow part that is cut away to prevent water from pooling in the basket.
[0019] In still another embodiment, there is a plurality of units
according to one or
more of the embodiments set forth above. The plurality of units is arranged in
a single
vertically aligned stack. A first of the plurality of units is placed onto the
bottom and a
second of the plurality of units is vertically aligned with the first of the
plurality of units.
The distance between any point on the first of the plurality of units and the
same
corresponding point on the second of the plurality of units is less than one-
half,
preferably less than one quarter, more preferably less than one-eighth, and
even more
preferably less than one tenth of the height of the distance from the
peripheral lip to the
apex ridge of any one unit.
[0020] The plurality of stacked units of one embodiment, wherein the
plurality are
arranged in one vertically aligned stack on a pallet. A first of the plurality
of units is
placed directly onto the pallet on the bottom of the stack and a second of the
plurality of
units is vertically aligned with and stacked upon the first of the plurality
of units, wherein
distance between any point on the first of the plurality of stacked units and
the same
corresponding point on the second of the plurality of units is less than one-
half,
preferably less than one quarter, more preferably less than one-eighth, and
even more
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preferably less than one tenth of the height of the distance from the
peripheral lip to the
apex ridge of any one unit.
[0021] In one embodiment, unassembled rails and other hardware can be
stacked between the first pair of posts and the second pair of posts in the
plurality of
stacked units on the pallet.
[0022] In one embodiment, there is a solar panel mounting system. The
solar
panel mounting system comprises a front row of units as described above.
Wherein the
first pair of posts of each front row unit is the only pair of posts on the
unit. The
mounting system further comprises a first medial row of units as described
above where
the first pair of posts of each first medial row unit are defined as front
posts and the
second pair of post of each first medial row units are defined as back posts
and the
back posts are smaller than the front posts.
[0023] The system further comprises a plurality of rails extending from
and
fastened to the top of the first pair of posts of each front row unit. The
rails extend
towards and are fastened to the top of front posts of the first medial row of
units that are
placed behind the front row of units;
[0024] The system also has a row of solar panels in solar panel frames.
The
solar panel frames are fastened to respective pairs of adjacent rails. The
system also
has a plurality of ground wires that are connected to adjacent solar panels in
the front
row and the first medial row by ground wire fasteners. The ground wire
fasteners create
an electrical connection between the panel frames. In one embodiment, the
fasteners
are sufficient to break the annealed surface of the solar panel frame to
effect a
favorable connection.
[0025] The present invention is described hereinafter in Detailed
Description of
the Invention in reference to the drawings and examples, which are intended to
teach,
describe and exemplify one or more embodiments of the invention and is in no
way
intended to limit the scope of the invention.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Figure 1 is a perspective view of a four posted mounting unit of one
embodiment of the present invention.
[0027] Fig. 2 is a front elevated view of the solar panel mounting unit of
Fig. 1.
[0028] Fig. 3 is a side elevated view of the solar panel mounting unit of
Fig. 2
taken along the lines 3-3.
[0029] Fig. 4 top view of the solar panel mounting unit of Fig. 2 taken
along the
lines 4-4.
[0030] Fig. 5 is a bottom view of the solar panel mounting unit of Fig. 2
taken
along the lines 5-5.
[0031] Fig. 6 is a side elevated view of a stack of solar panels of one
embodiment.
[0032] Fig. 7 is a front elevated view of the stack of solar panels of Fig.
6 taken
along the lines of 7-7.
[0033] Fig. 8 is a perspective view of a two posted mounting unit of one
embodiment of the present invention.
[0034] Fig. 9 is a front elevated view of the solar panel mounting unit of
Fig. 8.
[0035] Fig. 10 is a side elevated view of the solar panel mounting unit of
Fig. 9
taken along the lines 10-10.
[0036] Fig. 11 bottom view of the solar panel mounting unit of Fig. 9 taken
along
the lines 11-11.
[0037] Fig. 12 is a bottom view of the solar panel mounting unit of Fig. 9
taken
along the lines 12-12.
[0038] Fig. 13 is a front view of a stack of solar panel mounting units of
one
embodiment.
[0039] Fig. 14 is a side elevated view of the solar panel mounting units
of Fig. 13
taken along the lines 14-14.
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[0040] Fig. 15 is a solar panel mounting system of one embodiment.
