SOLAR PANEL MOUNTING STRUCTURE, SOLAR PANEL SYSTEM, AND METHODS OF MAKING AND INSTALLING THEREOF BACKGROUND TECHNICAL FIELD [0001] The technical field relates to solar panel installation. More particularly, the technical field relates to solar panel mounting structures and methods of installation therefor.

BACKGROUND ART [0002] Solar panels for use in commercial and residential environments are known. Solar panels are typically mounted on a mounting structure, which is supported on a mounting surface, such as a rooftop. Existing mounting structures are often overly complicated and difficult to install and manufacture. In addition, many mounting structures present too large a surface area to wind, and are therefore subject to strong wind uplift forces.

[0003] U. S. Patent No. 6,360, 491 Bl to Ullman discloses a roof support system for a solar panel. Ullman's system provides secure mounting to a roof structure. However, Ullman requires roof penetrations by lag bolts. Further, the rail system of Ullman requires many parts (see FIG. 10) to mount a panel on the roof. In addition, Ullman's system cannot be relocated without sealing existing roof penetrations and creating new roof penetrations.

[0004] U. S. Patent No. 6,105, 317 to Tomiuchi et al. discloses a solar panel mounting system having a plurality of vertical rails. Referring to FIGS. 2,8A and 8B, among others, Tomiuchi's device is also relatively complex, and requires mounting surface penetrations.

[0005] U. S. Patent No. 6,370, 828 Bl to Genschorek discloses a mounting system for a solar panel 1. The mounting system illustrated in FIG. 1, however, requires three separate interlocking roof profiles to support an edge of the solar panel 1. Multiple roof profiles increases complexity of installation and manufacturing.

[0006] U. S. Patent No. 5,768, 831 to Melchior discloses a rooftile support for a photocell panel. Melchior's support however, is formed from a roof tile.

Therefore, the direction and elevation of the solar panel 6 included in the rooftile support cannot be adjusted according to the predominant direction of sunlight.

[0007] U. S. Patent No. 6,105, 316 to Bottger discloses a device for supporting solar panels. Bottger's device is formed by injection-molding. Simple machine processes are not suitable for forming Bottger's injection-molded device.

SUMMARY [0008] According to a first embodiment, a mounting structure for a solar panel comprises a sheet metal frame. The frame comprises a front wall, a bottom wall connected to the front wall, a back wall connected to the bottom wall, a first panel support connected to the front wall, and a second panel support connected to the back wall.

[0009] According to a second embodiment, a panel system comprises a plurality of panel units arranged in at least one row of panel units, each panel unit comprising a frame having a front wall, a bottom wall connected to the front wall, a back wall connected to the bottom wall, the front, bottom, and back walls forming an elongated chamber within the frame, a first panel support connected to the front wall, and a second panel support connected to the back wall. A solar panel is supported by the first and second panel supports of each panel unit, wherein the front walls of the frames in a row are aligned, and the back walls of the frames in a row are aligned.

[00010] A method of making a solar panel mounting structure comprises providing a sheet of metal, cutting the sheet of metal to a desired shape, bending the sheet at a first bend to form a front wall, bending the sheet at a second bend to form a back wall, wherein a bottom wall extends between the front wall and the back wall, bending the sheet at third and fourth bends to form a first panel support at the front wall, and bending the sheet at fifth and sixth bends to form a second panel support at the back wall.

[00011] A method of installing a solar panel system comprises providing a plurality of mounting structures, each mounting structure comprising a frame having a front wall, a bottom wall connected to the front wall, a back wall connected to the bottom wall, the front, bottom, and back walls forming an elongated chamber within the frame, a first panel support connected to the front wall, and a second panel support connected to the back wall. The mounting structures are placed in a row so that front and back walls of the panels in a row are aligned. Solar panels are then mounted in the mounting structures, and the solar panels are electrically connected.

[00012] Those skilled in the art will appreciate the above stated advantages and other advantages and benefits of various embodiments of the invention upon reading the following detailed description of the embodiments with reference to the below-listed drawings.

[00013] According to common practice, the various features of the drawings are not necessarily drawn to scale. Dimensions of various features may be expanded or reduced to more clearly illustrate the embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS [00014] The detailed description will refer to the following drawings, wherein like numerals refer to like elements, and wherein: [00015] FIG. 1 is a perspective view of a panel unit according to a first embodiment.

[00016] FIG. 2 is a front elevational view of the panel unit illustrated in FIG.

1.

[00017] FIG. 3 is a sectional view in side elevation of the panel unit taken on line 3-3 in FIG. 2.

[00018] FIG. 4A is perspective view of a first embodiment of an endcap.

