Racking systems for solar panels and methods for using such systems

Abstract

A racking system for mounting a solar panel system at an installation site includes a plurality of elongate rods, each rod including a first lower end for insertion into the ground at the installation site and a second upper end; a plurality of elongate struts, each strut connectable to the upper ends of two or more rods aligned along a horizontal axis such that the struts are spaced apart from one another substantially parallel to one another; a plurality of tilt brackets mountable to the struts along their lengths, each tilt bracket including a central region mountable to a strut such that arms of the tilt bracket are positioned on either side of the strut; and a plurality of clamps mountable to the arms of the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between adjacent struts.

Description

[0001] RACKING SYSTEMS FOR SOLAR PANELS AND METHODS FOR USING SUCH SYSTEMS

[0002] RELATED APPLICATION DATA

[0003] The present application claims benefit of and priority to co-pending U.S. provisional applications Serial Nos. 63 / 716,689, filed November 5, 2024, and 63 / 851,631, filed July 26, 2025, the entire disclosures of which are expressly incorporated by reference herein.

[0004] TECHNICAL FIELD

[0005] The present application relates to renewable energy systems using a surface mounted application, and more particularly, to racking systems or mounts for solar panel systems and to methods for using such racking systems. The racking systems may also include components that provide electrical bonding paths and / or grounding systems for solar panels mounted to the racking systems.

[0006] BACKGROUND

[0007] It is well known that alternative renewable energy resources are proven to be an important element in an overall energy plan for the off taker. Cost savings initiatives and a renewable and sustainable clean energy solution to lower the cost of energy (“LCOE”), is a critical factor as the cost of carbon-based fuels and other fossil fuels are costly to use and continue to increase cost over time and these fossil fuels harm the environment and impact climate change. Grid parity has been achieved in large utility scale solar power plant installations, but not in distributed generation renewable energy applications. Solar (photovoltaic) energy, and battery energy storage systems (“BESS”) help recipients of this clean, renewable energy to load shift away from high rate tariffs and demand charges or be totally independent of the electrical grid. In order to produce sufficient usable and reusable clean energy from the sun, it is necessary to place one or more solar arrays in areas where they can capture the most solar radiation.

[0008] Conventional foundations and support structures required to install such solar arrays generally involve pre-development and engineering, geotechnical reports, environmental impact studies, site planning, grading, mobilization of heavy equipment, concrete, substantial procurement time and cost, installation time and cost, particularly for I-beam steel piles, ballasted concrete blocks, poured-in-place cement piers or helical ground screw foundations used for surface mounted solar arrays, and involve substantial earth and project site disruption which impact the local environmental. Therefore, improved solar power racking systems, platforms, support structures and foundations for solar arrays and methods for installing and / or using them would be useful, more economical and efficient, and most beneficial to the environment.

[0009] SUMMARY

[0010] The present application is directed to renewable energy systems using a surface mounted application, and more particularly, to racking systems or mounts for solar panel systems and to methods for using such systems. The racking systems may be modular, i.e., allowing any number of solar panels systems to be installed at a site. In some examples, the racking systems may also include components that provide electrical bonding paths and / or grounding systems for solar panels mounted to the racking system, e.g., including grounding clamps, bonding connectors, conductor hardware, and / or other components that may be used for rooftop and ground-mounted racking systems.

[0011] In accordance with one example, a racking system is provided for mounting a solar panel system at an installation site that includes a plurality of elongate rods, each rod including a first lower end for insertion into the ground at the installation site and a second upper end; a plurality of elongate struts, each strut connectable to the upper ends of two or more rods aligned along a horizontal (or other) axis such that the struts are spaced apart from one another substantially parallel to one another; a plurality of tilt brackets mountable to the struts along their lengths, each tilt bracket including a central region mountable to a strut such that arms of the tilt bracket are positioned on either side of the strut; and a plurality of clamps mountable to the arms of the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between adjacent struts.

[0012] In accordance with another example, a racking system is provided for mounting a solar panel system to a roof or other surface that includes a plurality of pedestals comprising a lower portion configured to secure the lower portion to a roof or other surface and a second upper end; a plurality of support brackets comprising upper ends and lower ends connectable to the upper ends of the pedestals; a plurality of tilt brackets mountable to one or both of the upper ends of the pedestals and the upper ends of the support brackets, a tilt bracket of the plurality of tilt brackets including a central region configured to be secured to the upper end of one of the pedestals and the support brackets such that first and second arms of the tilt bracket are positioned on either side of the central region; and a plurality of clamps mountable to the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between and above adjacent pedestals, a clamp of the plurality of clamps configured to be slidably received on and secured to the first arm of the tilt bracket.

[0013] In accordance with still another example, a racking system is provided for mounting a solar panel to a surface that includes four pedestals comprising a lower portion for placement on a surface and a second upper end; a plurality of support brackets comprising upper ends and lower ends connectable to the upper ends of the pedestals; a set of four tilt brackets mountable to one or both of the upper ends of the pedestals and the upper ends of the support brackets, each tilt bracket of the plurality of tilt brackets including a central region configured to be secured to the upper end of one of the pedestals and the support brackets such that first and second arms of the tilt bracket are positioned on either side of the central region; and a set of four clamps mountable to respective tilt brackets to secure edges of the solar panel to the tilt brackets such that the solar panel extends between and above adjacent pedestals.

[0014] In accordance with yet another example, a racking system is provided for mounting a solar panel system at an installation site that includes a plurality of elongate rods, each rod including a first lower end for insertion into the ground at the installation site and a second upper end; a plurality of elongate struts, each strut connectable to the upper ends of two or more rods aligned along a horizontal or other axis such that the struts are spaced apart from one another substantially parallel to one another; a plurality of tilt brackets integrally formed on the struts and spaced apart from one another along lengths of the struts, each tilt bracket including arms that extend laterally on either side of the respective strut; and a plurality of clamps mountable to the arms of the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between adjacent struts.

[0015] In accordance with another example, a pedestal is provided for a racking system for mounting a solar panel system to a roof or other surface that includes a lower portion including a plurality of side walls surrounding an opening in a lower surface, and a plurality of inner walls dividing the opening into a plurality of spaces for receiving adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; and an upper portion including an upper surface including a track and tapered surfaces extending from the upper surface towards the lower portion, the track configured to slidably receive one or more fasteners to secure a bracket to the pedestal.

[0016] In accordance with still another example, a pedestal is provided for a racking system for mounting a solar panel system to a roof or other surface that includes a lower portion including a plurality of side walls surrounding an opening in a lower surface configured to receive adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; an upper portion including an upper surface including a track configured to slidably receive one or more fasteners to secure a bracket to the pedestal; and a plurality of connectors for securing the upper portion to the lower portion.

[0017] In accordance with yet another example, a pedestal is provided for a racking system for mounting a solar panel system to a roof or other surface that includes a lower portion including a lower surface including a plurality of openings therethough communicating with an interior of the lower portion for receiving adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; and an upper portion including an upper surface including a plurality of tracks, each track configured to slidably receive one or more fasteners to secure a bracket to the pedestal. For example, the upper surface may include a first portion that is oriented substantially parallel to the lower surface and includes a first track, and a second portion that is inclined relative to the first portion and includes a second track.

[0018] Other aspects and features of the present invention will become apparent from consideration of the following description taken in conjunction with the accompanying drawings.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] It is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

[0021] FIG. 1 is a perspective view of an example of a racking system for a solar array system for a ground-mounted installation.

[0022] FIG. 2A is a side view of the racking system of FIG. 1 relative to the surface of the ground at an installation site.

[0023] FIGS. 2B and 2C are end and top views, respectively, of the racking system of FIG.

[0024] 1. FIGS. 3A and 3B are details showing exemplary mounting assemblies for securing solar panels to vertical supports of the racking system of FIG. 1 including end clamp securing edges of the solar panels to arms of tilt brackets mounted to an elongate strut or purlin.

[0025] FIG. 4 is a perspective view of an exemplary vertical support for the system of FIG. 1, namely an elongate rod.

[0026] FIGS. 5 A and 5B are perspective and top views, respectively, of an elongate strut or purlin of the racking system of FIG. 1.

[0027] FIG. 5C is a cross-sectional view of the strut of FIGS. 5A and 5B.

[0028] FIGS. 6 A and 6B are perspective and top views, respectively, of a shoe plate of the racking system of FIG. 1 that may be coupled to a vertical support, such as the elongate rod shown in FIG. 4.

[0029] FIG. 6C is a cross-sectional view of the shoe plate of FIGS. 6A and 6B.

[0030] FIG. 6D is a perspective view of an alternative shoe plate that may be used on a racking system.

[0031] FIG. 6E is a cross-sectional view of the shoe plate of FIG. 6D.

[0032] FIGS. 7A-7C are perspective, top, and side views of an exemplary tilt bracket of the racking system of FIG. 1 that may be mounted to a purlin such as that shown in FIGS. 5A- 5C.

[0033] FIGS. 8 A and 8B are perspective and side views, respectively, of an end clamp for the racking system of FIG. 1 that may be attached to an arm of a tilt bracket such as that shown in FIGS. 7A-7C for securing one edge of a solar panel to the purlin, e.g., as shown in FIGS. 3 A and 3B.

[0034] FIGS. 9 A and 9B are perspective and side views, respectively, of a bottom clamp portion of the end clamp of FIGS. 8 A and 8B.

[0035] FIGS. 10A and 10B are perspective and side views, respectively, of a top clamp portion of the end clamp of FIGS. 8A and 8B.

[0036] FIGS. 11 A-l 1C show alternative configurations for a tilt bracket that may be used in a racking system, such as the racking system of FIG. 1.

[0037] FIG. 12A is a detail showing a method for mounting the tilt bracket shown in FIG. 11 A to a purlin and rod of a racking system, such as that shown in FIG. 1.

[0038] FIG. 12B is a detail showing a method for mounting the tilt bracket shown in FIG. 11C to a purlin and rod of a racking system, such as that shown in FIG. 1. FIG. 13 is a detail showing a tilt bracket oriented relative to a purlin for mounting.

[0039] FIGS. 14A-14D show another example of a tilt bracket (FIG. 14 A) and end clamp (FIG. 14B) that may be used to secure solar panels to a racking system (FIGS. 14C and 14D).

[0040] FIGS. 15A and 15B are perspective and side views, respectively, of a wire management hook that may be attached to a racking system, e.g., to a vertical support, to receive wires of the racking system.

[0041] FIGS. 16A-16C are perspective, top, and side views of another example of a tilt bracket of that may be mounted to a purlin of a racking system, such as that shown in FIG. 1.

[0042] FIGS. 17A and 17B are perspective and side views, respectively, of another example of an end clamp that may be attached to an arm of a tilt bracket such as that shown in FIGS. 16A-16C for securing one edge of a solar panel to the purlin.

[0043] FIGS. 18A and 18B are perspective and side views, respectively, of a bottom clamp portion of the end clamp of FIGS. 17A and 17B.

[0044] FIGS. 19A-19C are perspective, side, and front views, respectively, of a top clamp portion of the end clamp of FIGS. 17A and 17B.

