Patent Application
20200266757
Solar panels are widely used in the production of electricity with multiple panels typically connected together as panel assemblies. These solar panel assemblies are usually arranged in arrays and mounted on structural racking systems on the roofs of buildings, on the ground or other fixed structures. A fixed structure can include, but is not limited to, existing residential or commercial roof tops, horizontal surfaces or vertical surfaces, existing fences, railings, walls or open ground-mounted areas. In many jurisdictions, these mounting systems pass loading tests to ensure they can withstand static and dynamic loading anticipated during the life of the installation. These solar racking systems are often custom designed for each application and custom installed by contractors and tradespeople using specialty skills and following the approved drawings.
PV Solar modules typically are constructed using a lamination of a front sheet of glass, a layer of adhesive sealant, photovoltaic materials and conductors, another layer of adhesive and a sheet of specially designed polymer sheet, called the backsheet. These PV “glass-backsheet” modules are typically constructed with a frame to add rigidity to the “glass-backsheet” lamination and to provide a mounting point for the module.
In addition, a number of solar panel manufacturers have released new solar panels with integrated micro-inverters to simplify the electrical installation process. But a simple, low skill mechanical installation of a solar array remains unavailable on the market today.
Typical solar mounting or racking systems fail to provide the flexibility and ease of installation that many believe necessary for large scale adoption of solar power in the United States and around the world.
It is desired to have a solar module system that includes a flexible, configurable design that allows direct attachment either to the roof sheathing (plywood spanning over structural roof rafters or roof trusses that serves as a foundation for roofing materials) or to the roof rafters or roof trusses themselves. It is further desired to have a flexible, configurable solar module system that may be installed in a streamlined installation process which eliminates much if not all of the expense of custom design and installation activities. It is desired to have a solar module system that reduces work on the roof and reduces the skills and experience potentially necessary on the roof to perform a high quality solar array installation.
An array of two or more preassembled solar panel modules is provided. Each preassembled solar panel module includes a solar panel configured for receiving and converting solar radiation to produce electrical power. Multiple panel rails are coupled in preassembly to backside surfaces of said solar panels, including at least two panel rails disposed halfway or more along opposing long edges of each solar panel. Multiple snap connector components are coupled to or integrated with the panel rails and protrude from proximate edges of adjacent preassembled solar panel modules at matching locations for snapping together said adjacent modules. The multiple snap connector components may include snap lock components that are each movable to a locked position to prevent decoupling of said adjacent modules after said snapping together of said adjacent modules. One or more mounting feet are each coupled both at a selected location to one of the at least two panel rails and at a selected location to a roof or other sunlight receiving surface upon which said array is installed.
The snap connector components may include a pair of flexible members including protrusions or defining recesses for matching a complementary snap connector component of an adjacent module for snapping together the adjacent modules. The snap-lock components may be configured to lock the snap connectors of adjacent modules together in a locked position by inhibiting flexing of the flexible members. The flexing may be inhibited by one or more slide-lock components occupying areas alongside the flexible members.
Snap-lock components may be rotatable or slidable between unlocked and locked positions. Mounting feet and/or snap connectors may be snap-coupled or snap-lock coupled to panel rails.
The mounting feet may be configured for height adjustment. The mounting feet may include a rack and pinion mechanism for height adjustment.
A height (H) to gap (G) ratio may be between 0.42<H/G<15. H may include a height of a preassembled solar panel module measured as a spacing of said backside surface of the preassembled solar panel module from the roof or other sunlight receiving surface. G may include a gap spacing between nearest edges of adjacent preassembled solar panel modules. The height to gap ratio H/G may be between 0.42<H/G<3, or between 0.42<H/G<1.5. The gap (G) may be between 20 mm<G<120 mm. The height (H) may be between 50 mm<H<300 mm. The height (H) may be 75 mm or less. The gap (G) may be 37.5 mm or more. The ratio H/G may be approximately 1.
Multiple wind deflectors may be coupled to sides of preassembled solar panel modules that each define a peripheral segment of the array.