[00019] FIG. 4B is a perspective view of a second embodiment of an endcap.

[00020] FIG. 5 is a perspective view of a stiffening member [00021] FIG. 6 is a sectional view of an alternative mounting structure embodiment.

[00022] FIGS. 7A-7C illustrate a method of manufacturing a frame.

[00023] FIG. 8 is a top plan schematic view of such a first embodiment of a panel system.

[00024] FIG. 9 is a perspective view of the panel system 1000 with elements of the panel system 100 shown in detail.

[00025] FIG. l0A is a front elevational view of a securing strap mounted between two panel units.

[00026] FIG. lOB is a sectional view taken on line lOB-lOB in FIG. 10A.

[00027] FIGS. 11A and 11B illustrate a conversion unit for converting the DC power to AC power.

[00028] FIG. 12 is a rear elevational view of a portion of the panel system illustrated in FIG. 9.

[00029] FIGS. 13-16 illustrate a panel system having interconnect members.

[00030] FIGS. 17-19 illustrate a method of installing a panel system.

DETAILED DESCRIPTION [00031] FIG. 1 is a perspective view of a solar panel unit 100 according to a first embodiment. The panel unit 100 comprises a mounting structure 10 and a solar panel P supported by the mounting structure 10. The panel unit 100 is of a type that may be mounted on, for example, a rooftop. Other mounting surfaces, such as, for example, a relatively flat surface at ground level, are also suitable for mounting the mounting panel unit 100. Relatively level and/or mildly sloped mounting surfaces are preferred.

[00032] FIG. 2 is a front elevational view of the panel unit 100 illustrated in FIG. 1, and FIG. 3 is a sectional view of the panel unit 100 taken on line 3-3 in FIG. 2. Referring to FIG. 2, the mounting structure 10 includes a frame 12. The frame 12 may include insulation sheets 14, which are disposed over the mounting surface for the panel unit 100. The insulation sheets 14 prevent direct contact of the frame 12 with the mounting surface supporting the frame 12, and gaps between the insulation sheets 14 allow water drainage beneath and around the unit 100. The panel unit 100 can be mounted on any relatively stable mounting surface, such as, for example, a rooftop. Endcaps 16 may be attached at either end of the frame 12, thereby closing off the interior of the mounting structure 100. Endcap embodiments 16 and 16'are illustrated in detail in FIGS. 4A and 4B, respectively.

[00033] The sectional view FIG. 3 illustrates the panel unit 100 in greater detail. As shown in FIG. 3, the frame 12 includes a front wall 20, a bottom wall 22, and a back wall 24. The frame 12 has a continuous open channel structure, and encloses an elongated chamber 26. A first panel support 30 extends from the front wall 20, and a second panel support 32 extends from the back wall 24. The panel supports 30,32 support the panel P in the mounting structure 10. The panel P therefore closes off the top of the elongated chamber 26.

[00034] The panel supports 30,32 can be formed from, for example, one or more bends in the frame 12. The panel supports 30,32 illustrated in FIG. 3 are relatively simple structures formed from as few as two bends in a sheet material used to form the frame 12. The panel supports 30,32 may include, for example, one or more apertures (see also FIG. 2) in which screws 34 can be advanced. The apertures can be preformed in the panel supports 30,32, or technicians can drill apertures during installation of the panel unit 100. The panel P can include a metal frame having corresponding apertures, or apertures can be formed in the panel P frame during installation. The screws 34 may be screwed into the frame 12 and also into the apertures in the panel P to securely hold the panel P in place in the mounting structure 10. The screws 34 can be, for example, self-tapping screws.

[00035] The panel unit 100 may also include ballast B within the elongated chamber 26. The ballast B is placed in the frame 12 to keep the panel unit 100 stationary during, for example, high winds or other adverse weather conditions.

The weight of the ballast B is typically selected according to the requirements of local building codes where the panel unit 100 is to be installed. In one embodiment, the ballast B is selected to impart a weight of about 20 lbs. (9 kg) per lineal foot of panel unit. The selection of ballast weight, however, is subject to many factors, and a wide range of ballast weights may be used. The use of interconnect members, described in detail below, may reduce the amount of ballast B required.

[00036] The panel units 100 can include one or more apertures (not illustrated) formed in the bottom walls 22 of the frames 12 (see FIG. 3), or, near the bottom of the front walls 20 or back walls 24. The apertures, or"weep holes" allow water entering the chamber 26 to escape from the frame 12.