[0045] FIG. 20 is a detail showing a method for mounting edges of adjacent solar panels to arms of the tilt bracket of FIGS. 16A-16C using the end clamp shown in FIGS. 17A and 17B.

[0046] FIG. 21 A is a perspective view of an example of a racking system for a solar array system for a surface-mounted installation, including a plurality of bases or pedestals and vertical supports to which tilt brackets and end clamps are mounted to support edges of solar panels of the solar array system.

[0047] FIG. 2 IB is a perspective view of another example of a racking system for a solar array system for surface-mounted installation, including a plurality of bases or pedestals and vertical supports supporting individual solar panels.

[0048] FIG. 22A is a detail showing the tilt bracket of FIGS. 16A-16C mounted to a horizontal pedestal, e.g., to support a lower edges of solar panels of the solar array system of FIG. 21 A.

[0049] FIG. 22B is a side view of the pedestal and tilt bracket shown in FIG. 22A with an end clamp coupled to the edge of a solar panel and mounted to the tilt bracket. FIG. 22C is a detail showing the tilt bracket of FIGS. 16A-16C mounted to another example of a pedestal configured to provide a tilt angle to the lower edges of solar panels.

[0050] FIG. 22D is a side view of the pedestal and tilt bracket shown in FIG. 22C with an end clamp coupled to the edge of a solar panel and mounted to the tilt bracket, showing the resulting tilt angle of the solar panel.

[0051] FIGS. 23A-23C are perspective views showing different length vertical support brackets mounted to a pedestal including the tilt bracket of FIGS. 16A-16C mounted to an upper end of the support bracket with an end clamp securing a solar panel to one arm of the tilt bracket.

[0052] FIG. 23D shows another example of a vertical support bracket mounted to a pedestal and including a tilt bracket mounted to an upper end of the support bracket with a pair of end clamps securing adjacent solar panels to opposite arms of the tilt bracket.

[0053] FIGS. 24 A and 24B are perspective and side views, respectively, of a lower clamp member for a vertical support bracket, such as the support brackets shown in FIGS. 23 A- 23C.

[0054] FIGS. 25 A and 25B are perspective and side views, respectively, of an upper clamp member for a vertical support bracket, such as the support bracket shown in FIG. 23 A.

[0055] FIGS. 25C and 25D are perspective and side views, respectively, of another example of an upper clamp member for a vertical support bracket, such as the support bracket shown in FIG. 23C, longer than the upper clamp member of FIGS. 25 A and 25B.

[0056] FIGS. 26 A and 26B are perspective views of another example of a pedestal for engaging support brackets of a racking system for solar panels.

[0057] FIG. 26C is an end view of the pedestal of FIGS. 26A and 26B.

[0058] FIG. 27 shows an example of a grounding lug that may be secured to an arm of a tilt bracket of a racking system.

[0059] FIG. 27A is a detail of the grounding lug of FIG. 27.

[0060] FIG. 28A is a cross-sectional view of still another example of a pedestal.

[0061] FIG. 28B is a side view of the pedestal of FIG. 28 A.

[0062] FIGS. 29A and 29B are perspective and top views of an example of ballasted base for a racking system including a tray receiving one or more ballast blocks (two shown), e.g., to which a support member may be secured. FIG. 29C is a cross-section of the ballasted base of FIGS. 29 A and 29B showing a pair of bolts received through the base for attaching a lower end of a support member thereto.

[0063] FIG. 29D is a bottom view of the tray of the ballasted base of FIGS. 29A and 29B.

[0064] FIG. 29E is a cross-section of an alternative ballasted base including a single bolt to which an alternative support member may be attached.

[0065] FIG. 30 is a top view of another example of a strut or purlin for a racking system for a solar array system for a ground-mounted installation including integral tilt brackets.

[0066] FIG. 30A is a cross-sectional view of the strut of FIG. 30, showing.

[0067] FIG. 30B is a cross-sectional view of an alternative example of a strut.

[0068] FIGS. 31 A and 3 IB are perspective views of another example of a pedestal for engaging support brackets of a racking system for solar panels.

[0069] FIG. 31C is a cross-sectional view of the pedestal of FIGS. 31 A and 3 IB.

[0070] The drawings are not intended to be limiting in any way, and it is contemplated that various examples of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

[0071] DETAILED DESCRIPTION

[0072] The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

[0073] Before the examples are described, it is to be understood that the invention is not limited to particular examples described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular examples only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims. Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limits of that range is also specifically disclosed. Each smaller range between any stated value or intervening value in a stated range and any other stated or intervening value in that stated range is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included or excluded in the range, and each range where either, neither or both limits are included in the smaller ranges is also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the invention.

[0074] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, some potential and exemplary methods and materials are now described.

[0075] It must be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a compound” includes a plurality of such compounds and reference to “the polymer” includes reference to one or more polymers and equivalents thereof known to those skilled in the art, and so forth.

[0076] Certain ranges are presented herein with numerical values being preceded by the term “about.” The term “about” is used herein to provide literal support for the exact number that it precedes, as well as a number that is near to or approximately the number that the term precedes. In determining whether a number is near to or approximately a specifically recited number, the near or approximating unrecited number may be a number which, in the context in which it is presented, provides the substantial equivalent of the specifically recited number.

[0077] The term “substantially” is used throughout this document to indicate variations in the thus qualified terms. These variations are variations that do not materially affect the manner in which the invention works and can be due, for example, to uncertainty in manufacturing processes or to small deviations from a nominal value or ideal shape that do not cause significant changes to the invention. Turning to the drawings, FIGS. 1-2C show an example of a solar panel installation 10 that includes a racking system or frame 12 for supporting a plurality of solar panels 90. Generally, the system 12 includes a plurality of elongate rods or support legs 20, and a plurality of elongate struts or purlins 30 attached to the rods 20, e.g., such that the purlins 30 are spaced apart from one another substantially parallel to a desired horizontal, e.g., northsouth, axis. Optionally, base or shoe plates 26 may be provided that may be secured to the rods 20, e.g., at the surface of the ground 80, as described further elsewhere herein.

[0078] The system 12 also includes a plurality of brackets, e.g., tilt brackets 40, mounted to the purlins 30, and end clamps 50 that together mount solar panels 90 between adjacent purlins 30, e.g., as shown in FIGS. 3A and 3B and described further elsewhere here. The system 12 may include various fasteners, e.g., bolts, nuts, screws, rivets, brackets, and the like, to permanently or removably attach the various components of the system 12 together during installation, as shown in the drawings and as described elsewhere herein. In addition or alternatively, components may be attached together by one or more of clinching, welding, bonding with adhesive, and the like.

[0079] In addition, as described elsewhere herein, during installation, one or more earth anchor systems 60, e.g., toggle anchors with rod and / or cable, may be attached to the system 12, e.g., to one or more of the purlins 30 or other structures of the system 12, e.g., the base plates 26, and inserted into the ground at the installation site, e.g., to provide an earthanchoring foundation that may be used to substantially permanently or removably install the solar panels 90 at a desired location, similar to the anchors described in U.S. Patent No. 10,622,938, the entire disclosure of which is expressly incorporated by reference herein.

[0080] Optionally, one or more cables or additional struts 70 may be provided that may be attached to or otherwise extend between the rods 20, purlins 30, base plates 26, and / or anchor systems 60, e.g., in an “X” configuration within a plane, to further reinforce or support the frame 12 as desired.

[0081] It will be appreciated that the components of the system 12 may be formed using conventional materials and methods, e.g., formed from metal such as steel or aluminum, plastics, or composites, e.g., fiberglass or fiberglass reinforced plastic (FRP), and the like, having desired cross-sections or configurations. Optionally, some of the components may be formed from fiberglass coated or embedded with graphene, e.g., to enhance structural properties of the components and / or provide electrical conductivity to the components, as described further elsewhere herein. For example, as described further elsewhere herein, one or more of the purlins 30, tilt brackets 40, and end clamps 50 may be formed from conductive materials to provide a electrical bonding paths and / or grounding systems for solar panels 90 mounted to the system 12. The components may be provided in preset lengths and / or sizes or may be provided in stock lengths and / or sizes that may be modified, as desired, e.g., cut-to length during installation.

[0082] During installation, e.g., as shown in FIGS. 2 and 3, the rods 20 may be inserted into the ground 80 in a desired arrangement, e.g., in a plurality of rows spaced apart from one another based on the necessary spacing for the solar panels 90 mounted to the system 12, e.g., with two or more rods 20 in each row. For example, a first or lower end 22 of each rod 20 may be inserted into the ground, e.g., by driving a second or upper end 24 of the rod 20 using a mallet or other manual tool or a motorized tool (not shown), to orient each 20 vertically with the upper end 24 extending out of the ground 80, as best seen in FIG. 3.

[0083] Optionally, a base plate 26 may be secured to each of the rods 20, e.g., to further support and / or stabilize the rods 20 relative to the ground 80. For example, as shown in FIGS. 6A-6C, each base plate 26 may include a substantially flat (or otherwise shaped) plate 27 and a tubular body 28 extending vertically from the flat plate 27, which is sized to receive the rod 20 therethrough. The base plate 26 may be formed from metal, such as steel or aluminum, plastics, such as polyurethane, hard rubber, and / or composite materials, such as fiberglass or FRP. The flat plate 27 of each base plate 26 may have any desired shape, e.g., a square, rectangular, round, or oval shape. If the plate 27 has a rectangular or other asymmetrical shape, the plate 27 may be oriented as desired when placed on the ground at an installation site, e.g., with the longer dimension oriented to enhance support of the system 12, e.g., oriented substantially parallel to a length of the purlins 30 to enhance support against wind loads.

[0084] In one example, the tubular body 28 may have an inner diameter that is larger than the outer diameter of the rod 20 such that the tubular body 28 may receive the upper end 24 of the rod 20 to allow the base plate 26 to be inserted over the rod 20 until the flat plate 27 is seated against the ground 80. Optionally, the flat plate 27 may include one or more bent or otherwise angled corners 29, e.g., including a hole 29a therethrough. For example, as shown in FIGS. 6A-6C, each corner 29 of the flat plate 27 may be angled upwardly, which may facilitate coupling a support cable, such as cables 70, to the flat plate 27 through the holes 29a. As best seen in FIG. 6C, the tubular body 28 may extend vertically from the flat plate 27, e.g., substantially perpendicular to a horizontal surface of the flat plate 27. Alternatively, as shown in FIGS. 6D and 6D, a base plate 26’ may be provided that includes a tubular body 28’ that is not perpendicular to the flat plate 27,’ e.g. extends at an acute angle less then ninety degrees (90°), e.g., offset from vertical between about five and fifteen degrees (5-15°), or between about five and ten degrees (5-10°), which may allow the flat plate 27 to be placed on a non-horizontal surface over a rod (not shown) inserted vertically into the surface. The tubular body 28 may be substantially rigid or may be sufficiently pliable such that the tubular body 28 may be crimped inwardly, e.g., after receiving a rod 20 therethrough, to enhance engagement with the rod 20.

