APPARATUS FOR MOUNTING A SOLAR PANEL AND METHOD AND APPARATUS FOR FORMING THE MOUNTING APPARATUS

Abstract

A support member for a solar panel is provided comprising a base member having first and second surfaces and first and second sides, the first surface defining a recess configured to receive the solar panel. The first side of the support member defines a first flange extending therefrom that is flush with the first surface of the base member and the second side of the support member defines a second flange extending therefrom that is flush with the second surface of the base member.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to solar panel support apparatuses and methods and apparatuses for constructing the same.

2. Description of Related Art

The use of reusable energy sources is becoming increasingly more important to national and local governments due to concerns over global warming; the eventual exhaustion of certain conventional energy supplies, such as oil, natural gas and coal; and the increasing cost for such energy supplies. One reusable energy source is solar energy or sunlight, which is captured and converted into electricity using solar energy cells or panels of such cells, as is well known in the art. While solar energy is an abundant energy source and the technology involved in capturing and converting the solar energy into electricity relatively well developed, solar energy remains relatively underused due to, among other factors, the need to have large, unobstructed areas to position the panels and the adverse aesthetic impact of such panels.

One proposal to increase the usage of solar panels is to locate the panels on roof tops of residential and/or industrial structures. However, there remain aesthetic concerns with locating conventional solar panels on a roof top due to the height such panels extend above the roof line. In addition, the weight of the solar panels and support structure on the roof top and the structural ability of the panels and support structure to withstand high winds and other ambient conditions is also a concern. Finally, the efficiency of a solar panel decreases as the temperature of the panel increases, so an important objective in developing a solar energy system is to ensure that heat does not build up around the panels. Thus, there remains a need for a support structure for a solar panel that can be used to position one or more panels inconspicuously on a roof top, that is light enough not to adversely affect the structural integrity of the roof top but that still has sufficient mechanical strength and weight to withstand high winds and other ambient conditions, and that allows for air to circulate around the solar panel to reduce overheating.

SUMMARY OF THE INVENTION

Embodiments of the present invention provide improved apparatus for mounting a solar panel and method and apparatus for forming the mounting apparatus. More particularly, embodiments of the present invention provide a support member for a solar panel comprising a base member having first and second surfaces and first and second sides, wherein the first surface defines a recess configured to receive a solar panel. In one embodiment, the support member is formed of polymer concrete. In another embodiment, the recess is configured such that the solar panel can be positioned within the recess with relatively insubstantial gaps between the sides of the recess and the sides of the panel and with the front of the panel being substantially flush with the first surface of the support member. The first surface of the base member defines at least one aperture within the recess to provide space for air to circulate and to reduce the weight of the support member. In one embodiment, the at least one aperture comprises at least one slot. In another embodiment, the at least one aperture comprises at least one circular opening.

In another embodiment of the present invention, the first surface of the base member defines a plurality of raised members within the recess that are structured to engage the solar panel and to provide space between the first surface of the base member and the solar panel. In one embodiment, the raised members within the recess comprise an elongate rib.

In yet another embodiment, the first side of the base member defines a first flange extending therefrom that is flush with the first surface of the base member and the second side defines a second flange extending therefrom that is flush with the second surface of the base member. In one embodiment, the first flange defines a first lip at the distal end of the first flange and a groove between the first lip and the first side of the base member and the second flange defines a second lip at the distal end of the second flange and a groove between the lip and the second side of the base member.

In still another embodiment of the invention, the base member defines a second recess configured to receive a junction box, wherein the second recess defines an aperture configured to accommodate the wiring of the solar panel and to provide space for air to circulate about the back of the solar panel.

Embodiments of the invention also provide a solar panel array, comprising at least two solar panels and at least two support members in accordance with the present invention. Each of the support members comprises a base member having first and second surfaces and first and second sides. The first surface of each of the base members defines a recess configured to receive one of the solar panels. In one embodiment, the first surface of each of the base members defines at least one aperture within the recess to enable air to circulate about the back of the corresponding solar panel and to reduce the weight of the support member. The first side of each base member defines a first flange extending therefrom that is flush with the first surface of the base member, the second side of each base member defines a second flange extending therefrom that is flush with the second surface of the base members. In one embodiment, the first flange of each base member defines a first lip at the distal end of the first flange and a groove between the first lip and the first side of the base member and the second flange of each base member defines a second lip at the distal end of the second flange and a groove between the second lip and the second side of the base member. At least two support members are positioned adjacent to one another such that the first flange of one of the at least two support members overlaps said second flange of the adjacent one of said at least two support members.