[00037] The panel unit 100 can have any dimensions suitable for supporting a selected solar panel P. For example, in one embodiment, the panel unit 100 can have a length of, for example, about ten feet (3 m), and a height (measured along the back wall 24) of about 1'4 feet (0.5 m). The inclination angle a that the panel P is supported at can be selected according to the expected environment in which the panel unit 100 will be installed. For example, in the embodiment illustrated in FIG. 3, the inclination angle a is about 27°. Different angles may be selected to accommodate, for example, the latitude of the site at which the units 100 are to be installed, and for manufacturing and cost considerations.

[00038] FIG. 4A is perspective view of a first embodiment of an endcap 16.

The endcap 16 can be formed from, for example, a piece of cut or stamped sheet metal. Aluminum is one preferred material of construction. The endcap 16 includes two attachment portions 42,44 used to attach'the endcap 16 to the frame 12 (see FIG. 2). The endcap 16 may have apertures 40 formed in the attachment portions 42,44 to receive the screws 34 (FIG. 2) for attaching the endcap 16 to the frame 12. The endcap 16 may optionally include one or more knockouts 46 stamped in the endcap 16 to facilitate interconnection of the panel P with components outside of the panel units 100, and for connection with other devices.

The endcap 16 shown in FIG. 4 is the"left"endcap 16 shown in FIG. 2. The "right"endcap 16 may be a mirror image of the left endcap 16.

[00039] FIG. 4B is a perspective view of an alternative embodiment of an endcap 16'. The endcap 16'is similar to the endcap 16 illustrated in FIG. 4A, as indicated by the similar numbering of elements in FIG. 4B. The endcap 16', however, includes a vent 48. The vent 48 may be in the form of, for example, a screen held in place by welds or screws. The vent 48 can also be formed by forming apertures in sheet metal used to form the endcap 16'.

[00040] The endcaps 16,16'are not required in the panel units 100.

However, the endcaps 16,16'improve the structural rigidity of the panel unit 100.

The endcaps 16,16'also close off the interior chamber 26 of the panel unit 100 (FIG. 3), preventing small animals such as birds from entering the chamber 26 and possibly damaging circuitry on the underside of the panel P. The vented endcap 16'provides the added advantage that excess heat within the interior chamber 26 of a panel unit 100 may be vented by airflow traveling through the vent 48.

[00041] FIG. 5 is a perspective view of a stiffening member 64 used for connecting the back walls 24 of panel units 100 when the units are arranged end to end. The stiffening member 64 can include one or more apertures 68 on either side of the stiffening member 64, which may receive screws 66 for attaching the stiffening member 64 to the adjacent panel units 100. The back walls 24 of the panel units 100 may include corresponding apertures for receiving the screws 66.

Alternatively, the apertures may be formed during installation of a system of the units 100. Stiffening members 64 can be used to connect one or more adjacent panel units 100, thereby increasing the structural rigidity of a row of units 100.

The stiffening members 64 can be formed from, for example, aluminum sheet metal.

[00042] FIG. 6 is a sectional view of an alternative mounting structure 70.

The mounting structure 70 comprises a frame 71. The frame 71 includes a front wall 72, a bottom wall 74 and a back wall 76. A panel support 78 is connected to the front wall 72. An adjustable panel support 82 is adjustably mounted to the back wall 76. The vertical position of the panel support 82 can be adjusted by changing the position at which the panel support is secured to the back wall 76.

Screws 84 can be used to secure the panel support 82 to the back wall 76. The adjustable panel support 82 can be adjusted to provide an inclination angle range of P to ß + y for the panel P.

[00043] As is evident from FIG. 3, the frame 12 can be formed from a single sheet of material, such as, for example, a metallic sheet. In one embodiment, the frame 12 is formed from an elongated sheet of aluminum. Aluminum is a desirable material for construction because it is lightweight and relatively easy to form.

Aluminum is also corrosion-resistant, and will not degrade over time with exposure to ultraviolet rays, as will many plastics. Other metals in sheet form, such as steel, and alloys thereof, may also be used. A preferred range of thicknesses for aluminum sheet material is about. 04 inches (0.1 cm) to. 25 inches (0.6 cm). In one embodiment, the aluminum sheet material is 0.063 inch (1.6 mm) mill-certified sheet aluminum. Screw and bolt fasteners may be, for example, stainless steel.

[00044] The mounting structure 10 used in the panel units 100 have a relatively simple construction, which may be easily manufactured. For example, the frame 12 may be manufactured from a single piece of metal sheet material. A method of manufacturing a frame is illustrated in FIGS. 7A-7C. In FIG. 7A, sheet metal 150 is provided. The metal sheet 150 may have a length L corresponding to a width (as measured across the front of the frame 12-FIG. 2) of several panel units 100. The width W of the metal sheet 150 can correspond to the sum of the lengths of the individual sections of the frame 12 as shown in FIG. 3. In one embodiment, the length L is 10 feet (3 m).