[0085] In one example, shown in FIG. 4, each rod 20 may be a section of rebar or other solid or tubular members, e.g., formed from metal such as carbon steel, galvanized steel, aluminum, and the like, composite materials, such as fiberglass, and the like. For example, the rods 20 may have a solid cross-section or a tubular cross-section, e.g., having a round, square, or other cross-section, which may be formed, e.g., by one or more of extruding, casting, machining, and the like, from metal, such as steel or aluminum, plastics, such as polyurethane, hard rubber, and / or composite materials, such as fiberglass or FRP with or without graphene. The rods 20 may be previously cut to length before delivery into desired lengths or, alternatively, individual rods 20 may be cut from longer sections of material at the installation site. Optionally, at least an intermediate portion of the rod 20 may be threaded such that a nut and / or washer may be threaded over the rod 20 to engage the upper end of the tubular body 28 of the base plate 26 and secure the flat plate 28 against the ground 80. In addition or alternatively, the base plates 26 may be secured to respective rods 20 at a desired location, e.g., by one or more of cinching or otherwise compressing the tubular body 27 around the rod 20, bonding with adhesive, welding, and the like.

[0086] The purlins 30 may be attached to the upper ends 24 of the rods 20, e.g., during installation, to secure the purlins 30 in a plurality of horizontal rows substantially parallel to one another, e.g., as best seen in FIG. 1. Alternatively, the purlins 30 may be oriented at a desired angle, e.g., with one end higher than the other such that the solar panels 90 supported by the purlins 30 are angled in a desired manner, e.g., at an angle between about five and ten degrees (5-10°) from horizontal. For example, in the northern hemisphere, the system 12 may be installed with the southern ends of the purlins 30 lower than the northern ends to enhance exposure of the solar panels 90 to sunlight, as described elsewhere herein. For example, as shown in FIGS. 5A-5C, each purlin 30 may be a length of “C” channel, e.g., including a base 32 and a pair of sidewalls 34 extending from the base 32 opposite one another. The base 32 includes a plurality of holes or other passages 36 therethrough, e.g., spaced apart evenly between opposite ends of the purlin 30, which may be sized to receive the upper end 24 of the rods 20. One or more brackets, bolts, and / or other fasteners (not shown) may then be attached to the upper end 42 of the rod 20 to secure the purlin 30 to the rod 20. The purlins 30 may be formed, e.g., by one or more of extruding, casting, machining, and the like, from metal, such as steel or aluminum, plastics, such as polyurethane, hard rubber, and / or composite materials, such as fiberglass or FRP with or without graphene.

[0087] Tilt brackets 40 may be attached to each of the purlins 30, e.g., two for each solar panel 90 intended to be secured along the length of each purlin 30. For example, as shown in FIG. 1, each purlin 30 may include four tilt brackets 30, two for each solar panel 90 being mounted to the purlin 30. As shown in FIGS. 7A-7C and 11-13, each tilt bracket 40 may include a central region 42 that may be secured to the purlin 30 such that arms 44 of the tilt bracket 40 are positioned on opposite sides of the purlin 30. Thus, each solar panel 90 may be positioned on at least two arms 44 along each of the opposite side edges of the panels 90. End clamps 50 may then be used to secure the side edges 92 of the panels 90 to respective tilt brackets 40, e.g., as shown in FIGS. 8A-10B and 12A-12B.

[0088] Turning to FIGS. 7A-7C, a first example of a tilt bracket 40 is shown that includes a central region 42, e.g., intended to be oriented substantially horizontally (or at the angle of the purlins 30), and a pair of arms 44 extending from the central region 42 at an angle 46 relative to a horizontal plane defined by the central region 42. Optionally, as shown in FIGS. 12A and 12B, the central region 42 may include a block 42a, 42b extending upwardly and / or downwardly from the central region 42. In FIG. 12A, the tilt bracket 40 includes an upper block 42a and an upper block 42b, while in FIG. 12B, the tilt bracket 40” only includes a lower block 42b.” For example, as shown, the lower block 42b, 42b’ may extend downwardly from the central region 42, 42’ having a width corresponding to the purlin 30, e.g., such that the lower block 42 may be introduced between the sidewalls 34 of the purlin 30 with minimal gap, which may stabilize the tilt bracket 40, 40” during installation. Optionally, in the example shown in FIG. 12A, the lower block 42b may be longer than the upper block 42a, which may facilitate inserting a bolt (not shown) upwardly through a vertical hole 43 passing through the block 42a, 42b, and then accessing the head below the lower block 42b for tightening.

[0089] As shown in FIGS. 7A-7C, the outer end 48 of each arm 44 (opposite the central region 42) may include a flange or hook 49 extending transversely from the arm 44, e.g., upwardly and downwardly from the outer end 48. As shown, the flanges 49 are substantially perpendicular to the arms 44, although alternatively, the flanges 49 may extend at other angles, e.g., at an acute angle less than ninety degrees (90°), e.g., at about thirty degrees (30°) towards the central region 42. The flanges 49 may be configured to enhance engagement with a frame or other perimeter of solar panels 90 placed on the arms 44, as described further elsewhere herein.

[0090] In the examples shown in FIG. 11 A, the arms 44 may extend diagonally from the central region 42, thereby defining an incline angle 46 between the planes of the central region 42 and the arms 44. In one example, the arms 44 define an incline angle 46 about of eight degrees (8°), with both arms 44 inclined upwardly from the central region 42 (or downwardly if the tilt bracket 40 is inverted, as shown in FIG. 11 A). Alternatively, as shown in FIG. 1 IB, tilt bracket 40’ may include arms 44’ that define an angle of about thirty five degrees (35°) relative to the plane of the central region 42,’ although it will be appreciated that the arms may have any desired inclined angle, which may be the same or different from one another. In a further alternative, shown in FIG. 11C, the tilt bracket 40” may include arms 44” that incline in opposite directions from the central region 42,” i.e., with one arm 44” inclined upwardly and one downwardly. For example, as further shown in FIG. 12B, the arms 44” may have substantially the same angle relative to the central region 42” except with one arm 44” angle up and one down. Such a configuration may be useful for solar panels being installed on a slope of a hill, e.g., with the angle corresponding to the slope of the hill. The arms of the tilt brackets may have any desired angles, e.g., with each arm having the same or different angle relative to the central region.

[0091] In another alternative, a tilt bracket may be provided that only includes one arm, e.g., extending diagonally from the central region. Such a tilt bracket may be installed to a purlin along one end, e.g., the western or eastern end, of an installation where the arm is not needed since there is not another solar panel beyond the system. Alternatively, having both arms on tilt brackets at one or both ends may allow grounding lugs or other components to be mounted to the free arms, as described elsewhere herein. In addition, additional arms may allow another set of solar panels to be subsequently added to the system, e.g., with another set of rods, purlins, and, the like, subsequently installed adjacent the western and / or eastern end.

[0092] Alternatively, the arms of the tilt brackets may be constructed as hinges, e.g., pivotally attached to the central region (not shown), such that the angle of one or both arms may be adjusted, as desired, and then locked in position at a set angle. For example, with an east-west array, the angles may be adjusted to configure east-facing and / or west-facing panels mounted to the system at desired angles to maximize efficiency during use. In a further alternative, a gear mechanism (not shown) may be mounted to the purlins that may receive fixed tilt brackets at desired angles, e.g., with the central region horizontal or oriented diagonally, if desired to provide desired angles for the arms.

[0093] In yet another alternative, as shown in FIG. 30, struts or purlins 430 may be provided that include tilt bracket elements integrally formed on the purlin 430. For example, as shown, the purlin 430 may include pairs of arms 440 spaced apart from one another along the length of the purlin 430. As shown in FIGS. 30A and 30B, each pair of arms 440, 440’ may extend diagonally from the purlin 430, 430’, e.g., at a desired angle similar to the arms of the separate tilt brackets described elsewhere herein. For example, as shown in FIG. 30A, the purlin 430 may be formed from a “C” channel including a base 432 and a pair of legs 434 extending perpendicular to the base 432, and the arms 440 may be formed at the free ends of the legs 434. Optionally, each arm 440, 440’ may include one or more slots, holes, hooks, teeth, or other features (not shown), e.g., similar to the arms on any of the tilt brackets described elsewhere herein. The purlin 430 and arms 440 may be formed using any of the materials and methods described herein, e.g., by cutting the features from a flat sheet to provide a blank and then breaking the blank to form the legs 434 and arms 440 at the desired angles.

[0094] In the example shown in FIG. 30A, the purlin 430 is oriented with the legs 434 extending upwardly from the base 432 and the arms 440 extending diagonally downward from the legs 434. In the alternative shown in FIG. 30B, the purlin 430’ is oriented with the legs 434 extending downwardly from the base 432’ and the arms 440’ extending diagonally downward from the legs 434.’ It will be appreciated that the arms 440, 440’ of each pair may have the same or different angles and / or may have one arm extending diagonally upwardly and the other arm extending diagonally downwardly (not shown), as desired.

[0095] Returning to FIGS. 7A-7C, the central region 42 of each tilt bracket 40 may include a hole 43 therethrough, e.g., to allow the central region 42 to be secured to a purlin 30, e.g., as shown in FIGS. 3A-3B. For example, a bolt or other fastener 41a may be inserted through the hole 43, e.g., upwardly from below, and one of the holes 36 in the purlin 30 and secured with a corresponding nut and washer 41b, e.g., threaded over the bolt 41a above the central region 42. Alternatively, a bracket or other fastener may be used or, alternatively, the central region may include a shaft or other portion that may be inserted into the purlin 30, e.g., between the sidewalls 34 as shown in FIGS 12A and 12B, and then attached together.

[0096] Consequently, as shown in FIGS 3A-3B and 12A-12B, when solar panels 90 are secured to the arms 44 of the tilt bracket 40, the panels 90 lie diagonally relative to the purlins 30, i.e., inclining or declining relative to the purlins 30 and, consequently, the ground 80 at the installation site, as shown in FIG. 2A.

[0097] Turning to FIGS. 8A-10B, each end clamp 50 may include a bottom clamp portion 52 that may be attached to one of the arms 44 of a tilt bracket 40 and a top clamp portion 54 that may be secured to the edge of a solar panel 90, e.g., as shown in FIGS. 3A and 3B. For example, as best seen in FIGS. 9A and 9B, the bottom clamp portion 52 may have an “L” shaped cross-section, including a lower leg 52a that may be placed against an arm 44 of a tilt bracket 40 and an upper leg 52b that extends perpendicular to the lower leg 52a, e.g., to prevent horizontal movement of the solar panel 90 placed on the arm 44 adjacent the bottom portion 52.