[0041] Fig. 16 is an enlarged view of the fastening system of Fig. 15
taken
around circle A.
[0042] Fig. 17 is a perspective view of a panel grounding system of the
present
invention.
[0043] Fig. 18. is an elevated view of the grounding system including
grounding
wire and grounding clamps of one embodiment.
[0044] Fig. 19 is an end view of the system of Fig. 18 taken along the
lines of 19-
19.
[0045] Fig. 20 is a side view of a C-clamp housing of one embodiment.
[0046] Fig. 21 is a rear view of the housing of Fig. 20 taken along the
lines 21-21.
[0047] Fig. 22 is an unassembled C-clamp housing.
[0048] Fig. 23 is one embodiment of a pin fastener for tool-less assembly
according to of the present invention.
[0049] Fig. 24 shows four mounting units partly assembled with supporting
rails.
[0050] Fig. 25 shows the mounting units of Fig. 24 with a solar panel
affixed to
supporting rails.
[0051] Fig. 26a-d shows a process for affixing a solar panel to supporting
rails by
a tool-less fastener according to one embodiment of the present invention.
[0052] Fig. 27-36 illustrate the sequential assembly of a solar panel
supporting
system of Fig. 25.
DETAILED DESCRIPTION
[0053] With reference to Figure 1 and Figs. 2-5, the present invention
comprises
a stackable ballasted roof mounted solar panel mount unit 10. The ballasted
unit is
integrally formed into a single molded piece. By integrally formed, it is
meant that the
piece is molded and contoured from a sheet that is preferably a single unitary
piece, but
may include multiple pieces that are adhered together into a single piece that
cannot be
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separated without destroying the integrity and function of the piece. For
example and
without limitation, the piece could not be separated without cutting the mount
unit 10.
The mount unit 10 is made of fiberglass in one embodiment. In another
embodiment, it
is made of plastic such as polyethylene and polypropylene preferably high
density
polyethylene and high density polypropylene or blends of polypropylene or
polyethylene
of any density. In one embodiment the mount unit is formed from a composite
that is
capable of being molded into the desired shape. For example, graphite
composites or
other high strength composites known to a person of ordinary skill in the art
may be
suitable in one embodiment.
[0054] The mount unit 10 forms a plurality of generally elevated side
walls 12, 14,
16, or 18 of a ballast receiving basket 21. Each of the generally elevated
side walls
taper upward and inward from a generally downward facing peripheral edge 23 to
respective apex ridges 28, 30, 32, and 34 of the wall to form the outer face
20, 22, 24,
26 of each of the side walls 12, 14, 16, and 18. The generally elevated side
walls taper
downward and inward from the apex ridges of the walls to form the inner faces
12B,
14B, 16B and 18B. The side walls further extend inward from the base of the
inner face
to form a ballast supporting basket lip 46. With reference to the bottom view
of Fig. 5,
each side wall 12, 14, 16 and 18 defines a plurality of downwardly facing open
channels
48, 50, 52, and 54 that are configured to receive a corresponding side wall
from a
corresponding solar panel mount in a stacking relation.
[0055] The mount unit 10 further comprises a first pair of posts 56 and
58,
wherein each of the first pair of posts 56 and 58 extend upward from the
peripheral
edge 23 to the top 60 and 62 of the first pair of posts 56 and 58 at a first
predetermined
height above the generally elevated side walls 12, 14, 16 and 18 to form the
outer side
of each of the first pair of posts 56 and 58. Each of the first pair of posts
56 and 58
taper downwardly and inwardly from the top of each of the first pair of posts
to form the
generally inner side of each of the posts 56 and 58. Each of the first pair of
posts 56
and 58 forms a downwardly facing post receiving first pair of mouths 60 and 62
(See
Fig. 5) that is configured to receive a corresponding post from a
corresponding first pair
of posts of a corresponding solar panel mount in a stacking relation.
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[0056] In one embodiment, the mount unit 10 further comprises a second
pair of
posts 66 and 68. Each of the second pair of posts 66 and 68 extend upward from
the
peripheral edge 23 to the top 70 and 72 of the second pair of posts at a
second
predetermined height to form the outer side of the support posts 66 and 68.