[00045] Referring to FIG. 7B, the metal sheet 150 can be cut or stamped to size to form a blank 152. The blank 152 may also be preformed and provided having the correct dimensions. Any holes or other apertures (not shown) in the blank 152 can then be punched in the blank 152 at their respective locations. Bend locations 161-166 are illustrated on the blank 152. The blank 152 may then be bent along its length at the respective bend locations 161-166 shown in FIG. 7C. A metal brake, for example, may be used to bend the blank 152. Only six bends are required to form the embodiment of the frame 12 illustrated in FIG. 3.

[00046] Holes may alternatively be drilled in the front wall 20 and the back wall 24 to receive the screws 66 (FIG. 12) and 34 (FIG. 2) after bending of the blank 152 in the metal brake. Further, if self-tapping screws are used, it may not be necessary to drill holes in the frame 12. Ventilation louvers (not shown) may be stamped in the front wall 20 and the back wall 24 of the frame 12. Louvers increase convective air flow through and thereby cool the interior of the panel units 100.

[00047] The endcaps 16 or 16' (illustrated in FIGS. 4A and 4B) may be formed from cut or stamped sheet metal patterns. A first bend is used to form the attachment portion 42 and a second bend is used to form the attachment portion 44.

Apertures in the endcaps 16,16'for receiving screws may be formed by drilling or punching. The apertures 40 may be formed before or after the bending operations.

The vent 48 in the endcap 16'can be formed by, for example, welding or screwing a screen to sheet metal used to form the endcap 16'. Apertures may also be cut or stamped in the sheet metal used to form the endcap 16'in order to form the vent 48. The insulation sheets 14 (FIG. 3) may be formed from, for example, a rubber or plastic material. The insulation sheets 14 may also be made from a sheet of rigid insulation. The insulation sheets 14 may be attached to the bottom of the frame 12 using, for example, adhesives. Alternatively the sheets 14 can be provided separate from the frame 12.

[00048] The panel unit 100 may be combined with other panel units to form an array or system of solar panels. FIG. 8 is a top plan schematic view of such a panel system 1000. As shown in FIG. 8, each row of the panel system 1000 includes a plurality of panel units 100 in an end-to-end arrangement. The solar panels P included in the panel units 100 can include circuitry on the back side of the panels P, facing into the elongated interior chamber 26 (FIG. 3) of each panel unit 100. One or more cables and connectors can be used to interconnect the panels P. Preferably, endcaps are only placed on the panel units 100 at the end of a row of panel units 100. A minimum spacing d is used between the rows. The minimum spacing d may be selected so that shadow from nearby rows does not interfere with sunlight reaching a row. In one embodiment, the spacing d is four feet (1. 2 m).

[00049] FIG. 9 is a perspective view of a panel system 1000 with selected elements of the panel system 100 shown in detail. The panel system 1000 is formed by a plurality of rows of panel units 100 lined up end-to-end. Securing straps 90 can be mounted between adjacent panel units 100. The panel units 100 included in the system 1000 include insulation sheets 14, which may be attached to the bottom of the frames 12 or provided separately. The dimensions of the sheets 14 can be selected to provide gaps or channels between the sheets 14 so that water can flow freely beneath the system 1000. Alternatively, a single continuous insulation sheet can be sized to accommodate a row of panel units 100 in the system 1000. Each row of the panel system 1000 can include a conversion unit 200 for converting power from the panels P from DC to AC. A conversion unit 200 is shown in detail in FIGS. 11A and 1 nib.

[00050] FIG. 10A is a front elevational view of a securing strap 90 mounted between two panel units 100 (only a portion of two adjacent panel units 100 are shown in FIG. 10A). The securing strap 90 can be wide enough to extend over a portion of each of the adjacent panels P. The width of the securing strap 90 can be about, for example, two inches. FIG. 10B is a sectional view taken on line 10B- 10B in FIG. 10A, and illustrates the securing strap 90 in further detail. Referring to FIG. 10B, the securing strap 90 extends over the panel P and securely retains the panel P in place in the mounting structure 10. The securing strap 90 also adds rigidity to the system 1000. The added rigidity may prevent spreading of the system 1000 under, for example, a snow load. Securing straps 90 in the system 1000 can also reduce or eliminate the number of screws 34 required to secure the panels P in the panel units 100.

[00051] A securing strap 90 can be secured to the frame 12 of mounting structure 10 by screws 94. The screws 94 can be advanced into the panel supports 30,32, and further advanced into a panel P. The strap 90 includes an upper portion 98 that may closely conform to the panel support 32, and a lower portion 96 that may closely conform to the panel support 30. A gap is illustrated between the strap 90 and the panel P. The strap 90 may, however, contact and exert a downward force on the panel P to maintain the panel P in position in the frame 12.

