Patent Application
20090056792
None.
A. Field of the Invention
The field of the present invention relates generally to structures made up of a plurality of interconnecting panels for supporting one or more useful objects, such as a layer of photovoltaic laminate strips. More particularly, the present invention relates to an interconnecting panel that is configured to join with an adjacent panel to provide a substantially planar surface to support a plurality of objects. Even more particularly, the present invention relates to such interconnecting panels that are configured join together to form a planar surface that provides improved span capabilities and does not interfere with the operation of the object(s) supported thereby.
B. Background
Support structures are commonly utilized in many different types of situations to beneficially support one or more useful objects in a position that allows the object to perform its function and/or the user to more easily access the useful objects. Often it is particularly beneficial or even necessary that the support structure have a generally planar upper surface to or on which the useful object is attached or mounted. An example of a useful object that typically can benefit by being supported by a support structure having a generally planar upper surface is the photovoltaic component(s) of a solar energy electrical generating system. As concerns over the use, cost and availability of fossil fuels continue to rise, the desire to utilize readily available, silent, nonpolluting solar power as a source of electrical energy also increases. Over the years, many people have utilized rooftops and other locations on building structures as the support structure for the solar energy components. More recently, the economics of solar energy systems has allowed persons to consider the use of a dedicated, stand-alone structure to support the solar energy system components.
Many people are at least generally or somewhat familiar with the use of rigid conventional solar cells as the photovoltaic component of the solar energy producing system. One of the relatively recent improvements to solar energy technology is the use of thin film photovoltaic devices to generate the electricity from the solar energy system. Typically, these thin film photovoltaic devices, also referred to as photovoltaic laminates, are encapsulated in a transparent, durable, flexible and UV stabilized polymer, such as ETFE. The polymer ETFE, which is commercially available as Tefzel®, is known to be a particularly durable and high-light-transmissive polymer. Due to their flexible nature, thin film photovoltaic devices have been formed into “solar shingles” or strips for use as or in conjunction with other roofing material. An example of such shingles are the Uni-Solar® available from United Solar Ovonic. Typically, such photovoltaic devices are provided in a stick-on configuration that is rolled out on to a support surface, which may be a roof, and then connected together in series by joining the wires that extend from the photovoltaic laminate strip at one end thereof.
As stated above, although most solar energy systems have been attached to or incorporated into a building structure, stand-alone installations of solar energy systems have, relatively recently, become much more economical to install. In fact, the planned or constructed size some stand-alone systems is so large that they are commonly referred to as “solar energy farms.” Because they do not rely on a building structure, stand-alone installations require their own support structure to support the photovoltaic component, such as the photovoltaic laminates. Naturally, any support structure should be configured so as to receive the photovoltaic component in a manner that most benefits the solar collection aspect of the component, namely supporting the photovoltaic component in an upwardly manner in the general direction of the sun.
Presently, the support structure commonly utilized for photovoltaic components incorporates the standard standing seam roof panel, an example of which is identified by numeral 1 and shown as Prior Art in
The use of standing seam roof panels 1 as the upward supporting component of a support structure utilized to support the photovoltaic components of a solar energy systems has a number of significant limitations. One such limitation is that the standing seam resulting from interconnected panels 2 will result in shade covering a portion of the photovoltaic component during at least part of the day, resulting in loss of electrical generating efficiency. Another limitation with standing seam roof panels 1 is that they are generally somewhat limited with regard to the distance which they are able to span unsupported. Because of these and other limitations, what is needed is an improved support panel that can be utilized as the supporting component of a support structure to support a useful object. The preferred support panel should be configured to interconnect with adjoining cooperatively configured panels to provide an upper surface on which to place or attach a useful object. Preferably, the support panel should be able to interconnect with a select number of adjoining like-configured panels to provide the desired width for the upper surface on which the object is positioned. The preferred support panel should provide a generally planar upper surface to facilitate placement of the object thereon and to improve the performance of certain types of useful objects by not shading the objects, such as strips of photovoltaic laminates that are the photovoltaic component of a solar energy system. Preferably, the support panel should be configured to be less limited with regard to the distance which it is able to span unsupported by support posts, cross-members and like structural components.
The interconnecting support panel of the present invention solves the problems and provides the benefits identified above. That is to say, the present invention discloses a support panel which is configured to be the supporting component of a support structure on or to which a useful object can be placed or attached. The support panel of the present invention can be interconnected with other like-configured support panels to obtain the desired width of upper surface on which can be placed or attached one or more useful objects, such as a plurality of photovoltaic laminate strips. The support panel of the present invention interconnects with other like-configured support panels to provide a generally planar surface on which a useful object can be beneficially placed or attached thereto. In the preferred embodiments, the interconnecting components of adjacent support panels interconnect in a manner that forms the generally planar surface. The support panel is also configured to be less limited with regard to the distance it is able to span unsupported by support posts, cross-members and other structural components of the support structure.
In one general aspect of the present invention, the interconnecting support panel is configured for use in a support structure to support one or more work objects, such as photovoltaic elements comprising photovoltaic laminate strips. The support panel has a panel member with opposing first and second ends, opposing first and second sides and a substantially planar upper surface disposed between the ends and sides. Located at the first side of the panel member, typically integral therewith, is a generally downwardly projecting first connector having a downwardly disposed section and an angled upward section. Located at the second side of the panel member, also typically integral therewith, is a generally downwardly projecting second connector having a downwardly disposed section, a substantially horizontal section and a generally upward section. The first connector and second connector are both shaped and configured to cooperatively join with an adjacent support panel so as to maintain the generally planar upper surface in a generally planar configuration so as to beneficially support the work object thereon. The support panel can include an endcap that defines a raceway therein for substantially enclosing wires extending from the work objects, such as the photovoltaic laminate strips, and directed to use or distribution of electricity therefrom. The support panel can be attached to one or more frame members of the support structure.