The invention also provides a method of forming a solar panel support member. In one embodiment, the method includes providing a first mold defining a plurality of protuberances, encasing the first mold with a form, and filling the first mold with liquid polymeric material and aggregate. Thereafter, a second mold is provided and positioned on the first mold within the form and the first and second molds are urged together. Finally the polymeric material is cured to form a support member in accordance with the present invention and the support member is removed from the first and second molds.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 is a perspective view illustrating a solar panel support, according to one embodiment of the present invention;

FIG. 2 is front view illustrating the solar panel support of FIG. 1;

FIG. 3 is a side view illustrating the solar panel support of FIG. 1;

FIG. 4 is a rear view illustrating the solar panel support of FIG. 1; and

FIG. 5 is a sectional view illustrating the solar panel support of FIG. 4 along the lines 5-5;

FIG. 6 is a sectional view illustrating the solar panel support of FIG. 5 along the lines 6-6;

FIG. 7 is a sectional view illustrating the solar panel support of FIG. 4 along the lines 7-7;

FIG. 8A is a perspective view illustrating a first portion of a mold for constructing the solar panel support of FIG. 1, according to one embodiment of the present invention;

FIG. 8B is a side view illustrating the first portion of the mold in FIG. 8A;

FIG. 8C is a top view illustrating the first portion of the mold in FIG. 8A;

FIG. 8D is a sectional view illustrating the first portion of the mold in FIG. 8C along the lines 8D-8D;

FIG. 8E is a sectional view illustrating the first portion of the mold in FIG. 8C along the lines 8E-8E;

FIG. 8F is a sectional view illustrating the first portion of the mold in FIG. 8C along the lines 8F-8F;

FIG. 9A is a perspective view illustrating a second portion of a mold for constructing the solar panel support of FIG. 1, according to one embodiment of the present invention;

FIG. 9B is a side view illustrating the second portion of the mold in FIG. 9A;

FIG. 9C is a top view illustrating the second portion of the mold in FIG. 9A;

FIG. 9D is a sectional view illustrating the second portion of the mold in FIG. 9C along the lines 9D-9D;

FIG. 9E is a sectional view illustrating the second portion of the mold in FIG. 9C along the lines 9E-9E;

FIG. 9F is a sectional view illustrating the second portion of the mold in FIG. 9C along the lines 9F-9F;

FIG. 10 is a perspective view illustrating a solar panel support and a solar panel, according to one embodiment of the present invention; and

FIG. 11 is a perspective view illustrating a plurality of solar panel supports and solar panels installed on a roof top, according to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, embodiments of the inventions are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Referring to the drawings and, in particular, FIGS. 1-7, there is illustrated a solar panel support member 10, according to one embodiment of the present invention. The dimensions of the support member 10 illustrated in FIGS. 1-4 are provided for purposes of example only and may be modified depending on the dimensions and configuration of the solar panel to be supported. As illustrated in FIGS. 1, 2 and 4, the support member 10 includes a base member 11 having first and second surfaces 14a, b and a first pair of lateral sides 16a, b and a second pair of lateral sides 18a, b. The support member 10 can be formed of a variety of materials including metal, wood, plastic or cementitious materials. In one preferred embodiment, the support member 10 is formed of a polymer concrete.

As illustrated in FIGS. 1 and 2, the front surface 14a of the support member 10 defines a recess 12 structured to receive a solar panel 20, as illustrated in FIG. 10. More particularly, the width, length and depth of the recess 12 is such that the solar panel 20 can be positioned within the recess with relatively insubstantial gaps between the sides of the recess and the sides of the panel and with the front of the panel being substantially flush with the front surface 14a of the support member 10.