[00052] In the panel system 1000, the panels P generate DC power that is conveyed from the panels P by the interconnect cabling. FIGS. 11A and 11B illustrate a conversion unit 200 for converting the DC power to AC power, and other associated elements in detail. FIG. 11B is a rear elevational view of the DC- AC conversion unit 200, and FIG. 11A is a perspective view of an isolated portion of a panel system having the conversion unit 200. The conversion unit 200 comprises an inverter 210, a DC disconnect 220, and an AC disconnect 230. The inverter 210 and the disconnects 220,230 can be interconnected by flexible conduits 260,262 that contain cables for conveying AC and DC current.

[00053] The conversion unit 200 may include a frame 202 for mounting the inverter 210 and the disconnects 220,230. The frame 202 can include an overhang portion 204 that provides some protection from the elements for the inverter 210 and the disconnects 220,230. The frame 202 can include brackets 240,242 to increase the stability of the frame 202. The frame 202 can also be screwed to the back of the panel unit 100 at one or more locations.

[00054] Referring to FIG. 11A, the conversion unit 200 is located at the end panel unit 100 in a row of panel units 100 of a panel system 1000. Conversion units can, however, be located at any point along a row, and in other locations either apart from or attached the panel units 100. Only one panel unit 100 is illustrated in FIG. 11A. Rows of panel units 100 in a panel system 1000 are illustrated in FIG. 9. In the embodiment of FIG. 11A, the conversion unit 200 acts to covert the DC power supplied from all of the panel units 100 in a row. There may, however, be multiple conversion units 200 in a row of the system 1000.

[00055] As discussed above, each of the panels P in a row panel units 100 can be connected in series through a continuous open chase formed by the row of panel units 100. The end of the series circuit connection of the row of panel units 100 can be connected to the DC disconnect 220. The DC disconnect 220 is electrically connected to the inverter 210, which converts the DC current from the panels P in the panel units 100 into AC current.

[00056] Referring to FIG. 11A, the AC disconnect 230 can be coupled to a hard conduit 262 by a flexible conduit 254 at a coupling 260. The conduit 262 and the conduit 254 can house one or more conductive cables for conveying AC current from the row of panel units 100. The conduit 262 may extend rearward to subsequent rows in the panel system 1000, with each of the conversion units 200 of a row having an electrical cable extending through the hard conduit 262.

[00057] As an alternative to the above embodiments, DC-AC converters can be included inside one or more of the panel units 100, or, a DC-AC converter can be located at a remote site and connected to the system 1000 by interconnect cabling.

[00058] FIG. 12 is a rear elevational view of a portion of the panel system 1000 illustrated in FIG. 9. In FIG. 12, the panel units 100 are shown as abutting.

However, a gap may be included between one or more of the panel units 100. A stiffening member 64 may be mounted to the two adjacent panel units 100 in FIG.

12. An endcap 16 or 16'is preferably used at each end of the rows of the system 1000. In that arrangement, a continuous open chase extends through the entire system 1000, allowing easy access to interconnect wiring between panels P. Use of vented endcaps 16'at each end of the system 1000 allows for better cooling of the continuous open chase of rows of the system 1000.

[00059] FIGS. 13-16 illustrate a panel system 2000 having interconnect members 310,320, 330 that add to the stability of the system 2000. The system 2000 illustrated in FIG. 13 illustrated with a representative number of six rows 2001,2002, 2003,2004, 2005,2006 and five'columns' (i. e. , a line of panel units 100 extending vertically in FIG. 13) of panel units 100. Any number or rows and columns, however, can be assembled. The panel units 100 shown in FIGS. 13-16 can generally correspond to the panel units 100 discussed above. FIG. 14 is a rear perspective view of a smaller section of the system 2000.

[00060] The use of interconnects to connect panel units 100 is particularly desirable when the system 2000 is to be mounted on a rooftop or other elevated surface. The interconnect members 310,320, 330 illustrated in FIGS. 13-16 tie selected panel units 100 together, which adds to the overall stability of the system 2000. Therefore, lower amounts of ballast B are required to stabilize and anchor the system 2000 in place. Interconnects can be used to connect all units 100 in extremely large arrays. However, in large arrays, it may be desirable to secure only selected sections of the system 2000 using interconnects, such as at the rows at the back of the system 2000. In the embodiment shown in FIG. 13, only the rearmost three rows 2001,2002, 2003 of the system 2000 are interconnected by members 310,320, 330.