The
support posts 66 and 68 taper downwardly and inwardly from the second
predetermined
height to form the generally inner side of each of the posts 66 and 68. The
second
predetermined height is above the generally elevated side walls 12, 14, 16,
and 18.
Each of the second pair of posts 66 and 68 forms a downwardly facing post
receiving
mouths 74 and 76 (See Fig. 5) that is configured to receive a corresponding
post from a
corresponding solar panel mount in a stacking relation.
[0057] The mounting unit of one embodiment where the peripheral edge has a
plurality of raised gaps 78 around the base to allow water to flow under the
base without
obstruction.
[0058] The mounting unit of another embodiment, wherein the basket has a
large
hollow part that is cut away 80 to prevent water from pooling in the basket.
[0059] With reference to Figs 6 and 7, there are a plurality of units 64A,
64B,
64C, and 64D according to one or more of the embodiments set forth above. The
plurality of units 64A, 64B, 64C, and 64D is arranged in a single vertically
aligned stack
65. A first unit 64A of the plurality of units 64A, 64B, 64C, and 64D is
placed onto the
bottom and a second unit 64B of the plurality of units is vertically aligned
with the first
unit 64A of the plurality of units. The distance between any point on the
first of the
plurality of units and the same corresponding point on the second of the
plurality of units
is less than one-half, preferably less than one quarter, more preferably less
than one-
eighth, and even more preferably less than one tenth of the height of the
distance from
the peripheral lip to the apex ridge of any one unit.
[0060] The mounting unit of one embodiment where the peripheral edge has a
plurality of raised gaps 78 around the base to allow water to flow under the
base without
obstruction.
[0061] The mounting unit of another embodiment, wherein the basket 21 has a
large hollow part that is cut away 80 to prevent water from pooling in the
basket.
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[0062] With reference to Figs. 8-12, the present invention comprises
a
stackable ballasted roof mounted solar panel mount unit 110. The ballasted
unit is
integrally formed into a single molded piece. By integrally formed, it is
meant that the
piece is molded and contoured from a sheet that is preferably a single unitary
piece, but
may include multiple pieces that are adhered together into a single piece that
cannot be
separated without destroying the integrity and function of the piece. For
example and
without limitation, the piece could not be separated without cutting the mount
unit 110.
The mount unit 110 is made of fiberglass in one embodiment. In another
embodiment,
it is made of plastic such as polyethylene and polypropylene preferably high
density
polyethylene and high density polypropylene or blends of polypropylene or
polyethylene
of any density. In one embodiment the mount unit is formed from a composite
that is
capable of being molded into the desired shape. For example, graphite
composites or
other high strength composites known to a person of ordinary skill in the art
may be
suitable in one embodiment.
[0063] The mount unit 110 forms a plurality of generally elevated side
walls 112,
114, 116, or 118 of a ballast receiving basket 121. Each of the generally
elevated side
walls taper upward and inward from a generally downward facing peripheral edge
123
to respective apex ridges 128, 130, 132, and 134 of the wall to form the outer
face 120,
122, 124, 126 of each of the side walls 112, 114, 116, and 118. The generally
elevated
side walls taper downward and inward from the apex ridges of the walls to form
the
inner faces. The side walls further extend inward from the base of the inner
face 112B,
114B, 116B, 118B to form a ballast supporting basket lip 146. With reference
to the
bottom view of Fig. 5, each side wall 112, 114, 116 and 118 defines a
plurality of
downwardly facing open channels 148, 150, 152, and 154 that are configured to
receive
a corresponding side wall from a corresponding solar panel mount in a stacking
relation.
[0064] The mount unit 110 further comprises a first pair of posts 156 and
158,
wherein each of the first pair of posts 156 and 158 extend upward from the
peripheral
edge 123 to the top 160 and 162 of the first pair of posts 156 and 158 at a
first
predetermined height above the generally elevated side walls 112, 114, 116 and
118 to
form the outer side of each of the first pair of posts 156 and 158. Each of
the first pair of
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posts 156 and 158 taper downwardly and inwardly from the top of each of the
first pair
of posts to form the generally inner side of each of the posts 156 and 158.
Each of the
first pair of posts 156 and 158 forms a downwardly facing post receiving first
pair of
mouths 160 and 162 (See Fig. 11) that is configured to receive a corresponding
post
from a corresponding first pair of posts of a corresponding solar panel mount
in a
stacking relation.