One or more short panel rails may be coupled to the backside surface of one or more preassembled solar panel modules of the array disposed halfway or more along opposing shortest edges of the solar panel between the at least two panel rails that are disposed at opposing long edges.
Two or more short panel rails may be coupled to the backside surface of one or more preassembled solar panel modules of the array disposed halfway or more along short dimension segments spaced from either shortest edge of the solar panel between the at least two panel rails that are disposed at the opposing long edges.
Bumpers may be coupled at corners of the preassembled solar panel modules that extend normally from the backside surface further than any of the panel rails.
Bumpers may be coupled at corners of the preassembled solar panel modules that protrude from the backside surface away from both adjacent edges.
The at least two panel rails may include outer facing walls with one or more features for coupling with one or more complementary features of the mounting feet or of the snap connector components, or both, for preventing movement along the at least two panel rails by the mounting feet or by the snap connector components, or both. The one or more features may include a series of notches or recesses or both. The one or more features may include a series of cutouts and the one or more complementary features may include a series of protrusions.
The mounting feet may each include a slider and at least two panel rails may each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within each of the mounting feet, wherein the flange does overlap the slider in the direction normal to the preassembled solar panel module when the slider is slid to a closed position from an open position for securing the mounting feet to the at least two panel rails.
One or more snap connector components may include a slider for securing the snap connector components to the at least two panel rails.
One or more toggle anchors coupled to mounting feet may each include a rotatably-attached, elongated washer for piercing roof sheathing or other sunlight receiving surface material in a first position and rotating to a second position securing the toggle anchor after the piercing.
The solar panel may be framed or frameless. The framed or frameless solar panel may be strengthened by the panel rails being configured to stiffen the solar panel.
Adjacent solar panel modules may be coupled together by coupling together complementary snap connector components that are coupled one to each of two adjacent preassembled solar panel modules.
Adjacent preassembled solar panel modules may be relatively aligned by the coupling together of complementary snap connector components that are coupled one to each of the adjacent preassembled solar panel modules. Complementary snap connector components may include a locking mechanism to secure the coupling of the adjacent preassembled solar panel modules against snap decoupling.
Mounting feet may include one or more pivoting features configured to provide relative movement between a pair of components to prevent or reduce strain or stress within the array.
The mounting feet may include one or more pivoting features configured to provide relative movement of a preassembled solar panel module within the array to prevent or reduce stress or strain from wind or snow loading or other factors by flexing about the one or more pivoting features.
The mounting feet may be configured for height adjustment to a selected level among multiple levels. The mounting feet may include a rack and pinion mechanism for height adjustment to a selected level among multiple levels. The mounting feet may include a pair of height adjustment components, wherein at least one of the pair includes multiple matching recesses or protrusions or both corresponding to different levels of height adjustment. The mounting feet may include a threaded height adjustment component.
The mounting feet may include one or more pivoting features configured for relative movement between a pair of pivotably-coupled components to prevent or reduce strain or stress.
The solar panels may include two or more overlapping surfaces that are configured to receive and convert solar radiation to generate electrical power.
A preassembled solar panel module is provided that includes a solar panel configured for receiving and converting solar radiation to produce electrical power and one or more panel rails coupled in preassembly to a backside surface of the solar panel. Two or more panel rails may be disposed a quarter length or more along opposing longest edges of the solar panel. One or more flexible snap connector components may be coupled to each to one of the panel rails and configured for coupling with a complementary snap connector component of an adjacent preassembled solar panel module. One or more mounting feet may each be coupled at a selected location to a panel rail and each may be configured for coupling at a selected location to a roof or to another sunlight receiving surface.
One or two or more short panel rails may be coupled to the backside surface of the preassembled solar panel module disposed halfway or more along opposing shortest edges of the solar panel between two panel rails that are disposed at opposing long edges of the module.
A bumper may be coupled at each corner of the preassembled solar panel module that extends normally from the backside surface further than any panel rail.
The panel rails may include outer facing walls with a series of notches protruding therefrom for coupling with complementary notches of mounting feet and/or of snap connector components for preventing movement along the panel rails by the mounting feet and/or snap connector components.