[0098] The lower leg 52a of the bottom clamp portion 52 may include one or more holes, e.g., hole 52d shown in FIG. 9A, that be aligned with a corresponding hole 45 in an arm 44 of a tilt bracket 40 to receive a bolt or other fastener 56 to secure the bottom clamp portion 52 to the arm 44. Optionally, one or more both holes 45, 52d may be an elongated slot, e.g., slot 52d shown in FIG. 9A aligned along the length of the tilt bracket 40 to allow the location of the bottom clamp portion 52 to be adjusted along the arm 44 before securing the fastener 56. In one example, the hole 45 may be threaded and the fastener 56 may be a threaded bolt that may be inserted through the slot 52d and then threaded into the hole 45. Alternatively, the hole 45 may not include threads, and a nut (not shown) may be threaded onto the bolt 56 to secure the bottom clamp portion 52 to the arm 44.

[0099] Optionally, as shown in FIGS. 14A-14D, tilt brackets 140 and end clamps 150 may be provided that prevent the bottom clamp portion 152 of the end clamp 150 from sliding once positioned on the arm 144. For example, as best seen in FIG. 14A, each of the arms 144 of the tilt bracket 140 may include a plurality of teeth or other textured features 147 around the hole 146 and, as best seen in FIG. 14B, the lower leg 152a of the bottom clamp portion 152 may include a corresponding set of teeth or other textured features 152e. Thus, when the lower leg 152a is placed against the arm 144, e.g., as shown in FIGS. 14C and 14D, the features 152e, 147 engage to prevent the bottom clamp portion 152 from sliding along the arm 144, which may facilitate bolting or other securement of the end clamp 150 to the tilt bracket 140 and prevent subsequent slippage. The length of the regions including the features 152e, 147 may be sufficiently long to allow the bottom clamp portion 152 to be placed at various locations along the length of the arms 144, while preventing movement once placed.

[0100] Returning to FIGS. 8A-10B, the top clamp portion 54 includes a side leg 54a that may be coupled to the upper leg 52b of the bottom clamp portion 52 and a lip or flange 54b that may be received over the edge of the solar panel 90 being secured, e.g., as shown in FIGS. 14C and 14D. The upper leg 52b and side leg 54a may include one or more cooperating features to facilitate coupling the bottom and top clamp portions 52, 54 together during installation. For example, as best seen in FIGS. 9B and 10B, the lower and upper clamp portions 52, 54 may include a plurality of horizontal tongues and grooves 52c, 54c that may be slidably inserted together. For example, when the top clamp portion 54 is positioned adjacent the upper leg 52b of the bottom clamp portion 50, the tongues and grooves 52c, 54c allow the side leg 54a to be slid along the upper leg 52a to position the lip 54b over the edge of a solar panel 90 as shown.

[0101] The tongues and grooves 52c, 54c prevent the top clamp portion 54 from moving upwardly away from the tilt bracket 40, thereby preventing the panel 90 from moving upwardly. For example, during installation, the bottom clamp portion 52 may be placed on an arm 44 of a tilt bracket 40, as described above, an edge 92 of the solar panel 90 may be placed on the arm 44 adjacent the upper leg 52b of the bottom clamp portion 52, and then the top clamp portion 54 may be slid along the tongues and grooves 52c, 54c between the panel 90 and the upper leg 52b to secure the panel 90 under the lip 54b, e.g., as shown in FIGS. 3A and 3B. Once the solar panel 90 and clamp 50 are positioned optimally on the arm 44, the fastener 56 may be tightened to lock the solar panel 90 to the clamp 50 and arm 44. Optionally, one or more additional methods may be used to secure the end clamp 50 to the tilt bracket 40 and / or to the panel 90, in addition to the tongues and grooves, if desired. Further, optionally, if desired, the lip 54b may include one or more teeth (not shown), e.g. extending downwardly from its outer edge, which may penetrate the solar panel 90 when the fastener 56 is tightened to provide an electrical connection to the solar panel 90, similar to other clamps described elsewhere herein.

[0102] As shown in FIGS. 3A and 3B, opposite side edges 92 of the solar panels 90 may be secured to end clamps 50 mounted to tilt brackets 40 secured, in turn, to the purlins 30 spaced apart from one another along the opposite side edges. The end clamps 50 prevent the solar panels 90 from being lifted away from the arms 44 of the tilt brackets 40 and, consequently, securing the panels 90 to the adjacent purlins 30 and the racking system 12.

[0103] For example, in an east-west configured solar array, such as that shown in FIG. 2A, a first or western-most row of solar panels 90 may be mounted to the tilt brackets 40 such that the panels 90 are inclined upwardly or rise from west-to-east (between the first and second purlins 30), and then, a second row of panels 90 extend downwardly or descend from west-to-east (between the second and third purlins). This up and down pattern may be repeated as many times as desired for the intended installation 10.

[0104] The tilt brackets 40 may be configured such that the same tilt brackets may be used for both the upper and lower mounts for the solar panels 90, e.g. simply by mounting the arms 44 oriented upwardly or downwardly, as desired. Alternatively, tilt brackets may be provided that include arms that extend from the central region in opposite directions, e.g., as shown in FIGS. 11 and 12.

[0105] The western-most and eastern-most arms 44 of the tilt brackets may not be secured to any solar panels. However, given the modular nature of the system 12, if additional panels are desired at any time, additional rods may be installed adjacent the western-most and / or eastern-most purlins and tilt rackets, and additional purlin(s) and tilt brackets may be added to accommodate the additional panels added to the system 12. Alternatively, tilt brackets with only one arm (not shown), but otherwise similar to other tilt brackets herein, may be used for all or some of the tilt brackets at opposite ends of an installation.

[0106] Optionally, as shown in FIG. 27, one or more grounding lugs 101 may be attached to the free arms 244 of the western-most and / or eastern-most tilt brackets 240, e.g., to secure a ground wire or other electrical cable 94 extending along the purlin 30. As shown in FIG. 27 A, the grounding lug 101 may include a base 101a, which may be secured to an arm 244 of a tilt bracket 240, and an upper portion 101b defining a recess 101c for receiving the cable 94. As shown, a set screw or other fastener 10 Id may be received through the upper portion 101b, which may be tightened to secure the cable 94 within the recess 101c. In addition or alternatively, as shown in FIGS. 15 A and 15B, one or more wire management hooks 102 may be provided, e.g., attached to one or more of the rods 20 and / or purlins 30 to receive any wires or cables extending along the system 12. For example, as shown, the hook 102 may include a first end 102a including a bracket 102b opposite a second fee end 102c. The bracket 102b may be positioned against a rod (not shown), and clip (also not shown) may be attached to the bracket 102b to secure the hook to the rod. Alternatively, the first end 102a may be configured to be received through one of the holes 36 in a purlin 30, e.g., threaded through the hole 36 and / or inserted through such that a nut and / or washer (not shown) may be tightened over the first end 102a into the purlin 30 to secure the hook 102.

[0107] In addition, returning to FIGS. 1-2C, one or more earth anchor systems 60 may be attached to the system 12 during the installation to further secure the system 12 (in addition to the rods 20 inserted into the ground 80). In one example, an earth anchor system 60 may be coupled to each purlin 30 and, optionally, to the rods 20 that support each purlin 30, e.g., as shown in FIGS. 1-3. For example, one earth anchor 60 may be secured to the racking system 12 for every four or eight solar panels.

[0108] For example, each earth anchor system 60 may include a toggle anchor 62 including an anchor or foot portion pivotally coupled to a bolt portion at an intermediate location between first and second ends of the foot portion. The first end of the foot portion may include a tapered, pointed, and / or other shaped tip to facilitate advancement into the ground, and the second end includes a socket for removably receiving a rod therein, e.g., as described in U.S. Patent No. 11,271,520, the entire disclosure of which is expressly incorporated by reference herein.

[0109] During installation, a driving rod may be inserted, e.g., threaded, into the socket and the bolt portion may be positioned in its low profile orientation with a cable and / or rod 64 attached to the socket 35 extending substantially parallel to the driving rod. The anchor 62 may then be directed into the ground 80 at a desired location relative to the frame 12, e.g., using handheld tools, e.g., a portable percussion hammer, to drive the driving rod, and consequently, the toggle anchor 62 and cable and / or rod 64, a desired depth into the ground 80 with a second end of the driving rod and cable and / or rod 64 remaining exposed outside the ground 80. Once the target depth is reached, the driving rod is unthreaded and / or otherwise removed from the socket in the foot portion and out of the ground 80. Then, the exposed second end of the cable and / or rod 64 is pulled to cause the foot portion to engage with the surrounding soil and pivot to its deployed orientation, e.g., substantially perpendicular to the cable and / or rod 64. Once the anchor 62 is properly deployed, the exposed end of the cable and / or rod 64 may extend out of the ground a desired distance. Optionally, any undesired length of the exposed end of the cable and / or rod 64 protruding from the ground may be cut off or otherwise removed.

[0110] The exposed end of the cable and / or rod 64 may be attached to the frame 12 in a desired manner to secure the frame relative to the ground 80. For example, as shown, the cable and / or rod 64 (or an extension cable or rod) may be coupled to the purlin 30, e.g., with one anchor system 60 installed for each length of purlin 30, as shown.

[0111] Turning to FIGS. 16A-16C, another example of a tilt bracket 240 is shown that includes a central region or block 242 and first and second arms 244 extending from the central region 242 opposite one another, e.g., generally similar to the other tilt brackets described elsewhere herein. As shown, the central region 242 defines a substantially horizontal plane on either side of the block and the arms 244 extend diagonally from the central region 242, e.g., such that both arms 244 extend diagonally upwards out of the plane, e.g., at an angle of about eight degrees (8°). Also as shown, the block 242 includes a vertical hole 243 therethrough for receiving a bolt (not shown) similar to other tilt brackets herein.

[0112] Unlike the previous tilt brackets, each arm 244 of the tilt bracket 240 comprises a slot 246 extending from an outer end 248 of the arm 244 partially towards the central region 242, which may be configured to slidably receive a clamp, such as clamp 250 shown in FIGS. 17A and 17B. In addition, the outer ends 248 of the arms arm comprises flanges or hooks 249 extending transversely from the outer end 248, e.g., configured to engage a lower edge of a solar panel placed on the arm 244, as described further elsewhere herein. In the example shown, the hooks 249 extend diagonally from the outer end 248 towards the central region 242, e.g., defining an angle of about thirty degrees relative to the arm 244. The hooks 249 may be provided at a distance from the block 242, e.g., between about twenty five and forty five millimeters (25-45 mm), such that the frame of a solar panel being installed may be placed between the hook 249 and the block 242 to engage and / or otherwise stabilize the solar panel 90 during installation. In addition, the arms 240 include notches 248a adjacent the outer ends 248, which may facilitate placing a clamp 250 on an arm 244, as described further below. Turning to FIGS. 17A and 17B, an exemplary clamp 250 is shown that may be received on one of the arms 244 of the tilt bracket 240 shown in FIGS. 16A-16C, e.g., to secure an edge of a solar panel to the tilt bracket 240, e.g., as shown in FIG. 20. Generally, the clamp 250 is configured to be slidably received on and then secured to an arm 244 of the tilt bracket 240 and, once positioned at a desired location, the clamp 250 may be secured to the arm 244, e.g., to secure a solar panel 90 to the arm 244, e.g., as shown in FIG. 20 and described further elsewhere herein. For example, as shown, the clamp 250 includes a lower block 252 configured to be slidably received on an arm of a tilt bracket, an upper clamp member 254 mounted on the lower block 252 by a bolt or other fastener 256.