[0065] The mounting unit basket 121 has a large hollow part that is cut
away 180
to prevent water from pooling in the basket.
[0066] With reference to Figs 13 and 14, there is a plurality of units
164A, 164B,
164C, and 164D according to one or more of the embodiments set forth above.
The
plurality of units 164A, 164B, 164C, and 164D is arranged in a single
vertically aligned
stack 65. A first unit 164A of the plurality of units 164A, 164B, 164C, and
164D is
placed onto the bottom and a second unit 64B of the plurality of units is
vertically
aligned with the first unit 164A of the plurality of units. The distance
between any point
on the first of the plurality of units and the same corresponding point on the
second of
the plurality of units is less than one-half, preferably less than one
quarter, more
preferably less than one-eighth, and even more preferably less than one tenth
of the
height of the distance from the peripheral lip to the apex ridge of any one
unit.
[0067] The method of installing an array 95 of solar panels is illustrated
with
reference to Figs. 15, 16 and 23-36. Installation begins following a site plan
indicating
where the panels are to be located. A chalk line is snapped to square and
center the
system. The chalk line represents the line along which the front row mounting
units are
aligned.
[0068] There is a front row mounting unit 82 and a first medial row
mounting unit
81 aligned behind the front row mounting unit 82. The front row mounting unit
has a
first pair of posts 84. The first medial row mounting unit 81 has a first pair
of posts 88
and a second pair of posts 83. A rail 86 is shown extending from one of the
first posts
84 of the front row mounting unit 82 to the second posts of the first medial
row mounting
units 81. The rail 86 is fastened to the posts by a fastener known in the art.
In one
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embodiment the fastener is a pin fastener 85 that is the subject of U.S.
Patent Appl.
No. 61/548,024 filed October 17, 2011. In another embodiment, it is a clevis
pin, a
detent pin, a locking pin, a hitch pin or a nut and bolt.
[0069] With reference to Fig. 16 and Figs 26a through 26d illustrating how a
solar
panel 90 having a lipped frame 91 is fastened to a rail 86. The rail 86 is
configured
with a pair of fastener clamps 87 and 89 that fasten the solar panel 90 to the
rail 86.
Step one 26a of the fastening procedure places the lip 92 of the frame 91 on
the rail
86 in front of the clamp 89 in its desired position.
[0070] Then the clamp mechanism 89 is slid forward until the lip 92 of the
frame 91
is positioned between a top clamp plate 93 and the rail 94 surface as shown in
Fig
26b. A wedge plate 95 is pivoted into position between the bottom surface of
the lip
92 and the top surface of the rail 94. This wedge action clamps the frame 91
to the
rail 94 thereby securing the solar panel to the mounting system.
[0071] With continued reference to Fig. 24, the mount/rail configuration of
the
outside row (designated S) requires only one rail 86S extended between the
front
row mounting unit 82S and a medial row mounting unit 86S and fastened
preferably
by a fastener 85. Space apart just less than three-fourths of a panel length
from the
outside rail 86S, is a second set of a front row mounting unit 82, a medial
row
mounting unit 81 and a pair of rails 86 extending from each of the pair of
posts of the
front row mounting unit 82 to the tall posts of the medial row mounting unit.
Likewise,
in one embodiment, the rails are fastened by a tool-less pin fastener 85.
[0072] With further reference to Fig. 25, a panel 90 is placed over rail 86S
and the
adjacent rail 86S. The medial facing edge of each panel should be positioned
equidistance between the legs of the respective baskets.
[0073] Turning now to Fig. 27, the first row 10DA of basket is continued in
the
same manner illustrated in Fig. 25, by placing an additional set of supports
including
a front row mounting unit 82, a medial row mounting unit 81 connected by a
pair of
rails 86 fastened in one embodiment by tool-less pin fastener 85.
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[0074] As shown in Fig. 28, a second panel 90 is positioned adjacent the
first
panel 90 and fastened to a pair of rails 86 as hereinbefore described in one
embodiment. Fig. 29 illustrates that the first row 100 A continues by
following the
pattern described above with reference to Figs. 24 through 27 until the last
set of a first
row mounting unit 82S connected to a medial row mounting unit 81 by a single
rail 86S
on the outside edge. The last panel 90 is affixed as shown in Fig. 30. In each
instance,
the baskets of any mounting unit are filled with ballasts prior to attaching
the panel.
