# US 2021/0242827 A1 · Solar panel racking system > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0242827 A1 - Document ID: US20210242827A1 - Status: Published application - Kind: A1 - Application number: 17/233,388 - Filed: 2021-04-16 - Published: 2021-08-05 - Earliest claimed: 2019-02-07 - Assignees: United States Department of Energy - Inventors: Donald S. Scipione; Rob Martens - Web page: https://patentgrep.com/patent/US20210242827A1 ## CPC - H02S 30/10: Frame structures - H02S 20/24: specially adapted for flat roofs - H02S 30/00: Structural details of PV modules other than those related to light conversion (semiconductor device aspects of modules of electrolytic light sensitive devices H01G9/20, of inorganic PV modules H10F10/00, H10F19/00, of organic PV modules H10K30/00) - H02S 40/30: Electrical components - H02S 40/34: comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes - Y02B 10/10: Photovoltaic [PV] - Y02E 10/47: Mountings or tracking - Y02E 10/50: Photovoltaic [PV] energy - H02S: GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES (obtaining electrical energy from radioactive sources G21H1/12; light sensitive inorganic semiconductor devices H10F; light sensitive organic semiconductor devices H10K30/00; thermoelectric devices H10N10/00; pyroelectric devices H10N15/00) - Y02B: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION ## Abstract A method of installing on a horizontal or near-horizontal support surface a solar panel array including multiple solar panels may include, at the deployment site, fabricating from metal coil stock longitudinally continuous rack channels each having upstanding legs of different heights, locating the channels in parallel rows with a spacing determined by a width of the solar panels with interior spaces of the channels facing upwardly, weighing the channels down on the support surface by placing ballast in the channel spaces, and positioning the solar panels each with an edge supported by a high leg of one channel of the channels and an opposite edge supported by a low leg of an adjacent channel of the channels. ## Claims ### Claim 1 A method of installing on a horizontal or near-horizontal support surface a solar panel array including multiple solar panels, the method comprising: at a deployment site, operating a coil roll-forming machine to fabricate from metal coil stock longitudinally continuous rack channels each having a length of over 40 feet and upstanding legs of different heights; locating the channels in parallel rows with a spacing determined by a width of the solar panels with interior spaces of the channels facing upwardly; weighing the channels down on the support surface by placing ballast in the channel spaces; and positioning the solar panels each with an edge supported by a high leg of one channel of the channels and an opposite edge supported by a low leg of an adjacent channel of the channels, the deployment site corresponding to (a) an area within which the support surface resides plus (b) an adjacent area corresponding to (i) a length of the coil roll-forming machine plus the length of the rack channel times (ii) a width of the coil roll-forming machine. ### Claim 2 (depends on 1) The method of claim 1, comprising: clamping longitudinal edges of the solar panels to the channel legs using clamps, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween. ### Claim 3 (depends on 1) The method of claim 1, comprising: hingedly clamping longitudinal edges of the solar panels to the channel legs using hinged clamps, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween and to permit a longitudinal edge of a panel opposite the longitudinal edge to be pivotably raised about the hinged clamps while the longitudinal edge remains connected to an adjacent support. ### Claim 4 (depends on 1) The method of claim 1, comprising: securing grounding circuitry for the solar panels to the channels. ### Claim 5 (depends on 1) The method of claim 1, comprising: keeping each of the rack channels within the deployment site from fabrication of the rack channel to operation of the solar panel array to produce electricity. ### Claim 6 A method of installing on a horizontal or near-horizontal support surface a solar panel array including multiple solar panels, the method comprising: converting metal coil stock to rack channels made of a single piece of sheet metal each having a length of over 53 feet and upstanding legs of different heights; locating the channels in parallel rows with a spacing determined by a width of the solar panels with interior spaces of the channels facing upwardly; weighing the channels down on the support surface by placing ballast in the channel spaces; and securing the solar panels to the channels each with an edge supported by a high leg of one channel of the channels and an opposite edge supported by a low leg of an