Apparatus for mounting a solar panel and method and apparatus for forming the mounting apparatus

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.

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;

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