The mounting feet may each include a slider and panel rails may each include a flange that does not overlap the slider in a direction normal to the preassembled solar panel module when the slider is in an open position, thereby permitting receipt of a flange end of a panel rail within a rail receiving recess defined within each of the mounting feet, wherein the flange does overlap the slider in the direction normal to the preassembled solar panel module when the slider is slid to a closed position from the open position for securing the mounting feet to the panel rails. One or more snap connector components may include a slider for securing the snap connector component to a panel rail.
One or more toggle anchors may each include a rotatably-attached, elongated washer for piercing roof sheathing or other sunlight receiving surface material in a first position and rotating to a second position securing the toggle anchor after the piercing.
The preassembled solar panel module may be frameless and strengthened by the panel rails being configured to stiffen said solar panel. The preassembled solar panel module may be configured for coupling with one or more adjacent preassembled solar panel modules by coupling together complementary snap connector components that are coupled to panels rails of adjacent preassembled solar panel modules.
Snap connector components may provide relative alignment with adjacent modules of an array by the coupling together of complementary snap connector components coupled one to each of the adjacent preassembled solar panel modules.
Snap connector components may include a locking mechanism to secure the coupling with a snap connector component of an adjacent preassembled solar panel module.
A method of installing an array of preassembled solar panel modules with precision alignment is provided, wherein the preassembled modules includes mounting feet and pairs of snap connectors that are coupled to panel rails or other components that are coupled to a backside surfaces of said modules, wherein the pairs of snap connectors are configured to protrude from proximate edges of adjacent preassembled solar panel modules. The method includes installing a first preassembled solar panel module to a roof or other sunlight receiving surface, including coupling multiple mounting feet that are coupled to a backside surface of the first module to a roof or other surface. A second preassembled solar panel module is then coupled to the first module, including snap coupling together one or more pairs of snap connectors protruding from proximate edges of the first and second modules at matching locations. The second solar panel is then installed to the roof or other surface in alignment with the first solar panel module, including coupling one or more mounting feet that are coupled to a backside surface of the second module to the roof or other surface.
Pairs of snap connectors may include spring-loaded pins configured to snap into complementary recesses defined within respective snap connector components of each pair and/or may include flexible members and catch features configured for snapping together adjacent preassembled solar panel modules. The method may include locking the snap connectors together to prevent snap decoupling after snapping them together. The locking of the snap connectors may include moving a snap-lock component to a locked position to prevent decoupling of adjacent modules after snapping them together. The moving of the snap lock component may include rotating and/or sliding a snap lock handle.
Mounting feet may be configured to structurally attach to a roof surface at any location without first locating roof structural members such as rafters.
The method may include anchoring four mounting feet of the first preassembled solar panel module to the roof or other sunlight receiving surface, and anchoring two mounting feet of the second preassembled solar panel module to the roof or other sunlight receiving surface, wherein the two mounting feet may be coupled to a panel rail or other backside component of the second preassembled solar panel module and may protrude from a distal edge opposite the proximate edge to the first preassembled solar panel module
Another method of installing an array of two or more preassembled solar panel modules with precision alignment is provided. The method includes mounting a first preassembled solar panel module to a sunlight receiving surface with two corners disposed a predetermined distance from an edge of an area of the sunlight receiving surface within which the array is being installed. A second preassembled solar panel module is then snap coupled to the first preassembled solar panel module. An alignment tool is then engaged between adjacent corners of the first and second modules. The second module is adjusted such that a corner opposite to the engaged alignment tool is disposed the same predetermined distance from the edge. The second module is then mounted to the sunlight receiving surface.
The alignment tool may include two or more corner plates, and the engaging the alignment tool may include receiving adjacent corners of the first and second modules at two of the corner plates. Each corner plate may include a pair of perpendicular plates including a first plate of a first corner plate that is coplanar with a first plate of second corner plate and a second plate of the first corner plate that is parallel to a second plate of the second corner plate, wherein the second plates are spaced apart a predetermined distance. The two corner plates may be configured to receive a corners of corner bumpers that are coupled to backside surfaces of the first and second modules.