adjacent channel of the channels. ### Claim 7 (depends on 6) The method of claim 6, comprising: clamping longitudinal edges of the solar panels to the channel legs using clamps, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween. ### Claim 8 (depends on 6) The method of claim 6, comprising: hingedly clamping longitudinal edges of the solar panels to the channel legs using hinged clamps, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween and to permit a longitudinal edge of a panel opposite the longitudinal edge to be pivotably raised about the hinged clamps while the longitudinal edge remains connected to an adjacent support. ### Claim 9 (depends on 6) The method of claim 6, comprising: securing grounding circuitry for each of the solar panels to respective portions of the channels to which the solar panels are secured. ### Claim 10 (depends on 6) The method of claim 6, comprising: keeping each of the rack channels within a deployment site within which the support surface is located from the converting to operation of the solar panel array to produce electricity. ### Claim 11 A solar panel array deployed on a deployment site, comprising: multiple solar panels; longitudinally continuous rack channels each having a length of over 53 feet and upstanding legs of different heights, the channels located on a support surface in parallel rows with a spacing determined by a width of the solar panels with interior spaces of the channels facing upwardly; and ballasts disposed in the channel spaces to weigh the channels down on the support surface, the solar panels each mounted with an edge supported by a high leg of one channel of the channels and an opposite edge supported by a low leg of an adjacent channel of the channels. ### Claim 12 (depends on 11) The solar panel array of claim 11, comprising: clamps clamping longitudinal edges of the solar panels to the channel legs, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween. ### Claim 13 (depends on 11) The solar panel array of claim 11, comprising: hinged clamps hingedly clamping longitudinal edges of the solar panels to the channel legs, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween and to permit a longitudinal edge of a panel opposite the longitudinal edge to be pivotably raised about the hinged clamps while the longitudinal edge remains connected to an adjacent support. ### Claim 14 (depends on 11) The solar panel array of claim 11, comprising: ground connections for securing grounding circuitry for the solar panels to the channels. ### Claim 15 (depends on 11) The solar panel array of claim 11, comprising: solar panels ground connections for securing grounding circuitry for solar panels mounted to a channel to the channel, the channel having a single ground connection to earth or a remote power system. ### Claim 16 A solar panel array deployed on a deployment site, comprising: multiple solar panels; longitudinally continuous rack channels each having a length of over 40 feet and upstanding legs of different heights, the channels located on a support surface in parallel rows with a spacing determined by a width of the solar panels with interior spaces of the channels facing upwardly; and ballasts disposed in the channel spaces to weigh the channels down on the support surface, the solar panels each positioned with an edge supported by a high leg of one channel of the channels and an opposite edge supported by a low leg of an adjacent channel of the channels, the deployment site corresponding to (a) an area within which the support surface resides plus (b) an adjacent area corresponding to (i) a length of the coil roll-forming machine plus the length of the rack channel times (ii) a width of the coil roll-forming machine. ### Claim 17 (depends on 16) The solar panel array of claim 16, comprising: clamps clamping longitudinal edges of the solar panels to the channel legs, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween. ### Claim 18 (depends on 16) The solar panel array of claim 16, comprising: hinged clamps hingedly clamping longitudinal edges of the solar panels to the channel legs, wherein the clamps space the longitudinal edges of the solar panels from respective channel legs to form a gap therebetween and to permit a longitudinal edge of a panel opposite the longitudinal edge to be pivotably raised about the hinged clamps while the longitudinal edge remains connected to an adjacent support. ### Claim 19 (depends on 16) The solar panel array of claim 16, comprising: ground connections for securing grounding circuitry for the solar panels to the channels. ### Claim 20 (depends on 17) The solar panel array of claim 17, comprising: solar panels ground connections for securing grounding circuitry for solar panels mounted to a channel to the channel, the channel having a single ground connection to earth or a remote power system.