[00061] For simplicity of illustration, there is no power conveying or conversion equipment shown for the system 2000. However, the system 2000 can include conversion units 200 and associated cables and conduits as are illustrated in FIGS. 9,11A and 11B. Further, the system 1000 shown in FIG. 9 can be equipped with interconnect members as discussed below.

[00062] Referring to FIGS. 13 and 14, one or more rows of the system 2000 may be interconnected by the members 310,320, 330. The members 310,320, 330 can be constructed from, for example, metallic ell-shaped members. The members 310,320, 330 may be made from, for example, steel or aluminum. The members 310,320 can extend along the left and right ends of the rows of the system 2000, respectively, and can be secured to the panel units 100 by, for example, bolts and/or screws. The members 310,320 have an ell-shape. The members 330 have a"T"shape, and can be formed from two ell-shaped members. Alternatively, the T members 330 can be formed from a unitary extruded T-shaped piece. The members 310,320, 330 extend beneath the panel units 100.

[00063] FIG. 15 illustrates the connection of the member 310 to a panel unit 100. A screw 316 secures a bracket 315 to the back of a panel unit 100. A bolt 317 and a nut 318 secure the bracket 315 to the member 310. The member 310 can be attached in this way to each panel unit 100 located at the end of each row 2001, 2002,2003. The member 320 can be attached in a similar manner at the opposite ends of the rows 2001,2002, 2003. The member 310 is illustrated as an ell member, but a T-shaped member may also be used to form the member 310.

[00064] FIG. 16 illustrates the connection of the T member 330 to adjacent panel units 100. In FIG. 16, the member 330 is illustrated as comprising two ell- shaped metallic members 331,332, but a single extruded T-shaped member 330 may also be used. Brackets 334,335 secure the members 331,332 to adjacent panel units 100. Bolts or screws 337 (only one bolt 337 is visible in FIG. 16) may be used to secure the brackets 334,335 to the panel units 100. A nut 338 and a bolt 339 secure the members 331,332 to the brackets 334,335. The member 330 can be connected to each row of the system 2000 in this manner, and may extend along the length of the system 2000, as shown in FIG. 16. The system 2000 is illustrated as including only one member 330, however multiple members 330 can be arranged to extend through the interior of the rows in the system 2000. For example, members 330 can extend between each of the columns of panel units 100 in the system 2000.

[00065] According to the above embodiments, the panel units 100 are securely attached to one another, increasing the stability of the system 2000. In addition, individual panel units which may be susceptible to wind loads, such as the panel units in the back rows of the system 2000, may be selectively interconnected to more securely hold them within the system 2000.

[00066] The systems 1000,2000 discussed above can be mounted either on the ground, on the roofs of buildings, and on other surfaces. A method of installing the system 2000 is discussed in detail below with reference to FIGS. 17- 19.

[00067] Referring to FIG. 17, first, a straight line is established on a mounting surface, such as a roof. The line is selected to run generally perpendicular to the predominant direction of incoming sunlight (indicated by the arrow in FIG. 17), and having a length equal to the length of the system 2000. The line will serve as an alignment device to ensure that the rearmost or back row 2001 of panel units 100 in the system 100 is properly arranged. The back row 2001 will generally correspond to the North end of the system 2000 when installed in the northern hemisphere, and the South end when installed in the southern hemisphere.

A limited number of additional rows can additionally be laid out to begin the installation process, for example, the back three rows 2001,2002, 2003 of the system 2000 can be arranged first.

[00068] A first mounting structure 10 is then lined up with the line corresponding to the back row 2001. The first mounting structure is labeled'A'in FIG. 17. Next, a mounting structure B is lined up with a row 2002, and a mounting structure C is lined up with a row 2003, forming a column. Starting on the outer edge of the rows 2001,2002, 2003, an ell member 310 is connected to the end of the mounting structures A-C, the member 310 extends perpendicular to the rows 2001,2002, 2003. The ell member 310 forms a rigid connection between the rear three rows 2001,2002, 2003, and helps prevent movement of the competed units 100 due to wind forces.

[00069] The ell members 310 may be pre-punched with holes to accept the brackets 334,335 (shown in FIG. 16). The installer may drill holes on the back side of the mounting structures 10 in alignment with the holes in the brackets 334, 335. The brackets 334,335 are then bolted to the member 310 and to the back side of the mounting structures 10. In FIG. 17, the brackets are illustrated as secured to the exterior of the mounting structures 10. The brackets 334,335 may alternatively be placed inside of the mounting structures 10 and bolted or screwed to the back vertical walls 24 so that the brackets 334,335 are not visible in the finished system 2000. A T-member 330 is then mounted to the other side of the mounting structures A-C, as shown in FIG. 16.