Another method of installing an array of two or more preassembled solar panel modules with precision alignment is provided. The method includes coupling a pair of alignment string mounting stands to a sunlight receiving surface each disposed a predetermined distance from an edge of an area of the sunlight receiving surface within which the array is being installed. A taut line is coupled at each end to one of the pair of alignment string mounting stands. Multiple preassembled solar panel modules are installed in a row each with two corners disposed on the taut line or a predetermined distance from the taut line or otherwise aligned with the taut line.
The alignment string mounting stands may each include a base plate and one or more perpendicular plates that include one or more string mounting tabs and define one or more string holes. The method may include anchoring the taut line at each end to a mounting tab of one of the alignment string mounting stands, and elevating the taut line above the sunlight receiving surface including running the taut line through a string hole that is spaced a predetermined height above the sunlight receiving surface. The coupling the pair of alignment string mounting stands to the sunlight receiving surface may include tucking the base plate of each stand underneath spaced apart shingles or tiles of a shingle or tile roof.
The installing of multiple preassembled solar panel modules may include snap coupling adjacent modules and adjusting a position of one or more of the snap couplers along an edge of a module to align the module with the taut line.
In general, a preassembled solar panel module in accordance with embodiments described herein may include a framed solar panel or a frameless solar panel. A framed or frameless, preassembled solar panel module is provided that includes a respectively framed or frameless solar panel configured for receiving and converting solar radiation to produce electrical power and multiple panel rails coupled in preassembly to a backside surface of the solar panel, including at least two panel rails disposed a quarter length or more along opposing longest edges of the solar panel. Multiple flexible snap connector components are each coupled in preassembly to one of the at least two rails and are each configured to for coupling with a complementary snap connector component of an adjacent preassembled solar panel module or of a wind deflector accessory, or both. One or more mounting feet are each coupled in preassembly at a selected location to one of the at least two panel rails and each mounting foot is configured for coupling at a selected location to a roof or to another sunlight receiving surface. A framed or frameless, preassembled solar panel module may include one, two or more overlapping surfaces that are each configured to receive and convert solar radiation to generate electrical power.
In certain embodiments, the frame of a conventional solar panel is replaced on a glass-backsheet solar photovoltaic (PV) module by a set of long panel rails coupled to the bottom or backside of the module along the long edges of the module. A set of one or more short rails may be coupled along one or more short edges of the modules and/or spaced significantly from the short edges for example even at mid-rail locations between the long rails or for example a pair of short rails may be disposed ⅓ of the length of the long rails from the ends of the long rails. The rails may be configured to provide rigidity to glass-backsheet lamination in certain embodiments.
The rails may also be configured for providing a base for side snap brackets to couple to the solar PV module and/or for providing a base for corner snap brackets to couple to the module. The rails may also be configured for providing a base for mounting feet to couple to the solar PV module for securing the module to a roof or other sunlight receiving surface. The rails may also be configured to provide a structure for securing power electronics, cables and/or wires.
The coupling of a mounting foot to a panel rail can be performed in a number of ways including inserting pins from the foot into holes or slots in the rail (see, e.g.,
In certain embodiments, polymer materials are employed for snaps, bumpers, brackets, mounting feet, or rail coatings, or combinations thereof, that allow the safe installation, use and operation of the pre-assembled solar panel modules without needing any equipment grounding or bonding alternative metal parts contained within the system.
Furthermore, the back coupling of the rails to the solar module serves in certain embodiments to prevent premature degradation of the solar module, which could otherwise reduce a module's power production over time, primarily but not exclusively due to the elimination of potential induced degradation, which is a condition that has afflicted many conventional framed, glass-backsheet modules.
An array of preassembled solar panel modules is provided in certain embodiments including one or more short panel rails coupled to the backside surface of the preassembled solar panel module disposed a quarter length or halfway or three-quarters or more along a length of opposing shortest sides of the solar panel between at least two long panel rails that are disposed at opposing longest sides of the solar panel.
An array of preassembled solar panel modules is provided in certain embodiments including bumpers at corners of the preassembled solar panel modules that extend normally from the backside surface further than any of the panel rails.