The support member 10 defines a plurality of apertures 22 therethrough within the recess 12. The apertures 22 can include slots 24 and circular apertures 26 that advantageously allow for circulation of air around the exposed areas on back of the solar panel 20 and reduce the weight of the support member 10 by removing excess material. The remaining material between the apertures 22 defines a framework that provides the structural strength to the support member 10 to support the solar panel 20. The slots 24 and circular apertures 26 are shown for illustration purposes only. The dimensions and configurations of the apertures 22 can vary depending on, without limitation, the size and shape of the support member 10, the excess material that needs to be removed, and the structural requirements of the support member and solar panel 14 as determined by the weight of the support member and solar panel, the anticipated wind forces and other ambient conditions, and the load-bearing ability of the roof or other underlying structure to which the support member will be anchored. According to another embodiment of the present invention (not shown), the support member defines a honey-comb configuration or pattern within the recess 12.

In one embodiment of the present invention, as illustrated in FIG. 2, the support member 10 includes a second recess 28 that is structured to receive or accommodate a junction box (not shown) on the back of the solar panel 20. An aperture 30 may be provided through the support member 10 within the second recess 28 to accommodate the wiring of the solar panel 20 and to allow air to circulate around the exposed surface of the junction box. In other embodiments, the wiring of the solar panel 20 can be configured substantially within the plane of the back surface of the solar panel, in such case, the second recess 28 and aperture 30 may be omitted.

As illustrated in FIGS. 1 and 2, the support member 10 includes a plurality of raised members 40 on the framework within the recess 12 that contact the back of the solar panel 20 and create a further gap between the support member and the back of the panel, substantially increasing the exposed area of the back of the panel so that air can circulate around a greater portion of the back of the panel. The configuration of the raised members 40 can vary. In the embodiment illustrated in FIG. 2, the raised members 40 are configured as elongate ribs. In other embodiments (not shown), the raised members 40 can have other configurations, including, without limitation, circular, elliptical, square, or rectangular configurations.

As illustrated in FIGS. 1 and 3, the lateral sides 16a, b of the support member define a pair of opposed first and second flanges 32a, b. The first flange 32a extends from the first lateral side 16a and is flush with the first surface 14a. The second flange 32b extends from the second lateral side 16b and is flush with the second surface 14b. As illustrated in FIGS. 1 and 3, each flange 32a, b defines a lip 33 at the distal end of the flange and a groove 35 between the lip and the corresponding lateral side 16a, b. As illustrated in FIG. 11, a plurality of the support members 10 can be positioned on a roof top adjacent one another wherein the first flange 32a of one support member 10 overlaps and secures the second flange 32b of an adjacent support member to thereby interconnect the support members and secure them to the roof top. The first and second flanges 32a, b are secured together by the lip 33 of the first flange 32a being inserted into the groove 35 of the second flange 32b and by the lip 33 of the second flange being inserted into the groove 35 of the first flange. The support members 10 are preferably positioned on a roof top so that the second surface 14b of each support member is substantially flush with, and parallel to, the plane defined by the roof top so that the support members and solar panels 14 are relatively inconspicuous and aesthetically blend into the covering of the roof top. In other embodiments, the flanges 32a, b can be omitted and the support member 10 secured to the roof top with fasteners via apertures 36 (for example, as shown in FIGS. 2 and 4), which can also be used to mount the support member and solar panel on a vertical wall.

Referring to FIGS. 8a-8f and 9a-9f, there is illustrated a two-part mold 34a, b that can be used to form the support member 10 using cementitious, metal or plastic materials, such as polymer concrete. As can be seen, the individual parts of the mold have protuberances and recesses corresponding to the apertures 22 and recesses 12, 28 of the support member 10. The support member 10 is formed by positioning the first part 34a of the mold within an external form, such as a wood form. The cementitious, metal or plastic material is pored into the first part of the mold 34a to the height of the protuberances and then the second part 34b of the mold is placed on top of the material and the first part of the mold. The two parts of the mold 34a, b are then urged together to form the support member and, thereafter, the material is allowed to cool or cure. The second part of the mold 34b is then removed and the support member removed from the first part of the mold 34a. If necessary, apertures 36 can be formed in the support member 10 by drilling.

The solar panel 20 is secured within the recess 12 of the support member 10 using suitable fasteners and/or adhesives, such as silicone caulk. The support members 10 can then be mounted to the roof top either by overlapping the opposed flanges 32a, b extending from the lateral sides 16a, b of the support member or using fasteners.

Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A support member for a solar panel, comprising:

a base member having first and second surfaces and first and second sides, said first surface defining a recess configured to receive the solar panel, said base member being formed of polymer concrete.