Accordingly, the primary objective of the present invention is to provide an interconnecting support panel that provides the advantages discussed above and overcomes the disadvantages and limitations associated with presently available support panels and support structures.
It is also an important object of the present invention to provide an interconnecting support panel that is configured to interconnect with adjacent support panels in a manner that forms the desired supporting surface on which to place or attach useful objects.
It is also an important object of the present invention to provide an interconnecting support panel that has interconnecting components on the sides thereof that interconnect with adjacent support panels in a manner which defines a substantially planar upper surface.
It is also an important object of the present invention to provide an interconnecting support panel that improves the operation and/or efficiency of a useful object placed on or attached to a substantially planar upper surface defined by two or more interconnecting support panels.
It is also an important object of the present invention to provide an interconnecting support panel that is particularly configured to beneficially receive one or more photovoltaic laminate strips thereon in a manner which facilitates full exposure of such strips to the sun by eliminating components that can cause shade to be placed over the photovoltaic components.
It is also an important object of the present invention to provide an interconnecting support panel that increases the distance such panel can span between support posts, cross-members or other structural frame members of the structural support system.
The above and other objectives of the present invention will be explained in greater detail by reference to the attached figures and the description of the preferred embodiment which follows. As set forth herein, the present invention resides in the novel features of form, construction, mode of operation and combination of processes presently described and understood by the claims.
In the drawings which illustrate the preferred embodiments and the best modes presently contemplated for carrying out the present invention:
With reference to the figures where like elements have been given like numerical designations to facilitate the reader's understanding of the present invention, the preferred embodiments of the present invention are set forth below. The enclosed figures are merely illustrative of a preferred embodiment and represent one of several different ways of configuring the present invention. Although specific components, materials, configurations and uses are illustrated, it should be understood that a number of variations to the components and to the configuration of those components described herein and in the accompanying figures can be made without changing the scope and function of the invention set forth herein. For instance, although the figures and description provided herein are primarily described as being utilized to support a plurality of photovoltaic laminate strips as part of a solar energy system, those skilled in the art will readily understand that this is merely for purposes of simplifying the present disclosure and that the present invention is not so limited.
An interconnecting support panel that is manufactured out of the components and configured pursuant to a preferred embodiment of the present invention is shown generally as 10 in
Support panel 10, as best shown in
To join with adjacent, like-configured support panels, such as 10b and 10c, support panel 10 of the present invention also comprises a first connector 46 at the first side 40 of panel member 34 and a second connector 48 at the second side 42 of panel member 34. In the preferred embodiment, both first 46 and second 48 connectors are integral with panel member 34 and are formed therewith during the manufacturing process 48. As shown in
In a preferred embodiment of support panel 10 of the present invention, first 46 and second 48 connectors are cooperatively configured to be joined together in a manner that does not impede or otherwise interfere with the placement and attachment of first 50 and second 52 attachment devices. As best shown in
In a preferred configuration and use of support panels 10 of the present invention and support structure 12 utilizing these panels, which is to beneficially support one or more photovoltaic elements 14, a specially configured endcap 66 is positioned at the first ends 36 of the support panels to define a raceway 68 for the collection and passage of wires from photovoltaic elements 14 and a C-shaped trim member 70 is placed at the second ends 38 of the various support panels 10. If endcap 66 is utilized, the raceway 68 allows the user to protect the wires that extend from and then connect in series the various photovoltaic elements 14 on support panels 10 and the wires that connect the photovoltaic elements 14 to devices, machines or apparatuses that are powered by the electricity generated thereby or to distribution systems (i.e., power grid) that distribute the electricity for use at other locations.
In use, the support structure 12 is constructed by utilizing appropriate frame members, such as posts 18 and cross-members 26, to form a frame-like structure for receiving support panel 10 of the present invention. If desired, the lower end 20 of the posts 18 can be placed in a hole 28 that is filled with concrete 30 or like material to secure posts 18 in a generally upright position or the posts 18 can be bolted to a concrete slab to obtain the desired configuration for the posts 18. With the basic frame installed, the various support panels, such as 10, 10b, 10c and 10d, are placed on top in a manner that they interconnect with each other at the first 40 and second 42 sides thereof and are secured to the frame of the support structure 12 in a manner that maintains the generally planar configuration of generally planar surface 16. In the preferred embodiment, as set forth above, second attachment device 52 is utilized to secure second connector 48 to cross-member 26 or another secure portion of the frame and first connector 46 is placed within second connector 48 and first attachment device 50 is utilized to attach adjacent support panels, such as 10 and 10b, together. With support panels 10 attached to the structural members the photovoltaic elements 14, such as photovoltaic laminate strips, are affixed to the planar upper surface of support panels 10. In a preferred embodiment, endcap 66 is placed at first end 36 to provide a raceway 68 for the wires which interconnect the various photovoltaic elements 14 and to transfer the power collected thereby for use or distribution. A C-shaped trim member 70 is then placed at second end 38.
While there are shown and described herein specific forms of the invention, it will be readily apparent to those skilled in the art that the invention is not so limited, but is susceptible to various modifications and rearrangements in design and materials without departing from the spirit and scope of the invention. In particular, it should be noted that the present invention is subject to modification with regard to any dimensional relationships set forth herein and modifications in assembly, materials, size, shape, and use. For instance, there are numerous components described herein that can be replaced with equivalent functioning components to accomplish the objectives of the present invention.