An array of preassembled solar panel modules is provided in certain embodiments, including at least two panel rails with outer facing walls having one or more features, e.g., notches, recesses, cutouts or protrusions, or combinations thereof, for coupling with complementary features of mounting feet or of snap connector components, or both, for preventing movement along the panel rails of the mounting feet or of the snap connector components, or both.
An array of preassembled solar panel modules is provided in certain embodiments, including one or more frameless solar panels. The one or more frameless solar panels may be strengthened by coupling two or more panel rails to a backside surface that are configured to stiffen the solar panel.
In certain embodiments, adjacent solar panel modules of an array are secured together by coupling together complementary snap connector components that may be coupled one to each of two adjacent preassembled solar panel modules.
The mounting feet are designed in certain embodiments to be coupled to preassembled solar panel modules before anchoring the feet and the modules of the array to a roof or other sunlight receiving surface. A fully preassembled solar panel module includes the one or more mounting feet coupled thereto at least by the time of anchoring to the roof. During shipping, the mounting feet may or may not be coupled to a partially preassembled solar panel module.
A partially preassembled solar panel module may include two or more panel rails coupled to a backside surface. The solar panel module may be deemed to be fully preassembled when the one or more mounting feet are each coupled to one of the backside-attached panel rails. A fully or partially preassembled solar panel module may include one or more bumpers, one or more brackets, e.g., that may couple to ends of one or more panels rails or may include built-in snap connector components, and/or one or more snap connector components along one or more sides and/or at one or more of the corners for coupling together adjacent modules of a solar array. Particular configurations of side snap connectors and/or corner snap connectors may be customized specific to installation applications, e.g., residential pitched roof solar arrays may include snap-connected adjacent solar panel modules or solar farm arrays or multi-directional arrays that may include some adjacent solar panel modules that are snap-connected together and some that are not, and an array may include no snap connected adjacent solar modules in certain applications.
For residential pitch roof applications, snap connector components are included with preassembled solar panel modules in accordance with several example embodiments. For other applications, like low slope commercial or residential roof, preassembled solar panel modules may include fewer preassembled components. In such low slope applications, for example, either the side snaps, the corner snaps or the bumpers or combinations thereof may be excluded from a preassembled solar panel module in certain embodiments.
As another example, for an installation in which a customer prefers not to see brackets or snap-connector components along a perimeter edge of a solar array, the brackets or the side snaps or the corner snaps or the bumpers or combinations thereof may be optionally removed to provide a clean frameless aesthetic and an edge free from components which can catch debris or be used by insects for nesting. Wind deflectors may be provided that also serve aesthetically to block certain components from view and from damaging effects from wind or rain or other natural factors.
in some applications, like low slope commercial or residential roof, fewer than all installed components may be coupled in preassembly to the solar panel module. In a low slope application, for example, either the side snaps, the corner snaps or one or more bumpers or wind deflectors, or combinations thereof, may be excluded from a preassembled solar panel module or optionally included even module-to-module depending on the arrangement and particulars of the array and the installation surface. Any one or more of these components may be installed in a subsequent assembly step before transport to an install site or at an install site prior to mounting to a roof or other sunlight receiving surface, or even after mounting, or may be subsequently removed, or may left off one or more modules or from an entire array of preassembled solar panel modules.
A long panel rail, i.e., a panel rail that is aligned with a longest side of a solar panel, may be as long as the longest side of the solar panel, or may be much smaller, e.g., a quarter, a half or three-quarters of the length of the long side of the solar panel. When shorter panel rails are used, there may be more than one of them disposed coaxially or non-coaxially, and spaced-apart along the long side of the solar panel. For example, there may be two panels rails coupled along each long side of a preassembled solar panel module, one for coupling with a mounting foot and the other for coupling with a snap coupler component. In another example, three panel rails, each being one quarter of the length of the longest side of a solar panel module, are disposed coaxially along the longest side of a preassembled solar panel module and spaced apart by an eighth of the length of the longest side of the module.