[0113] With additional reference to FIGS. 18A and 18B, the lower block 252 includes a central body 252a including a slot 252b adjacent a lower end of the central body for slidably receiving the first arm therein, e.g., defined by a pair of flanges 252c opposite one another. The central body 252a also includes a hole or passage 252d extending therethrough, e.g., on a vertical bolt axis 252e, for receiving the bolt 256 such that the bolt 256 may be slidably received through the lower block 252a along a bolt axis 252e.

[0114] With additional reference to FIGS. 19A-19B, the upper clamp member 254 includes a side leg 254a that is oriented substantially parallel to the bolt axis 252e and slidable along the lower block 252, as best seen in FIG. 17B. A lip or flange 254b extending transversely from the side leg 254a, e.g., at an acute angle less than ninety degrees (90°), configured to engage an edge 92 of a solar panel 90, e.g., as shown in FIG. 20. The lip 254b of the upper clamp member 254 includes a hole 254c therethrough for slidably receiving the bolt 256 such that upper clamp member 254 is movable along the bolt 256 to adjust a location of the lip 254b along the bolt axis 252e.

[0115] With additional reference to FIGS. 17A and 17B, in one example, the upper clamp member 254 is biased to move away from the lower block 252 along the bolt 256. A nut or other fastener 257 may be provided on the bolt 256, e.g., above the lip 254b such that when the bolt 256 and nut 257 may be tightened to direct the upper clamp member 254 downwardly to direct the lip 254b to engage an edge 92 of a solar panel 90, e.g., as shown in FIG. 20. For example, as best seen in FIG. 17B, a spring 258 may be provided around the bolt 256 between the lower block 252 and the lip 254b such that the spring 258 may bias the upper clamp member 252 to move upwardly along the bolt axis 252e.

[0116] The length of the bolt 256 may be sufficient to provide a desired gap or distance between the lip 254b and an arm 244 on which the lower block 252 is placed. For example, the maximum gap or distance between the lip 254b and the slot 252b on the lower block 252 may be between about 29-46 millimeters, e.g., to accommodate solar panels having different thicknesses.

[0117] Optionally, as best seen in FIGS. 19A-19C, the lip 254b may include one or more teeth configured to penetrate the edge 92 of the solar panel 90 to provide an electrical connection to the solar panel 90. In the example shown, the lip 254b includes a plurality of teeth 254d oriented downwardly from the outer end of the lip 254b separated by a plurality of tongues 254e, e.g., with the teeth 254d and tongues 254e alternating along the length of the lip 254b.

[0118] For example, during installation, as shown in FIG. 20, a clamp 250 may be placed on an arm 244 of a tilt bracket 240, e.g., by inserting the outer end 248 of the arm 244 into the slot 252b and the lower end of the bolt 256 into the slot 246 in the arm 244. As shown in FIGS. 16A-16C, the notches 248a may accommodate the flanges 252c being inserted over the arm 244 before sliding the lower block 252 along the arm 244 towards the central region 242, whereupon the flanges 252c may slidably engage a lower surface of the arm 244.

[0119] An edge 92 of a solar panel 90 may be placed on the arm 244 adjacent the clamp 250 and then the lower block 252 may be slid further along the arm 244 to position the lip 254b over the edge 92. Once the solar panel 90 and clamp 250 are positioned where desired on the arm 244, the bolt 256 and / or nut 257 may be tightened to engage the lip 254b over the edge 92 to secure the solar panel 90 to the arm 244. The tongues 254e may engage against the solar panel 90 and, if provided, the teeth 254d may penetrate the solar panel 90 to provide an electrical connection.

[0120] In the example where the upper clamp member 254 includes teeth 254d, various components of the system may be formed from electrically conductive material to provide a conductive path from the solar panel 90, e.g., to adjacent solar panels and / or to the electrical system that stores and / or transports electricity generated by the solar panel(s) 90.

[0121] For example, the upper clamp member 254 and one or both of the lower block 252 and the bolt 256 may be formed from metal, such as steel or aluminum, or conductive composite materials, such as graphene fiberglass, to transfer electrical energy from the solar panel 90. In one example, the tilt bracket 240 may also be formed from conductive material and, if desired, the purlin 30 to which the tilt bracket 240 is mounted may also be formed from conductive material. For example, a set of solar panels 90 mounted to the system 12 including such conductive materials may be thus mounted in parallel with one another. Alternatively, one or more electrical cables may be coupled to the clamp 250 and / or tilt bracket 240, e.g., to provide an electrical path from the solar panel(s) 90, e.g., if the purlins 30 are not conductive or if the system does not include purlins. Thus, the components of the system may provide an electrical bonding path and / or grounding system for the solar panels of the installation, e.g., as described elsewhere herein.

[0122] Turning to FIG. 21 A, another exemplary racking system or frame 212 is shown for supporting a plurality of solar panels 90 relative to a roof or other surface 80, e.g., where rod and / or anchors cannot be directed into the surface. For example, unlike the system 12, the system 12 includes a plurality of pedestals 226 that may be secured to a roof or other surface without having to penetrate the surface 80. The system 12 also includes a plurality of support brackets 220 that may be connected to the pedestals 226 and support the solar panels 90, e.g., using tilt brackets 240 and clamps 250, similar to any of the examples described elsewhere herein. Alternatively, as shown in FIG. 21B, a racking system 312 may be provided that includes a set of pedestals 326 and support brackets 320, which may be used to mount individual solar panels 90, e.g., using tilt brackets 340 and clamps 350, to a surface. For example, a plurality of such racking systems 312 may be provided for an installation including a plurality of solar panels 90, e.g., three shown as an example. Such a modular system 312 may allow a plurality of solar panels 90 to be installed on an irregular surface, e.g., on a hill or slope (not shown) adjacent one another with the same or different tilt angles.

[0123] Turning to FIG. 22A, an exemplary pedestal 226 is shown that includes a lower surface or portion 226a for receiving adhesive or otherwise being secured to a roof or other surface and a second upper end 226b include an elongate track 226c therein, e.g., similar to the pedestals shown in U.S. Patent No. 9,315,999, the entire disclosure of which is expressly incorporated by reference herein. In the example shown, the lower portion 226a includes a plurality of protrusions that may receive adhesive to secure the pedestal 226 to a roof. The slot 226c in the upper surface may be configured to slidably receiving one or more fasteners, e.g., to secure a tilt bracket 240 and / or support bracket 220 to the pedestal 226.

[0124] As shown in FIG. 22A, the upper surface 226b is substantially parallel to the lower surface of the pedestal 226. Consequently, when a solar panel 90 is secured to the pedestal 226, e.g., using a tilt bracket 240 as shown in FIG. 22B, the solar panel 90 may be mounted substantially horizontally. Alternatively, as shown in FIG. 22C, a pedestal 226’ may be provided in which the upper surface 226b’ is not parallel to the lower surface 226a.’ For example, the upper surface 226b’ may be angled at an acute angle 9 relative to a horizontal plane parallel to the lower surface 226a’, e.g., between about five and ten degrees (5-10°). The track 226c’ may extend substantially horizontally along the angled upper surface 226b.’ Consequently, when a solar panel 90 is secured to a tilt bracket 240 as shown in FIG. 22D, the solar panel 90 may be mounted at the same angle as the upper surface 226b.’

[0125] Alternatively, the pedestal may include a plurality of tracks in the upper surface (not shown), e.g., similar to pedestal 626 shown in FIGS. 31 A-31C and described elsewhere herein. For example, the upper surface may include a horizontal portion including a first track and a second non-horizontal portion including a second track, e.g., sloping at a desired angle from horizontal (not shown). The tracks may extend substantially parallel to one another such a support bracket may be received in either track, e.g., depending on whether the intended orientation of the support bracket is vertical or offset from vertical.

[0126] Turning to FIGS. 23 A-23C, exemplary support brackets 220-220” are shown that may be mounted to a pedestal, such as the pedestal 226 shown in FIG. 22A. As shown, the support brackets 220-220” may have different overall lengths such that edges of solar panels 90 attached to the support brackets 220-220” at different heights or distances from the respective pedestals 226 and, therefore relative to the surface 80. For example, as shown in FIG. 21 A, solar panels 90 may be mounted to the system 212 such that the solar panels are sloped in a first direction, e.g., north-south, and also sloped in a second direction orthogonal to the first direction, e.g., east-west, in an alternating arrangement, as shown.

[0127] For example, a first corner of a solar panel 90, e.g., corresponding to a southwest comer, may be supported by a tilt bracket 240 coupled directly to a pedestal 226, e.g., as shown in FIG. 22D. A second corner of the solar panel 90, e.g., corresponding to a southeast corner, may be supported by a tilt bracket 240 coupled to first support bracket 220 mounted to a pedestal 226, e.g., as shown in FIG. 23 A. Similarly, third and fourth comers of the solar panel 90, e.g., corresponding to the northwest and northeast comers, may be coupled to second and third support brackets 220,” 220,’ respectively, as shown in FIGS. 23B and 23C.

[0128] Thus, the resulting system may tilt the solar panel 90 downwards in both an east-to- west direction and a north-to-south direction. In one example, the north-to-south tilt may be between about five and ten degrees (5-10°) and the east-to-west tilt may be between about eight and thirty five degrees (8-35°). Panels mounted east and west of each other may share arms 244 of the same tilt bracket 240, e.g., such that the east-to-west tilt alternates up and down along an installation.

[0129] To accommodate this tilt, the support brackets 220-220” may include components that may be assembled to provide the desired respective lengths. For example, as shown in FIGS. 24A and 24B, an example of a lower bracket 222 is shown that may be included in each of the support brackets 220-220.” The lower bracket 222 includes a lower leg 222a, e.g., intended to be oriented substantially horizontally, and an upper leg 222b extending upwardly from the lower leg 222a, which may be connected to an upper bracket 224-224” to provide the support brackets 220-220.” The support brackets 220-220” may be formed from substantially rigid materials, similar to other components herein, e.g., metal, such as steel or aluminum, plastics, such as polyurethane, hard rubber, and / or composite materials, such as fiberglass or FRP with or without graphene. For example, each of the upper and lower brackets 222, 224 may be formed from a flat plate or sheet having a desired thickness, e.g., cut, machined, and the like, and the flat plate may be broken or otherwise deformed to provide the final shape for the bracket.

[0130] As shown, the upper leg 222b tapers outwardly from its upper end towards the lower leg 222a, thereby providing a relatively wide lower leg 222a, which may enhance stability of the resulting support brackets 220-220.” Alternatively, as shown in FIG. 23D, the upper leg 222b” of the lower bracket 222” may have a substantially uniform width between its upper end and the lower leg 222a.” The lower leg 222a may include one or more holes 223, e.g., a pair of holes 223a spaced apart from one another. The holes 223a may be set diameter holes 223a or, alternatively, may be elongate slots (not shown), e.g., aligned with one another similar to the support bracket 520 shown in FIGS. 29A-29C, to allow the position of the lower leg 222a to be adjusted. Optionally, the lower leg may include a third hole, e.g., centered on the lower leg, similar to the support bracket 520 shown in FIGS. 29A-29C, e.g., for receiving a rod or bolt, as described further elsewhere herein.