[00070] The next column of mounting structures D, E and F is then placed next to the mounting structures A-C. Referring back to FIG. 3, the front walls 20 of the mounting structures 10 are aligned, as are the back walls 24. The brackets 334,335 are then bolted to structures D, E and F and to the T member 330. Next, ballast B is placed in the chambers 26 of each of the mounting structures A-F for the rows 2001,2002, 2003. The weight of the ballast B can be selected according to the requirements of, for example, building codes. For example, according to ASCE 7-98, for a 90 mile per hour (145 km/hr) wind load, the last two rows 2001, 2002 require 18.5 Ibs. per linear foot (8.4 kg/m) of ballast, the third row 2003 requires 18 Ibs. per linear foot (8.2 kg/m), and all remaining rows going forward in the system 2000 require 9.1 Ibs. per linear foot (4.1 kg/m). This exemplary ballast requirement is based on the rows of the system 2000 being spaced at a distance d of six feet (1. 8 m) on center, with a panel P inclination angle a of 25 degrees.

[00071] The next length of T members 330 are then bolted to the outside edge of the structures D-F. The process of adding mounting structures 10 column- by-column is repeated across the back three rows 2001,2002, 2003 until a desired number of columns or width is achieved for the system 2000. When the last column is emplaced, an ell member 320 (not shown in FIG. 17) is mounted to the outside of the last column, as shown in FIG. 13.

[00072] The last section of mounting structure 10 for each row may be, for example, less than the length of the other mounting structures. A shorter end structure 10 may be used when the total length of the solar panels P in a row is not an integral multiple of structure 10 width.

[00073] Once the rear three rows 2001,2002, 2003 are installed, forward rows can be set in place, one complete row at a time. Alternatively, all rows may be laid out at one time. In one embodiment, as shown in FIG. 13, only the back three rows are interconnected by members 310,320, 330, which allows the forward rows to be laid out without interconnection.

[00074] The additional reinforcement provided by the members 310,320, 330 allows the system 2000 to resist the wind loads, which are typically the greatest on the back rows. The forward rows may also be connected together as shown in FIG. 17, but such interconnection may not be necessary. The addition of interconnect members 330 reduces the amount of ballast required for each mounting unit 10, so if the mounting surface is a rooftop with severe weight limitations, additional rows can be interconnected to reduce the overall weight load of the system 2000.

[00075] Once all rows of mounting units 10 are positioned and ballasted, stiffening members 64 are attached to the rear of the mounting units 10 as shown in FIG. 12. Stainless steel sheet metal screws 66 may be used for attaching the stiffening members 64.

[00076] The solar panels P may now be installed in the mounting structures 10. FIG. 18 is a cross section of a panel P installed in a first mounting structure 10.

Before placing the panel P in the panel supports 30,32, a stiffening strap 340 can be mounted in the panel supports 30,32. The stiffening strap 340 can be about 2 inches wide and made from sheet metal, and can have a shape similar to the mounting straps 90. The stiffening strap 340 can be mounted at or near where the center of a panel P placed in the mounting structure 10 will fall. The strap 340 offers additional strength to the mounting structure 10 and prevents deformation of the mounting structure 10 when under the weight of the panel P.

[00077] The lower edge of a panel P is then placed into the panel support 30 of the mounting structure 10, holding the panel P upright. With the panel P in this position, a grounding wire is attached to the underside of the frame 12. The grounding wires connect from one frame 12 to the next frame 12 in a row. The top of the first panel P is then lowered onto the panel support 32. Screws 34 are used to secure the panel P to the strap 340 and to the supports 30,32. Security screws, requiring a special bit for removal, may be used to deter theft of the panels P. As an alternative to grounding wires, a screw through the support 32 and through the panel P may be used for grounding.

[00078] Another stiffening strap 340 (not shown) is then placed on supports 30,32 at the center of where the next panel P in the row will fall. The bottom edge of the second panel P is placed on the mounting structure 30 of the next frame 12, and the ground wire from the first frame 12 is attached to the second frame 12, along with another ground wire that will attach to a third frame 12. The second panel P cables are then connected to the first panel P in series, and the second panel P is lowered onto the mounting structure 32. A small gap can be left between adjacent panels P to allow for thermal expansion of the panels P.

[00079] Referring to FIG. 19, a mounting strap 90 is laid over adjacent ends of the first and second panels P to hold them on the mounting structure 10. Screws are screwed through the mounting structures 30,32 and the mounting strap 90.

The"C"shaped end of the strap 90 over the bottom edge of the support 30 and the "L"shaped end of the strap 90 hooks over the support 32.