2. A support member according to claim 1 wherein said recess is configured such that the solar panel can be positioned within said recess with relatively insubstantial gaps between the sides of said recess and the sides of the solar panel and with the front of the solar panel being substantially flush with said first surface of said base member.

3. A support member according to claim 1 wherein said first surface defines at least one aperture within said recess structured to provide space for air to circulate about the back of the solar panel and to reduce the weight of said base member.

4. A support member according to claim 1 wherein said at least one aperture comprises at least one slot.

5. A support member according to claim 1 wherein said at least one aperture comprises at least one circular opening.

6. A support member according to claim 1 wherein said first surface of said base member defines a plurality of raised members within said recess that are structured to engage the solar panel and to provide space between said first surface of said base member and the solar panel.

7. A support member according to claim 6 wherein at least one of said plurality of raised members comprises at least one elongate rib.

8. A support member according to claim 1 wherein said first side of said base member defines a first flange extending therefrom that is flush with said first surface of said base member and wherein said second side of said base member defines a second flange extending therefrom that is flush with said second surface of said base member.

9. A support member according to claim 8 wherein said first flange defines a first lip at the distal end of said first flange and a groove between said first lip and said first side of said base member and said second flange defines a second lip at the distal end of said second flange and a groove between said second lip and said second side of said base member.

10. A support member according to claim 1 wherein said first surface of said base member defines a second recess configured to receive a junction box, said second recess defining an aperture configured to receive the electrical wiring of the solar panel and to provide space for air to circulate about the back of the solar panel.

11. A solar panel array, comprising:

at least two solar panels;

at least two support members, each of said at least two support members comprising a base member having first and second surfaces and first and second sides, said first surface of each of said base members defining a recess configured to receive one of said at least two solar panels, said first side of each of said base members defining a first flange extending therefrom that is flush with said first surface of the corresponding one of said base members, said second side of each of said base members defining a second flange extending therefrom that is flush with said second surface of the corresponding one of said base members; and

wherein said at least two support members are positioned adjacent to one another such that said first flange of one of said at least two support members overlaps said second flange of the adjacent one of said at least two support members.

12. A solar array according to claim 11 wherein said first surface of each of said base members defines a plurality of raised members within said recess that are structured to engage the back of said one of said at least two solar panels and to provide space between said first surface of each of said base members and the back of said one of said at least two solar panels.

13. A solar array according to claim 12 wherein at least one of said plurality of raised members comprises at least one elongate rib.

14. A solar array according to claim 11 wherein said first flange of each of said base members defines a first lip at the distal end of said first flange and a groove between said first lip and said first side of the corresponding one of said base members and said second flange of each of said base members defines a second lip at the distal end of said second flange and a groove between said second lip and said second side of the corresponding one of said base members.

15. A solar array according to claim 11 where in each of said at least two support members is formed of polymer concrete.

16. A solar array according to claim 11 wherein said recess of each of said base members is configured such that said one of said at least two solar panels can be positioned within said recess with relatively insubstantial gaps between the sides of said recess and the sides of said one of said at least two solar panels and with the front of said one of said at least two solar panels being substantially flush with said first surface of the corresponding one of said base members.

17. A solar array according to claim 17 wherein said first surface of each of said base members defining at least one aperture within said recess to enable air to circulate about the back of said one of said at least two solar panels and to reduce the weight of the corresponding one of said at least two support members.

18. A solar array according to claim 17 wherein said at least one aperture comprises at least one slot.

19. A solar array according to claim 17 wherein said at least one aperture comprises at least one circular opening.

20. A solar array according to claim 11 further comprising at least two junction boxes and wherein said first surface of each of said base members defines a second recess configured to receive one of said at least two junction boxes, said second recess defining an aperture configured to receive the electrical wiring of said one of said at least two solar panels and to provide space for air to circulate about the back of said one of said at least two solar panels.

21. A method of forming a support member for a solar panel, comprising:

providing a first mold defining a plurality of protuberances;

encasing the first mold with a form;

filling the first mold with liquid polymeric material and aggregate;

positioning a second mold on the first mold within the form;

urging the first and second molds together;

curing the polymeric material to form a support member, the support member comprising a base member having first and second surfaces and first and second sides, said first surface of said base member defining a recess configured to receive a solar panel; and

removing the support member from the first and second molds.