[0131] As best seen in FIG. 24B, the upper leg 222b may define an acute angle less then ninety degrees (90°) relative to the lower leg 222a, which may correspond to the desired north-to-south tilt. Thus, when the support brackets 220-220” including the lower bracket 222 are mounted to a pedestal 226 including a horizontal upper surface 226b, the upper leg 222b may extend upwardly at the desired tilt angle from vertical. The upper bracket 224- 224” attached to the lower bracket 222 thus also extends upwardly at the tilt angle. Turning to FIGS. 25A and 25B, a first example of an upper bracket 224 is shown that may be attached to the lower bracket 220 to provide the support bracket 220 shown in FIG. 23 A. The upper bracket 224 includes an upper leg 224a and a lower leg 224b extending from the upper leg 224a, e.g., substantially perpendicular to one another, as best seen in FIG. 25B. Thus, when the upper bracket 224 is attached to the lower bracket 220, the upper leg 224a tilts from horizontal at the tilt angle of the lower bracket 220. Optionally, one or both of the upper leg 224a and the lower leg 224b may include flanges extending along the edges thereof, e.g., such that the lower leg 224b has a “C” shaped crosssection, which may be enhance the structural integrity of the upper bracket 224. For example, the upper leg

[0132] As shown, the upper leg 224a may include a single hole 225a therethrough, e.g., for receiving a bolt or other fastener 241 used to secure a tilt bracket 240 to the support bracket 220, as shown in FIG. 23 A. The lower leg 224b may include a plurality of holes 225b, e.g., for receiving one or more fasteners, e.g., bolts 227. Similarly, the upper leg 222b of the lower bracket 222 includes a plurality of holes 223b that may also receive the bolts 227 to secure the upper and lower brackets 224, 222 together to provide the final support bracket 220.

[0133] In one example, the hole patterns of the holes 225b, 223b may be the same such that the upper and lower brackets 224, 222 can only be attached together in a single position. Alternatively, the hole patterns may be different, e.g., such that the upper bracket 224 may be mounted at different positions to the lower bracket 222, e.g., to adjust a distance between the upper leg 224b and the lower leg 222a. In addition or alternatively, one of the sets of holes 225b, 223b may be elongate slots (not shown), e.g., oriented vertically such that once bolts are received through the holes 225b, 223b, the height of the upper bracket 224 may be adjusted before tightening the bolts.

[0134] FIGS. 25C and 25D show another example of an upper bracket 224,’ which may be constructed similar to the upper bracket 224, except having a longer lower leg 224b.’ For example, this upper bracket 224’ may be attached to the lower bracket 222 to provide the support bracket 220’ shown in FIG. 23 C.

[0135] Turning to FIGS. 26A-26C, another example of a pedestal 326 is shown that may be used in any of the racking systems described herein. Generally, the pedestal 326 includes a lower portion defining a flat horizontal lower surface 326a for placement on a roof or other surface, and an upper portion defining an upper surface 326b. As shown, the upper surface 326b is substantially parallel to the lower surface 326a although, alternatively, the upper surface 326b may define an upper plane that tilts relative to a lower plane defined by the lower surface 326a, e.g., by a desired tilt angle for the solar panels being installed, e.g., between about five and ten degrees (5-10°). In a further alternative, the upper surface may include a plurality of tracks, e.g., a first track on a horizontal portion of the upper surface and a second track on a diagonal portion (not shown), as described elsewhere herein.

[0136] As shown, the lower portion of the pedestal 326 is defined by a plurality of outer side walls 227a surrounding an opening allowing adhesive to flow into the lower portion within the side walls 227a. In addition, the pedestal 326 also includes a plurality of inner walls 227b extending between the side walls 227a adjacent the opening. For example, the inner walls 227b may be arranged in a grid pattern with the inner walls 227b extending substantially parallel to respective outer side walls 227a. Alternatively, the inner walls may have other arrangements that provide an open bottom and separated spaces for receiving adhesive. For example, the inner walls could define a plurality of spaces having one or more of round, oval, hexagonal, or other shapes, as desired.

[0137] The inner walls 227b may extend only partially upwardly from the lower surface 326a towards the upper portion pedestal 326 such that adhesive entering the opening of the lower surface 326a is free to pass over top edges of the inner walls 227b. Thus, if excess adhesive is applied to one area of the roof or other surface before the pedestal 326 is placed on the surface, the adhesive may pass upwardly into the spaces between the inner walls 227b and, any excess adhesive may be free to flow over the inner walls into adjacent spaces where there is less adhesive.

[0138] Optionally, as shown, one or more horizontal flanges 326d may be provided on the lower portion, e.g., extending outwardly from lower edges of the side walls 227a, thereby increasing the surface area of the lower surface 326a of the pedestal 326. In addition or alternatively, horizontal flanges 326e may be extend from lower edges of the inner walls 227b to further increase the surface area.

[0139] Similar to the pedestal 226, the pedestal 326 includes a track 326c extending along the upper surface 326b, which is configured to slidably receive one or more bolts. For example, the track 326c may include a channel extending below the upper surface 326b, e.g., partially from one end of the upper surface 326b or the entire length of the upper surface 326b. Opposing ledges or lips provide a relatively narrow slot communicating with the channel such that a head of a bolt or other fastener (not shown) may be received in the channel with a shaft of the bolt extending upwardly through the slot. Thus, one or more bolts may be inserted into and slid along the track 326c to a desired position and then used to secure a tilt bracket or support bracket to the pedestal 326, as described further elsewhere herein.

[0140] Turning to FIGS. 28A and 28B, another example of a pedestal 426 is shown. Generally, the pedestal 426 includes an open lower surface 426a and an upper surface 426b including an elongate track 426c, similar to the other pedestals herein. Unlike the other pedestals, the pedestal 426 includes a separate lower portion 427 and an upper portion 428, which may be removably or permanently assembled together to provide the finished pedestal. For example, as shown, the lower portion 427 includes a plurality of side walls 427a and a plurality of inner walls 427b dividing the open lower surface 426a into a plurality of spaces for receiving adhesive, e.g., similar to the pedestal 326. Optionally, the side walls 427a and / or inner walls 427b may include flanges 426d at least partially defining the lower surface 426a, also similar to the pedestal 326. In addition, the lower portion 427 includes a top surface that includes a pair of elongate slots 427f, e.g., extending along opposite sides of the lower portion 427. The lower and upper portions 427, 428 may be formed from desired material, e.g., metal such as steel or aluminum, plastics, such as polyurethane, hard rubber, and / or composite materials, such as fiberglass or FRP with or without graphene.

[0141] The upper portion 428 includes a pair of elongate side walls 428a on opposite sides of the upper portion 428 and a tapered upper surface 428b extending upwardly and inwardly to the upper surface 426b and track 426c. Each of the side walls 428a includes a flange 428c that extends outwardly from the upper portion 428 such that the flanges 428c may be received in the slots 427f of the lower portion 427, as shown in FIG. 28A. Thus, the upper and lower portions 428, 427 may have similar widths that allow the flanges 428c to slide into the slots 427f to position and secure the upper portion 428 on the top surface of the lower portion 427, e.g., similar to a dovetail joint connection. As best seen in FIG. 28B, the upper portion 428 may have a length shorter than the lower portion 427 such that the upper portion 428 may be centered or otherwise positioned on the lower portion 427. For example, the upper portion 428 may be formed from by extruding aluminum or other material to define the cross-section shown in FIG. 28A. Optionally, the material may be extruded to provide a length longer than the upper portion 428, which may then be cut or otherwise separated to provide multiple upper portions. For example, the lower portion 427 could be molded cast, machined, and the like from hard rubber or fiberglass reinforced plastic, and then an upper portion 428, e.g., formed from aluminum, may be received in the slots 427f to provide a pedestal that be mounted to a roof or other surface using adhesive, similar to the other pedestals herein. The upper and lower portions 428, 427 may be removably assembled, if desired, or may be permanently attached together, e.g., using one or more fasteners (not shown), by bonding, welding, fusing, and the like.

[0142] Returning to FIG. 22 A, to secure a tilt bracket 240, such as that shown in FIGS. 16A-16C directly to the pedestal 326 (or pedestal 426), a bolt may be inserted upwardly through the central region 242 of the tilt bracket 240 and a nut and washer may be threaded partially over the end of the bolt above the central region 242. With the bolt sufficiently lose, the head of the bolt may be slidably received in the track 326c such that the tilt bracket 240 is slidable along the upper surface 326b. Once oriented and / or positioned as desired along the slot 326c, the nut may be tightened to secure the tilt bracket 240 to the pedestal 326.

[0143] Similarly to secure a support bracket 220-220” to the pedestal, a pair of bolts may be inserted upwardly through the holes 223a of the lower bracket 222, e.g., as shown in FIG. 20, and then the bolts may be slidably received in the track 326c such that the lower leg 222a of the lower bracket 222 slides along the upper surface 326b. Once oriented and / or positioned as desired along the track 326c, the bolt may be tightened to secure the lower bracket 222, and consequently, the support bracket 220-220” to the pedestal 326. Tilt brackets 240 may be secured to the upper ends of the support brackets 220-220,” e.g., as shown in FIGS. 23A-23C, and then clamps 250 may be used to secure edges of one or more solar panels to the arms of the tilt brackets 240, similar to the other racking systems herein.

[0144] Optionally, in any of the racking systems herein, one or more spacers may be added between the support bracket and the tilt bracket if desired, e.g., to adjust a tilt angle of the tilt bracket relative to a pedestal or other base. For example, with reference to FIG. 23 A, a support bracket 220 is shown mounted to a pedestal 226 and a tilt bracket 240 may be secured to the upper bracket 224. With the lower bracket 222 having a predetermined tilt angle, e.g., between about five and ten degrees (5-10°) from vertical, the tilt bracket 240 will have a similar tilt angle from horizontal. If desired, one or more spacers, e.g., two tapered bevel washers (not shown) may be placed between the tilt bracket 240 and the upper leg of the upper bracket 224 to adjust the tilt angle, e.g., to return the tilt bracket 240 to a true horizontal (zero degree tilt angle).

[0145] It will be appreciated that any of the racking systems may include any combination of tilt brackets, clamps, support brackets, and / or pedestals described herein to provide an installation for mounting solar panels to a roof or other surface where it is desired not to penetrate the surface. Alternatively, any of the racking systems herein may be used for ground-mounted systems, e.g., including one or more earth anchors, similar to the systems described in the patents incorporated by reference herein.