The panels rails in a dual glass, frameless solar panel module configuration may provide some stiffening support to the module, although dual glass module already has two plane glass stiffness. In a glass-polymer backsheet module, that may or may not include a frame, the panel rails would be configured to provide enhanced stiffness in both the short and long sides of the module.
In some embodiments, snap couplers or snap connectors or snaps may be provided at the corners, while snap couplers (or snap connectors or snaps) that are not at the corners may be coupled to long or short panel rails anywhere along the length of a rail. Snap connectors may be coupled in preassembly directly to a backside surface of a solar panel or to another component of a preassembled solar panel module other than a panel rail. In certain framed solar panel embodiments, snap connectors may be coupled to the frame of such a solar panel.
Snap connectors may couple to panel rails in the same way or in a different way as mounting feet couple to panel rails. Mounting feet and/or snap connectors may be shaped to include on one side a panel rail-receiving recess for receiving a panel rail at one of the remaining panel rail sides adjacent or opposite to the panel rail side that is attached to a backside of a preassembled solar panel module.
A slide-lock or rotation-lock mechanism may be provided on a mounting foot or snap connector, or instead on a panel rail or on the backside of the solar panel or on another attached or integrated component of a preassembled solar panel module, for securing a panel rail that has been received within the panel rail recess by moving a slide-lock or rotation-lock component from an unlocked position to a locked position and for decoupling the mounting foot and/or snap connector from the panel rail by moving the slide-lock or rotation-lock component back to the unlocked position.
The snap connectors may be otherwise configured as a sleeve disposed around a length of a panel rail, or the snap connectors may couple to the rails using a slider to catch a panel rail flange or using a bolt and nut mechanism or peg and slot mechanism in certain embodiments.
In certain embodiments, snap connectors may be coupled to rail connectors that connect long rails to short rails on one side (facing in away from the edge of the module) and that connect long rails to snap connectors on the other side (facing out towards the edge of the module). Snap connectors or snaps can serve multiple purposes, including creating a module to module coupling location, coupling to a long panel rail, coupling to a short panel rail, or efficiently transferring mechanical load from module to snap to foot, or combinations thereof. Snap connectors in certain embodiments offer a rotational lock of the snap coupling mechanism which improves the usability and the effectiveness of the snap locking operation by installers.
An array of preassembled solar panel modules is provided that exhibits a height to gap ratio that is in a range between 0.42<H/G<15. H is a height of a preassembled solar panel module measured as a spacing of said backside surface of said preassembled solar panel module from said roof or other sunlight receiving surface, and G is a gap spacing between nearest edges of adjacent preassembled solar panel modules.
Another array of preassembled solar panel modules is provided wherein 0.42<H/G<3.
Another array of preassembled solar panel modules is provided wherein 0.42<H/G<1.5.
An array of preassembled solar panel modules is provided in certain embodiments wherein 20 mm<G<120 mm.
An array of preassembled solar panel modules is provided in certain embodiments wherein 50 mm<H<300 mm.
An array of preassembled solar panel modules is provided in certain embodiments wherein H<75 mm and G>37.5 mm.
An array of preassembled solar panel modules is provided in certain embodiments wherein H/G≈1.
The heights (H) and gaps (G) present in an array may be precisely set in preassembly. Precision gaps (G) are provided in certain embodiments by coupling panel rails a certain distance from panel edges and coupling snap connectors to the panel rails, so that adjacent modules can be snap coupled together with precise gaps (G). Precision heights (H) are provided in certain embodiments by coupling mounting feet to panel rails, wherein the mounting feet are configured for mounting preassembled solar panel modules at predetermined heights above the roof or other mounting surface. Foot heights may be adjustable after installation to adjust module heights.
In certain embodiments, mounting feet couple to brackets, and the brackets are coupled to the backside of the solar panel. In other embodiments, mounting feet don't couple to brackets but to panel rails, e.g., as illustrated in
Mounting feet and/or snap couplers can couple to rails at any of several locations along the rails.
Referring now to
The example preassembled solar panel module 902 illustrated at
The preassembled solar panel module 1002 of
Corner brackets 1016 also couple with each end of the two long rails 1010. The corner snaps 1004A,1004B, the corner bumpers 1012 and the corner brackets 1016 may be separate components, may be coupled together or may be formed as an integral component that serves all three of these functions, or any two may be coupled or integral and separate from the third.