[00080] The process of setting panels P into the mounting structures 10, connecting ground wires from panel P to panel P, and making electrical ties from panel P to panel P, is repeated until a row is complete. The two panels P at either end of the rows may have additional security screws installed at the ends, since there are no mounting straps 90 at these locations. A plurality of rows are formed using this method.

[00081] For each row, the wiring from the panels P and the ground wire connection can then be connected to a conversion unit 200, as shown in FIG. 11A.

Referring to FIG. 11A, the wiring is connected through the back of the frames 12 to the DC disconnect 220 and the remainder of the connections can be made as discussed above. Once the wiring is completed, ventilated end caps 16'are screwed to the end panels P of each row, thereby closing off the interior of the system 2000. The conversion unit is illustrated as mounted on an end panel unit 100, but other mounting locations are possible.

[00082] Selected rows in the system 2000 may be provided with double stick tape attached to the bottom of the mounting structures in the row. The tape has a paper face that is removed before setting these mounting structures 10 in place, which provides the selected rows an increased coefficient of friction to offset wind . forces. This tape need not fully adhere to the roof, and if necessary, the mounting structure 10 can be picked up and moved.

[00083] In general, any number of mounting structures 10 can be used, and the number of panel units 100 in the system 2000 is selected based on the power required from the system 2000. The size of the mounting surface may also determine the size and shape of the system 2000. The front walls 20 of the mounting structures 10 are arranged to face a direction of the predominant supply of sunlight. The angle a (FIG. 3) of the mounting structures 10 may be pre- selected according to the latitude of the installation site and according to cost and manufacturing factors.

[00084] Insulation sheets 14 can be separate from the frames 12, or provided on the frames 12 prior to installation of a system 1000,2000. In the embodiments illustrated above, each frame 12 includes two sheets 14 glued to the bottom of the frame prior to installation. The sheets 14 may be, for example, 1 inch (2.54 cm) thick by 4 foot (1.2 m) long pieces of polystyrene insulation. The insulation sheets 14 protect the roofing material from the underside of the units 100 and creates channels for rainwater to flow through.

[00085] If separate layers or mats 14 are to be used, the individual sheets 14 may be laid out for the back rows before arranging the frames into rows. If a single continuous insulation sheet is to be used, that insulation sheets may instead be laid out on the mounting surface along a line corresponding to each row.

[00086] Any number of panel units 100, in any combination of rows and columns, may be connected end-to-end in the manner described above.

[00087] According to the panel unit 100 and the panel system 1000,2000 embodiments discussed above, the panel unit 100 has a relatively simple design that is easy and inexpensive to manufacture. Further, installation of the panel unit 100 requires minimal skill, and a system 1000,2000 of panel units 100 can therefore be quickly and easily installed with a minimal cost of labor. Because of the simplicity of the design of the mounting structure 10, the structure 10 can also be manufactured very quickly, reducing turnaround time for orders of the device.

[00088] The mounting structure 10 is also very light in weight, rendering transport of the mounting structure 10 easier. A typical commercial embodiment of a mounting structure, having a length of 10 feet (3 m), such as the one discussed above, will have weight (not including the ballast B or the solar panel P) of only about 40 pounds (18 kg). Therefore, a single technician can easily move the mounting structure without assistance. This feature is particularly advantageous when panel units 100 are to be installed on an elevated mounting surface, such as a rooftop. As a further advantage, the shape of the frame 12 of the mounting structures 10 allows the structures 10 to be stacked while in storage or in transport.

[00089] As shown in FIG. 1, the panel unit 100 has an aesthetically smooth and continuous exterior appearance, especially when endcaps 16 or 16'are included on the panel unit 100. The smooth exterior of the panel unit 100 also greatly reduces the wind uplift force exerted on the panel unit 100. Wind uplift forces are a primary concern when installing solar panel arrays.

[00090] As a further advantage of the above embodiments, the panel unit 100 is easy to move during or after installation. The panel unit 100 does not require bolting or screwing to the mounting surface, and penetrations in the mounting surface are thereby avoided. If, for example, a panel unit 100 is installed as part of system 2000, the panel unit 100 can be easily moved, removed or replaced, by disconnecting any interconnection circuitry between adjacent panel units 100 (and removing stiffening members 64, if present). Watertight quick disconnect plugs can be used to connect the solar panels P in adjacent panel units 100, speeding installation and removal. An entire system 100 of panel units 100 may therefore be easily relocated and rearranged.

[00091] The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected preferred embodiments of the invention, but it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art.

INDUSTRIAL APPLICABILITY [00092] As explained above, the solar panel mounting structures, solar panel systems, and the methods and making and installing thereof provide the ability to install solar panels for the generation of electric power. The systems are light weight and easy to install and to rearrange once installed.