[0146] In a further alternative, in some rooftop or other installations, one or more bolts or other fasteners may be preinstalled on the surface, e.g., using common heat weld procedures, and support brackets and / or tilt brackets may be secured to these fasteners to mount solar panels above the surface, and the pedestals may be omitted in this alternative. For example, a rod or bolt may be mounted to a roof or other surface, e.g., by screwing a cap (not shown) into the membrane of the roof into which a threaded rod or bolt may be inserted. A lower bracket, e.g., the lower leg 222a of the support bracket 220 shown in FIGS. 23 A, 24A, and 24B, may be provided with a center hole (not shown), which may receive the rod or bolt extending from the roof, and then a nut and washer may be threaded over the rod or bolt to secure the support bracket 220 to the roof. This process may be repeated multiple times to install a desired racking system for a set of solar panels, similar to any of the other systems described herein.

[0147] Turning to FIGS. 29A-29C, another pedestal or mounting arrangement is shown that uses a ballasted base 526 to which a support bracket 520 may be secured. As shown, the base 526 generally includes a tray 527 including a lower plate or panel 527a and a plurality of side flaps or flanges 527b, e.g., extending upwardly from an outer perimeter of the lower plate 527a. As shown, each edge of the lower plate 527a may include a plurality of flaps 527b spaced apart from one another although, alternatively, a continuous flange (not shown) may be provided along one or more of the edges, if desired. For example, the tray 527 may be formed from metal, such as steel or aluminum, plastic, or composite materials.

[0148] The lower plate 527a includes one or more holes therethrough, e.g., two holes 527c, as shown in FIG. 29D, which may receive bolts or other fasteners 529 therethrough, e.g., extending upwardly through the lower plate 527a, as best seen in FIG. 29C. The base 526 also includes one or more blocks 528 or other weighted members that may be received in the tray 527. For example, as shown in FIGS. 29A and 29B, two ballast blocks 528 may be received in the tray 527 such that the bolts 528 extend upwardly between the blocks 528. Thus, a support bracket 5209, which may be any of the support brackets, or a tilt bracket (not shown) may then be secured to the base 526 by the bolts 528. Alternatively, as shown in FIG. 29E, a ballasted base 526’ may be provided that includes a single bolt 528’ for securing a support bracket 528’ to the base 526.’

[0149] Turning to FIGS. 31 A-31C, another example of a pedestal 626 is shown, which may be used with any of the racking systems described herein. As shown, the pedestal 626 includes a lower portion 627 including an open lower surface 627a and an upper portion 628 including an upper surface 628a, which may be integrally formed as a single piece, as shown. Alternatively, the pedestal 626 may be formed as separate upper and lower portions including cooperating connectors, similar to other pedestals herein. The pedestal 626 may be formed using similar materials and methods as the other pedestals described herein.

[0150] As shown, the lower and upper portions 627, 628 include a plurality of side walls 627b, 628b, e.g., a pair of side walls 627b, 628b that extend along a length of the pedestal 626 between the upper and lower surfaces 628a, 627a. For example, as best seen in FIG. 31C, the upper side walls 628b may extend vertically between the upper surface 628a and an intermediate horizontal surface 627c, thereby at least partially enclosing an interior 628c of the upper portion 628, and the lower side walls 627b may extend diagonally outwardly from the intermediate surface 627c to the lower surface 627a. Optionally one or more inner struts or other supports (not shown) may be provided within the interior 628c of the upper portion 628, e.g., extending between one or both side walls 628b, the upper surface 628a, and / or the intermediate surface 627c, if desired to provide additional structural support for the pedestal 626.

[0151] The lower surface 627a includes a plurality of openings therethrough, e.g., elongate slots 627d extending at least partially along the length of the pedestal 626. For example, as best seen in FIG. 3 IB, the lower surface 627a may include two sets of elongate slots 627d aligned along the length of the pedestal 626, e.g., with each set extending about halfway down the length. As shown, each set of slots 627d includes five slots spaced apart adjacent one another between the lower side walls 627b, although it will be appreciated that any desired number of slots 627d may be provided. Also as shown, each slot 627d may include rounded ends, e.g., spaced apart from opposite ends of the pedestal 626. Alternatively, the openings 627d may have other shapes, e.g., square, rectangular, circular, oval, or other shapes, which may be provided in a variety of sizes, spacing, and / or numbers, that allow adhesive passing through the lower surface 627a into the interior of the lower portion 627.

[0152] Optionally, as best seen in FIG. 31C, the lower surface 627d may also include a plurality of inner walls 627 e extending partially upwardly from the lower surface 627d into the interior of the lower portion 627. In the example shown, the inner walls 627 e are provided between adjacent slots 627d and extend axially down the length of the pedestal 626, e.g., substantially parallel to the slots 627d. Thus, similar to the pedestal 326, the slots 627d may allow adhesive applied to a surface onto which the pedestal 626 is placed to enter the slots 627d and pass over top edges of the inner walls 627e. Thus, if excess adhesive is applied to one area of the roof or other surface before the pedestal 626 is placed on the surface, the adhesive may pass upwardly through the slots 627d into the spaces between the inner walls 627 e and, any excess adhesive may be free to flow over the inner walls 627 e into adjacent spaces where there is less adhesive.

[0153] In addition, as best seen in FIG. 31 A, the upper portion 628 includes a plurality of tracks 629 in the upper surface 628a, each configured to receive a connector for a tilt bracket and / or support bracket, similar to the other pedestals herein. For example, the upper surface 628a may include a first surface portion 628al that extends substantially parallel to the lower surface 627a and includes a first track 629a that extends along the length of the pedestal 626. In addition, the upper surface 628a includes a second surface portion 628a2 that extends diagonally from the first portion 628al, e.g., downwardly at a desired angle of inclination, e.g., between about five and ten degrees (5-10°), to the adjacent upper side wall 628. The second surface portion 628a2 includes a second track 629b that extends along the length of the pedestal 626, e.g., substantially parallel to the first track 629a.

[0154] The pedestal 626 allows an installer to use either track 629a, 629b to receive a tilt bracket or support bracket (not shown), e.g., generally similar to the other pedestals herein, depending on whether the bracket is to be mounted horizontally or at an incline for each bracket. Thus, the pedestal 626 allows the installer to choose the horizontal or inclined track 629a, 629b for each tilt bracket or support bracket, thereby providing greater flexibility than pedestals that include only a single track.

[0155] While the invention is susceptible to various modifications, and alternative forms, specific examples thereof have been shown in the drawings and are herein described in detail. It should be understood, however, that the invention is not to be limited to the particular forms or methods disclosed, but to the contrary, the invention is to cover all modifications, equivalents and alternatives falling within the scope of the appended claims.

Claims

What is claimed is:

1. A racking system for mounting a solar panel system at an installation site, comprising: a plurality of elongate rods, each rod including a first lower end for insertion into the ground at the installation site and a second upper end; a plurality of elongate struts, each strut connectable to the upper ends of two or more rods aligned along a horizontal or other axis such that the struts are spaced apart from one another substantially parallel to one another; a plurality of tilt brackets mountable to the struts along their lengths, each tilt bracket including a central region mountable to a strut such that arms of the tilt bracket are positioned on either side of the strut; and a plurality of clamps mountable to the arms of the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between adjacent struts.

2. The system of claim 1, wherein the rods comprise rebar rods.

3. The system of claim 1, wherein the rods are threaded along at least a portion of their lengths between the upper and lower ends.

4. The system of claim 1, further comprising a plurality of shoe plates, each shoe plate comprising a substantially flat plate and a tubular body extending from the flat plate for receiving a rod therethrough to position the flat plate against the ground when the lower end of the rod is inserted into the ground.

5. The system of claim 1, wherein each arm and clamp comprise a plurality of teeth or other raised features configured to prevent the clamp from sliding along the arm.

6. The system of claim 5, wherein each arm and clamp include a hole therethrough that may be aligned to receive a fastener to secure the clamp to the arm.

7. The system of claim 5, wherein each clamp comprises a bottom clamp portion configured to be secured to the arm of a tilt bracket, and a top clamp portion comprising a lip or flange, the bottom and top clamp portions comprising cooperatingfeatures to slidably secure the top clamp portion to the bottom portion, whereupon the lip or flange is positioned over an edge of a solar panel to secure the solar panel to the tilt bracket.

8. The system of claim 7, wherein the cooperating features comprise a plurality of tongues and grooves on the bottom and top clamp portions to allow the top clamp portion to slide between the bottom clamp portion and an edge of a solar panel positioned on the arm while preventing the top clamp portion from lifting away from the arm.

9. The system of any one of claims 1-8, wherein the central region defines a plane and wherein the arms extend from the central region at an angle relative to the plane.

10. The system of claim 9, wherein both of the arms extend from the central region such that the arms extend diagonally above the plane.

11. The system of claim 9, wherein a first arm of the arms extends above the plane and a second arm of the arms extends below the plane.

12. The system of claim 9, wherein the arms define an acute angle relative to the plane.

13. The system of claim 9, wherein the angle of the arms is fixed.

14. The system of claim 9, wherein the angle of the arms is adjustable.

15. The system of claim 14, wherein each arm is coupled to the central region by a hinge.

16. The system of any one of claims 1-8, wherein each clamp comprises a plurality of teeth configured to penetrate the edge of a solar panel to provide an electrical connection to the solar panel.

17. The system of any one of claims 1-8, further comprising one or more earth anchor systems configured to be coupled to one or more components of the racking system to secure the racking system relative to the ground at the installation site.

18. The system of claim 17, wherein each earth anchor system comprises a toggle anchor configured to be inserted into and deployed within the ground adjacent the racking system, and a cable and / or rod extending from the toggle anchor configured to be coupled to one of the struts.

19. The system of any one of claims 1-8, further comprising one or more wire management hooks attachable to respective rods such that the wire management hooks are spaced apart along respective struts to receive one or more wires extending from solar panels mounted to the system.

20. The system of any one of claims 1-8, further comprising a grounding lug configured to be secured to an arm of a tilt bracket.

21. A racking system for mounting a solar panel system to a roof or other surface, comprising: a plurality of pedestals comprising a lower portion configured to secure the lower portion to a roof or other surface and a second upper end; a plurality of support brackets comprising upper ends and lower ends connectable to the upper ends of the pedestals; a plurality of tilt brackets mountable to one or both of the upper ends of the pedestals and the upper ends of the support brackets, a tilt bracket of the plurality of tilt brackets including a central region configured to be secured to the upper end of one of the pedestals and the support brackets such that first and second arms of the tilt bracket are positioned on either side of the central region; and a plurality of clamps mountable to the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between and above adjacent pedestals, a clamp of the plurality of clamps configured to be slidably received on and secured to the first arm of the tilt bracket.

22. The system of claim 21, wherein the first arm of the tilt bracket comprises a slot extending from an outer end of the first arm partially towards the central region, and wherein the clamp comprises a bolt configured to be slidably received in the slot to allow adjustment of the clamp along the first arm before securing the clamp to the first arm.

23. The system of claim 22, wherein the outer end of the first arm comprises hooks extending transversely from the outer end configured to engage a lower edge of a solar panel placed on the first arm.

24. The system of claim 23, wherein the hooks extend diagonally from the outer end towards the central region, e.g., defining an angle of about thirty degrees relative to the first arm.