An interlocking photovoltaic (PV) mounting system is provided with adjustability to further reduce labor time and labor skill level in the installation of solar power systems. Adjacent preassembled solar panel modules are installed in precise alignment by snap connecting them together at selected locations along long and/or short edges and/or at the corners. Other methods are provided for precision alignment of preassembled solar panel modules in a solar array. In certain embodiments, the snap connectors are locked together by moving a rotational or slide locking mechanism from an unlocked to a locked position. The preassembled solar panel modules are configured to be adjustable in certain embodiment in the plane of and/or normal to the roof or other sunlight receiving surface upon which the module is installed.
In
In
In
In alternative embodiments, the male snap coupler includes flexible members, while the female snap coupler is rigid, or both the male and female snap couplers may include flexible members. In the latter embodiment, additional locking strength may be provided to counter the enhanced tendency of the flexible members of both the male and female snap couplers to flex to the point of snap decoupling. The slide lock illustrated at
In
Often PV module installers identify that a given roof has variability in its surface that can show up in the installed modules. Installers have a normal set of methods, tools and products they use to adjust standard PV modules to create a level solar PV array on the roof. SMASH has created a new method of module adjustment that can be performed immediately after a module is installed, after a row of modules is installed or after an entire array of modules has been installed. This method is enabled through a mechanism that allows quick adjustability and easy removal of the PV module for maintenance. In the first embodiment, we find an assembly of parts making up a module-adjusting mounting foot with built-in adjustability for raising or lowering a flat plate solar collector or PV solar power module to account for unevenness in the roofing or mounting surface.
In the example of
A tubular metallic flashing 2224 may also be joined and aligned with a tubular surface found in the bottom of the flashing base 1922 of
In the installation of flat plate solar collectors or solar PM modules, workers align the modules with
an area on a fixed structure (e.g. a roof or roof eave or roof ridge or any other sunlight receiving surface). This alignment can be done by placing a chalk line on the roof and following the line or by placing a string line on the first and last modules on a given row of modules to check their alignment or by measuring the modules' edges to the eave. In addition, in the implementation of a system to reduce labor time and skills in the installation of solar power, one may consider how to align modules as they are installed to prevent misalignment and rework.
For a first row of two or more preassembled solar panel modules of an array, workers may use the following example alignment steps. First, provide the location of the outer corner feet of the anchor module that is closest to the eave of the roof. This is the reference foot that controls the location of the subsequent foot installation. Second, measure the distance from the eave of the roof to the two corner bumpers on the anchor module that are closest to the eave. The two measurements should be within 1/16th of an inch as an example tolerance that may be specified. This ensures the module's front ends will be parallel to the eave. Third, snap on the next module and position the feet with the flashing. The feet may be moved after this step, but foot adjustment may be better performed before this step. Do not attach the foot to the roof at this time. Fourth, engage alignment tools 2930 at each inner corner of the module 3031 that are adjacent to the corners of the previous module. After engaging the alignment tool, measure the outer corner bumper of the new module to within 1/16″ (example tolerance) of the original measurement obtained from the anchor module or first preassembled solar panel module at a corner of the array. Adjust the new module location as necessary. This would ensure the new module is aligned with the anchor module, and therefore, aligned with the eave of the roof. Fifth, with the alignment tools 2930 engaged, attach the feet to the sheathing using toggle bolts (see U.S. Ser. No. 15/138,437, which is by the same Applicant as the present application and is incorporated by reference). Sixth, remove the alignment tools. Seventh, repeat the third to sixth steps for subsequent module installation. These seven steps should keep the first row parallel to the eave of the roof.