[0075] The second row 100B is altered due to a rooftop obstruction 96 that
will
interfere with the placement of the third row. A row of medial row mounting
units 81 are
placed behind the previous row of medial row mounting units 81 in row 100B
with the
long legs positioned towards the previous row. Two mounting units 98 are
turned in
opposite direction with the small legs positioned towards the previous row,
but the long
legs these reverse position mounting units 98 are aligned with the long legs
of the other
medial row mounting units 81 in the second row 100B. Rails 86 are fastened--
preferably by tool less fasteners 85--to the mounting units 81 or 98. The side
mounting
units 81S are attached with only one rail 86S. A row of panels are added as
shown in
Fig. 32 after ballasts are placed in the basket of the mounting units 81 or
98.
[0076] With reference to Fig. 33, a third row 100C is started by placing
an
additional row of medial mounting units 81 behind the preceding row of
mounting units
81. Any time that the mounting unit (81 or 82) cannot be connected to a
preceding row,
a front row mounting unit 82 is placed in position. Any time, the mounting
unit (81 or 82)
is connected to a unit in front of it and behind it, a medial row mounting
unit 81 is used
with the tall legs positioned towards the preceding row so that the basket
will be
positioned behind the solar panels 91 when fully assembled. Any time the
mounting
unit (81 or 82) is expected to be connected to a mounting unit the previous
row, but not
expected to be connected to mounting unit behind it, then the mounting unit 91
with four
legs is selected and positioned with the small legs adjacent the front of the
array so that
the basket of the mounting unit 91 is positioned under the solar panel 90 when
fully
assembled.
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[0077] Then, rails are attached between the small posts in front and the
tall posts
behind. Then, as shown in Fig. 34, ballasts weights can be placed in the
basket and the
panels 90 can be fastened to the rails to complete the third row 100C.
[0078] The fourth row 100D is added with reference to Figs. 35 and 36. The
mounting units 91 in the last row is positioned with the small legs forward so
that the
basket is oriented under the panel 91. If the basket cannot connect to the
previous row,
then a first row mounting unit 82 can be used in front of the mounting unit 91
to
accommodate attachment of the panel. Once the panels are in place, ballasts
can be
placed in the basket and the solar panels 92 can be connected to complete the
row
100D.
[0079] The system also has a plurality of ground wires and related
fasteners
explained with reference to Figs 17-22. The ground wire 180 is formed with two
wire
terminals. In one embodiment the wire terminals are ring wire terminals 181
that are
affixed to respective ends of the ground wires by a crimp fitting. The ground
wires are
clamped by a ground wire clamp apparatus 182 having a C-clamp housing 179
defining
a first clamping surface 183 and a second clamping surface185. The first
clamping
surface of one embodiment is flat. The first clamping surface of another
embodiment is
knurled or otherwise textured. In one embodiment the first clamping surface
183 is
formed with teeth 184. The second clamping surface 185 has a hole 186 that
receives
a nut 187 and bolt 188 through the hole 186. The bolt 188 extends through the
ring wire
terminal 181 and the ring wire terminal 181 is placed between the second
clamping
surface 185 and the nut 187. The bolt 188 is freely rotatable and slidable
along the axis
of the bolt 188 in the C-clamp housing 179. The nut 187 is slidably but not
rotatably
received in the C-clamp housing 179 so that rotation of the bolt 188 relative
to the C-
clamp housing 179 and the nut 187 in a tightening direction causes the nut 187
to
impinge against and clamp the ring wire terminals 181 to clamp the terminal
and cause
an electrical connection between the terminal and the C-clamp housing.
[0080] Likewise rotation of the bolt 188 relative to the nut 187 and the C-
clamp
housing 179 causes the end of the bolt to move towards the first clamping
surface 183.
When an edge of the solar panel frame189 is placed between the end of the bolt
188
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and the first clamping surface 183, the bolt forces the first clamping surface
183 and the
respective teeth 184 against the side of the panel frame 189. The teeth 184
penetrate
the annealing surface of the frame 189 to form a reliable electrical
connection between
the panel frame and the C-clamp. Thus, by use of the ground wire and clamping
mechanism, a plurality of solar panel frames can be adequately grounded
together.
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