25. The system of claim 22, wherein the clamp comprises: a lower block configured to be slidably received on the first arm of the tilt bracket, the bolt slidably received through the lower block along a bolt axis; an upper clamp member comprising a lip configured to engage an edge of a solar panel, the upper clamp member slidably mounted on the bolt such that upper clamp member is movable along the bolt to adjust a location of the lip along the bolt axis.

26. The system of claim 25, wherein the lower block comprises a central body comprising a passage for receiving the bolt and a slot adjacent a lower end of the central body for slidably receiving the first arm therein.

27. The system of claim 25, wherein the upper clamp member is biased to move away from the lower block along the bolt and wherein the bolt is configured to be tightened to direct the upper clamp member downwardly to direct the lip to engage an edge of a solar panel.

28. The system of any one of claims 25-27, wherein the lip of the upper clamp member comprises a plurality of teeth configured to penetrate the edge of a solar panel to provide an electrical connection to the solar panel.

29. The system of claim 28, wherein the upper clamp member comprises electrically conductive material.

30. The system of claim 29, wherein the tilt bracket comprises electrically conductive material, thereby providing an electrically conductive path from a solar panel coupled to the upper clamp member to the tilt bracket.

31. The system of claim 21, wherein a pedestal of the plurality of pedestals comprises a lower portion defining a horizontal lower surface for placement on a roof or other surface, and an upper portion defining an upper surface that extends transversely relative to the lower surface.

32. The system of claim 31, wherein the upper surface defines an upper plane that tilts between about five and ten degrees relative to a lower plane defined by the lower surface.

33. The system of any one of claims 21-27, 31, and 32, wherein the lower portion of the pedestal is defined by a plurality of outer side walls surrounding an opening allowing adhesive to flow into the lower portion within the side walls.

34. The system of claim 33, further comprising a plurality of inner walls extending between the side walls adjacent the opening.

35. The system of claim 34, wherein the inner walls extend between opposite side walls in a grid pattern.

36. The system of claim 35, wherein the inner walls extend only partially from the lower portion towards the upper portion such that adhesive entering the opening is free to pass over top edges of the inner walls.

37. The system of claim 33, further comprising horizontal flanges extending from lower edges of the side walls, thereby defining a lower surface of the pedestal.

38. The system of claim 37, wherein the flanges extend outwardly from the side walls.

39. The system of claim 38, wherein the flanges extend inwardly from the side walls partially into the opening.

40. The system of any one of claims 21-27, wherein a pedestal of the plurality of pedestals comprises a track extending along an upper surface of the upper portion.

41. The system of claim 40, wherein the track is configured to slidably receive a bolt received through the central region of the tilt bracket to secure the tilt bracket to the pedestal.

42. The system of claim 40, wherein the track is configured to slidably receive a bolt received through a lower end of a support bracket of the plurality of support brackets to secure the lower end to the pedestal.

43. The system of any one of claims 21-27, wherein a support bracket of the plurality of support brackets comprises: a lower bracket comprising the lower end configured to be secured to an upper end of a pedestal of the plurality of pedestals; and an upper bracket attachable to the lower bracket such that the upper bracket extends upwardly from the pedestal to provide the upper end of the support bracket.

44. The system of claim 43, wherein the lower bracket has a triangular shape such that the lower end is wider than the upper bracket.

45. The system of claim 43, wherein the lower bracket defines an “L” shaped cross-section including a horizontal portion configured to be secured to the upper end of the pedestal by one or more fasteners and a vertical portion to which the upper bracket is attachable.

46. The system of claim 45, wherein the horizontal portion is substantially perpendicular to the vertical portion.

47. The system of claim 45, wherein the horizontal portion defines an acute angle less than ninety degrees with the vertical portion, e.g., between about eighty and eighty five degrees.

48. The system of any one of claims 21-27, wherein the support brackets have different lengths such that a solar panel mounted to a set of four pedestals and support brackets is tilted at an angle relative to the roof or other surface, e.g., at an angle of about eight degrees from horizontal.

49. The system of any one of claims 21-27, wherein the support brackets have different lengths such that a solar panel mounted to a set of four pedestals and support brackets is tilted at an angle relative to the roof or other surface such that one corner of the solar panel is lower than other corners.

50. The system of claim 49, wherein the set of four pedestals and support brackets are configured such that a solar panel secured to the system tilts at an angle of about eight degrees in an east-west direction and at an angle of about five degrees in a north-south direction orthogonal to the east-west direction.

51. The system of any one of claims 21-42, further comprising a grounding lug configured to be secured to an arm of a tilt bracket.

52. A pedestal for a racking system for mounting a solar panel system to a roof or other surface, comprising: a lower portion including a plurality of side walls surrounding an opening in a lower surface, and a plurality of inner walls dividing the opening into a plurality of spaces for receiving adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; andan upper portion including an upper surface including a track and tapered surfaces extending from the upper surface towards the lower portion, the track configured to slidably receive one or more fasteners to secure a bracket to the pedestal.

53. The pedestal of claim 52, wherein the inner walls extend upwardly from the lower surface towards the upper portion, the inner walls having a height smaller than the side walls.

54. The pedestal of claim 53, wherein the lower portion is formed from separately from the upper portion, and wherein the lower portion and the upper portion include cooperating features for securing the upper portion to a top surface of the lower portion.

55. The pedestal of claim 54, wherein the cooperating features comprise a dovetail connection.

56. The pedestal of claim 54, wherein the cooperating features comprise elongate slots extending along opposite sides of the lower portion and flanges on the upper portion that are slidable received in the slots.

57. The pedestal of any one of claims 52-56, wherein the upper portion has a length shorter than a length of the lower portion.

58. A racking system for mounting a solar panel to a surface, comprising: four pedestals comprising a lower portion for placement on a surface and a second upper end; a plurality of support brackets comprising upper ends and lower ends connectable to the upper ends of the pedestals; a set of four tilt brackets mountable to one or both of the upper ends of the pedestals and the upper ends of the support brackets, each tilt bracket of the plurality of tilt brackets including a central region configured to be secured to the upper end of one of the pedestals and the support brackets such that first and second arms of the tilt bracket are positioned on either side of the central region; anda set of four clamps mountable to respective tilt brackets to secure edges of the solar panel to the tilt brackets such that the solar panel extends between and above adjacent pedestals.

59. The system of claim 58, wherein each clamp comprises features configured to penetrate the edge of a solar panel when the clamps are secured to the respective tilt brackets to provide an electrical connection to the solar panel.

60. The system of claim 59, wherein the clamps and tilt brackets comprise conductive material, the system further comprising one or more cables connectable to the clamps and tilt brackets to provide an electrical bonding or grounding path for the system.

61. The system of any one of claims 1-8, wherein each clamp comprises features configured to penetrate the edge of a solar panel when the clamps are secured to the respective tilt brackets to provide an electrical connection to the solar panel.

62. The system of claim 61, wherein the clamps and tilt brackets comprise conductive material, the system further comprising one or more cables connectable to the clamps and tilt brackets to provide an electrical bonding or grounding path for the system.

63. The system of claim 61, wherein the clamps, tilt brackets, and struts comprise conductive material to provide an electrical bonding or grounding path for the system.

64. A racking system for mounting a solar panel system at an installation site, comprising: a plurality of elongate rods, each rod including a first lower end for insertion into the ground at the installation site and a second upper end; a plurality of elongate struts, each strut connectable to the upper ends of two or more rods aligned along a horizontal or other axis such that the struts are spaced apart from one another substantially parallel to one another;a plurality of tilt brackets integrally formed on the struts and spaced apart from one another along lengths of the struts, each tilt bracket including arms that extend laterally on either side of the respective strut; and a plurality of clamps mountable to the arms of the tilt brackets to secure edges of solar panels to the tilt brackets such that the solar panels extend between adjacent struts.

65. The system of claim 64, wherein the tilt brackets comprise pairs of arms spaced apart from one another along the lengths of the struts.

66. The system of claim 65, wherein each pair of arms extends diagonally from the strut.

67. A pedestal for a racking system for mounting a solar panel system to a roof or other surface, comprising: a lower portion including a plurality of side walls surrounding an opening in a lower surface configured to receive adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; an upper portion including an upper surface including a track configured to slidably receive one or more fasteners to secure a bracket to the pedestal; and a plurality of connectors for securing the upper portion to the lower portion.

68. The pedestal of claim 67, wherein the plurality of connectors comprise one or more slots configured to slidably engage the upper portion to the lower portion.

69. The pedestal of claim 67, wherein the lower portion is formed from separately from the upper portion, and wherein the connectors are configured to secure the upper portion to a top surface of the lower portion.

70. The pedestal of claim 69, wherein the connectors comprise a dovetail connection.

71. The pedestal of claim 69, wherein the connectors comprise elongate slots extending along opposite sides of the lower portion and flanges on the upper portion that are slidable received in the slots.

72. The pedestal of claim 67, wherein the upper portion comprises first and second tracks configured to slidably receive one or more fasteners to secure a bracket to the pedestal.

73. The pedestal of claim 72, wherein the first and second tracks extend parallel to one another along the upper surface.

74. The pedestal of claim 72, wherein the upper surface comprises a horizontal portion including the first track and a diagonal portion including the second track.

75. A pedestal for a racking system for mounting a solar panel system to a roof or other surface, comprising: a lower portion including a lower surface including a plurality of openings therethough communicating with an interior of the lower portion for receiving adhesive when the lower surface is placed against a roof or other surface where adhesive has been applied; and an upper portion including an upper surface including a plurality of tracks, each track configured to slidably receive one or more fasteners to secure a bracket to the pedestal.

76. The pedestal of claim 75, wherein the upper surface comprises a first portion that is oriented substantially parallel to the lower surface and wherein the plurality of tracks comprises a first track in the first portion.

77. The pedestal of claim 76, wherein the upper surface comprises a second portion that is inclined relative to the first portion and wherein the plurality of tracks comprises a second track in the second portion.

78. The pedestal of claim 77, wherein the first and second tracks extend substantially parallel to one another along a length of the pedestal.

79. The pedestal of any one of claims 75-78, wherein the lower portion further comprises a plurality of inner walls extending from the lower surface into the interior.

80. The pedestal of claim 79, wherein the plurality of openings comprise a plurality of slots extending at least partially along a length of the pedestal, and wherein the inner walls extend at least partially along the length between adjacent slots.

81. The pedestal of any one of claims 75-78, wherein the upper portion comprises a pair of upper side walls extending downwardly from the upper surface to an intermediate surface, and the lower portion comprises a pair of lower side walls extending downwardly from the intermediate surface to the lower surface.

82. The pedestal of claim 81, wherein the upper side walls extend vertically downwardly from the upper surface to the intermediate surface, and the lower side walls extend diagonally outwardly from the intermediate surface to the lower surface.

83. The pedestal of any one of claims 75-78, wherein the lower portion is formed from separately from the upper portion, the pedestal further comprising a plurality of connectors for securing the upper portion to the lower portion.

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