In another example, an alignment control tool 3202 as in the example of
See
As an alternative embodiment to the rotational coupler locking described with reference to
In this example, the female snap coupler 3708 may have rigid members 3710 that include recesses that match protrusions from the flexible members 3704 of the male snap coupler 3706. The mating of the recesses and protrusions provides snap coupling capability, while the slide lock provides locking engagement and prevents snap decoupling when in the locked or closed position as in
In certain advantageous embodiments, solar installers can quickly adjust attachment points to the roof. In certain embodiments, one or two bolts may be loosened and/or tightened by hand or with a simple tool such as an electric drill, an allen wrench or a screwdriver to adjust a position of a mounting foot and/or a snap coupler to a different position along a panel rail or bracket that has been attached to a backside surface of a preassembled solar panel module. In this way, any modules within an array that are not aligned or that have preassembled mounting feet disposed at a roof or other surface location that is not readily available for mounting with a toggle bolt or that have adjacent snap couplers that are not precisely matched in their location protruding from an edge of a preassembled solar panel module can be efficiently and safely adjusted.
Several solar panel modules may be coupled together into an array using any of the preassembled solar panel modules described herein even if certain modules have not been described as being configured for coupling together with other modules into an array. Electrical current generated by solar radiation impinging upon the solar panels of the solar panel modules array and being converted to electrical energy may be passed from module to module until a power storage component is reached or until a circuit for powering lights, appliances or other electronically powered equipment is reached or until an outside power line is reached for transmitting the electrical power to the grid.
Various modifications and alterations of the invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention, which is defined by the accompanying claims. It should be noted that steps recited in any method claims below do not necessarily need to be performed in the order that they are recited. Those of ordinary skill in the art will recognize variations in performing the steps from the order in which they are recited. In addition, the lack of mention or discussion of a feature, step, or component provides the basis for claims where the absent feature or component is excluded by way of a proviso or similar claim language.
While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. The various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that may be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features may be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations may be implemented to implement the desired features of the present invention. Also, a multitude of different constituent module names other than those depicted herein may be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.
Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the such as; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the such as; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Hence, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
A group of items linked with the conjunction “and” should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as “and/or” unless expressly stated otherwise. Similarly, a group of items linked with the conjunction “or” should not be read as requiring mutual exclusivity among that group, but rather should also be read as “and/or” unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated.
The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other such as phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term “module” does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, may be combined in a single package or separately maintained and may further be distributed across multiple locations.
Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives may be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the such as represent conceptual views or processes illustrating systems and methods in accordance with particular embodiments. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.
This application claims priority to U.S. provisional patent application Ser. No. 62/203,902, filed Aug. 11, 2015, which is incorporated by reference. This application also claims priority to U.S. provisional patent application Ser. No. 62/209,860, filed Aug. 25, 2015; U.S. Ser. No. 62/260,321, filed Nov. 26, 2015; U.S. Ser. No. 62/321,467, filed Apr. 12, 2016; and U.S. Ser. No. 62/326,811, filed Apr. 24, 2016; which are each incorporated by reference. This application is also a continuation-in-part (CIP) of PCT/US16/44151, filed Jul. 27, 2016, which claims priority to U.S. Ser. No. 62/197,564, filed Jul. 27, 2015, which are each incorporated by reference. This application is also a CIP of U.S. Ser. No. 15/138,437, filed Apr. 26, 2016, which claims priority to U.S. Ser. No. 62/152,938, filed Apr. 26, 2015, which are each incorporated by reference. This application is also a CIP of PCT/US2016/000019, filed Mar. 2, 2016, which claims priority to U.S. Ser. No. 62/127,287, filed Mar. 2, 2015, which are each incorporated by reference. This application is also a CIP of U.S. Ser. No. 14/521,245, filed Oct. 22, 2014, which is a CIP of U.S. Ser. No. 14/054,807, filed Oct. 15, 2013, which claims priority to U.S. Ser. No. 61/712,878, filed Oct. 12, 2012, which are incorporated by reference.
This invention was made with government support under the SunShot Financial Assistance Award number DE-EE0006457 awarded by the Department of Energy. The government has certain rights in the invention.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US16/46649 | 8/11/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62326811 | Apr 2016 | US | |
| 62321467 | Apr 2016 | US | |
| 62260321 | Nov 2015 | US | |
| 62209860 | Aug 2015 | US | |
| 62203902 | Aug 2015 | US |
