Molded Solar Panel Racking Assembly

Abstract

The present invention comprises a stackable ballasted roof mounting solar panel mount unit integrally formed into a single piece. The mount unit comprises a plurality of generally elevated side walls of a ballast receiving basket. Each of the generally elevated side walls taper upward and inward from a generally downward facing peripheral edge to an apex ridge of the wall. The generally elevated side walls taper downward and inward from the apex ridge of the wall. The side wall further extends inward from the base of the inner face to form a ballast supporting basket lip. Each side walls defines a downwardly facing open channel that is configured to receive a corresponding side wall from a corresponding solar panel mount in a stacking relation. The mount unit further comprises a plurality of stackable posts that extend upward from the peripheral edge to the top of the first pair of posts at a first predetermined height above the generally elevated side wall. Each of the posts forms a downwardly facing post receiving first mouth that is configured to receive a corresponding post from a corresponding first pair of posts of a corresponding solar panel mount in a stacking relation.

What is claimed is: 
     
         1 . A stackable ballasted roof mounting solar panel mount unit integrally formed into a single piece comprising:
 a plurality of generally elevated side walls of a ballast receiving basket, wherein each of the generally side walls taper upward and inward from a peripheral edge to an apex ridge of the wall and then tapers downward and inward from the apex ridge of the wall and further extends inward from the base of the inner face to form a ballast supporting basket lip, wherein each side wall defines a downwardly facing open channel that is configured to receive a corresponding side wall from a corresponding solar panel mount in a stacking relation; and   a first pair of posts, wherein each of the first pair of posts forms a downwardly facing post receiving first mouth that is configured to receive a corresponding post from a corresponding first pair of posts of a corresponding solar panel mount in a stacking relation.   
     
     
         2 . The unit of  claim 1 , further comprising a second pair of posts of a second predetermined height above the generally elevated side wall, wherein each of the second pair of posts forms a downwardly facing post receiving mouth that is configured to receive a corresponding post from a corresponding solar panel mount in a stacking relation. 
     
     
         3 . The mount of  claim 1 , wherein the peripheral edge has a plurality of raised gaps around the base to allow water to flow under the base without obstruction. 
     
     
         4 . The unit of  claim 1 , wherein the basket has a large hollow part that is cut away to prevent water from pooling in the basket. 
     
     
         5 . A plurality of units of  claim 1  that are arranged in a single vertically aligned stack, wherein a first of the plurality of units is placed onto the bottom and a second of the plurality of units is vertically aligned with the first of the plurality of units, wherein the distance between any point on the first of the plurality of units and the same corresponding point on the second of the plurality of units is less than ½ the height of the distance from the peripheral lip to the apex ridge of any one unit. 
     
     
         6 . The plurality of units as set forth in  claim 5 , wherein the plurality are arranged in one vertically aligned stack on a pallet. 
     
     
         7 . The plurality of units of  claim 2 , wherein the plurality of units are arranged in one vertically aligned stack, wherein a first of the plurality of units is placed directly onto the pallet on the bottom of the stack and a second of the plurality of units is vertically aligned with and stacked upon the first of the plurality of units, wherein the distance between any point on the first of the plurality of units and the same corresponding point on the second of the plurality of units is less than ½ the height of the distance from the peripheral lip to the apex ridge of any one unit. 
     
     
         8 . The plurality of units as set forth in  claim 7 , wherein unassembled rails and other hardware can be stacked between the first pair of posts and the second pair of posts in the plurality of stacked units on the pallet. 
     
     
         9 . The mounting unit of  claim 1 , wherein a ballast block is placed in the basket over the plurality of lips to anchor the unit.