This disclosure generally relates to mounting systems for solar modules and, more specifically, to methods for mounting solar modules to a mounting surface using an adhesive.
Solar modules are devices which convert solar energy into other forms of useful energy (e.g., electricity or thermal energy). Such modules are typically positioned above an underlying support surface by a rack. This rack may be configured to position the solar module at an angle relative to the support surface to minimize an angle of incidence between the solar module and the sun's rays. Minimizing this angle of incidence increases the amount of solar energy gathered by the solar module.
When the underlying surface is the roof of a structure, the racks must comply with wind loading requirements that are meant to prevent racks from being blown from the roof. At least some known roof mounted racks include metal brackets that are fastened to the roof using a mechanical anchor. The anchors penetrate through the bracket and the roof to attach to the support joists of the structure. Such mounting systems typically require numerous penetrations of the roof to securely connect the solar module to the structure's support joists. Each roof penetration creates a potential inlet for water that may damage the structure. Furthermore, penetrating the roof with numerous fasteners may threaten the structural integrity of the roof and the building. Also, the time and number of mechanical fasteners required to securely mount the solar modules may be expensive.
Another method of connecting solar modules to rooftops is to add heavy ballasts to weigh down the solar modules. The ballast is typically formed from a heavy concrete. This additional ballast on the roof acts as a constant dead load on the concrete slab and support beams. Improper placement of the ballast or exceeding the dead load limit of the roof could damage the concrete slab. Also, roofs have a predetermined live load limit, and adding additional ballast constrains the use of the roof for other purposes.
This Background section is intended to introduce the reader to various aspects of art that may be related to various aspects of the present disclosure, which are described and/or claimed below. This discussion is believed to be helpful in providing the reader with background information to facilitate a better understanding of the various aspects of the present disclosure. Accordingly, it should be understood that these statements are to be read in this light, and not as admissions of prior art.
In one aspect, a solar assembly is provided. The solar assembly includes a solar module including a solar laminate mounted within a frame that circumscribes the solar laminate. The solar assembly also includes a mount supporting the solar module including a first end and an opposing second end. The first end is attached to the solar module, and the second end is attached to a mounting surface using a structural adhesive compound.
In another aspect, a solar system is provided. The solar system includes a solar module including a solar laminate mounted within a frame that circumscribes the solar laminate. The solar system also includes a mount supporting the solar module including a first end and an opposing second end, wherein the first end is attached to the solar module. The solar system further includes a structural adhesive compound and a mounting surface. The structural adhesive compound is positioned between the mount second end and the mounting surface to facilitate bonding the mount to the mounting surface.
In yet another aspect, a method of assembling a solar assembly is provided. The method includes providing a solar module and attaching a first end of a mount to the solar module. The method also includes applying a structural adhesive compound to at least one of a second end of the mount and a mounting surface. The mount is then bonded to the mounting surface using the structural adhesive compound.
Various refinements exist of the features noted in relation to the above-mentioned aspects. Further features may also be incorporated in the above-mentioned aspects as well. These refinements and additional features may exist individually or in any combination.
For instance, various features discussed below in relation to any of the illustrated embodiments may be incorporated into any of the above-described aspects, alone or in any combination.
Like reference symbols in the various drawings indicate like elements.
This disclosure generally relates to mounting systems for solar modules and, more specifically, to methods for mounting solar modules to a mounting surface using an adhesive.
Referring initially to
Solar laminate 102 includes a top surface 106 and a bottom surface 108 (shown in
As shown in
As shown in
Referring now to
Solar assembly 200 includes solar module 100 coupled to a plurality of mounting brackets 202, which are coupled to a roof 204 of a building (not shown). In the example embodiment, roof 204 is a corrugated metal roof having a plurality of ridges 206 that define a valley 208 between adjacent ridges 206. Mounting brackets 202 are configured to straddle a ridge 206 when positioned on roof 204. Solar assembly 200 also includes a structural adhesive compound 210 for bonding each mounting bracket 202 with a respective ridge 206 of roof 204.
Mounting bracket 202 includes a base portion 212 and an extension portion 214, as shown in
Extension portion 214 includes an extension segment 222 extending orthogonally from third segment 220 and a coupling flange 224 that extends orthogonally from a distal end of extension segment 222 such that coupling flange 224 is oriented parallel to third segment 220. Coupling flange 224 includes an opening 226 defined therein configured to receive a fastener (not shown) to couple mounting bracket 202 to solar module 100. In other embodiments, extension segment 222 and coupling flange 224 may be oriented in any configuration that enables mounting bracket 202 to function as described herein.
Base portion 212 and extension portion 214 may be constructed of any suitable material for the purposes described herein. In the example embodiment, base portion 212 and extension portion 214 are made of aluminum. In other embodiments, base portion 212 and extension portion 214 may be made of any suitable material including, for example, other metals, plastics, fiberglass, or any combination thereof.
In the example embodiment, base portion 212 and extension portion 214 are integrally formed as one piece. More particularly, base portion 212 and extension portion 214 are die cast. In other embodiments, base portion 212 and extension portion 214 may be formed by any other suitable process including, for example, stamping, machining, and 3D printing. Further, in some embodiments, base portion 212 and extension portion 214 may be formed separately and joined together to form mounting bracket 202, such as by welding.
Base portion 212 includes a bottom surface 228 positioned proximate a top surface 230 of ridge 206. In the example embodiment, structural adhesive compound 210 is applied to at least one of surfaces 228 and 230 to couple mounting bracket 202 to roof 204 such that surfaces 228 and 230 do not contact each other. Alternatively, in some embodiments, portions of surfaces 228 and 230 may contact each other. In the example embodiment, structural adhesive compound 210 is a substantially liquid adhesive such as, but not limited to, a polyurethane or polyether. Alternatively, structural adhesive compound 210 may be any adhesive that facilitates coupling mounting bracket 202 to roof 204. When applied, structural adhesive compound 210 reacts with moisture in the air to form a high molecular weight cross link polymer that requires approximately 24 hours to cure to approximately 50% of the maximum tensile strength of the structural adhesive compound 210 to allow for rapid installation. Alternatively, structural adhesive compound 210 may require any amount of time to cure to any tensile strength. After curing, structural adhesive compound 210 includes a minimum tensile strength of 100 pounds per square inch. Structural adhesive compound 210 includes elastic characteristics that allow a small amount of bracket movement that permits displacements of solar module 100 due to wind. As such, structural adhesive compound 210 reduces the shear stress and fatigue loading resulting from wind.
In an example embodiment, structural adhesive compound 210 includes a thickness in a range of between approximately 2 millimeters (mm) to approximately 10 mm. Alternatively, structural adhesive compound 210 may have any thickness that facilitates operation of solar assembly 200 as described herein. Generally, the thickness of structural adhesive compound 210 is based on the materials to be bonded together.
Furthermore, structural adhesive compound 210 is removable such that solar module 100 and mounting brackets 202 may be removed from roof 204 and repositioned at a different location either also on roof 204 or at a different facility. More specifically, the adhesion bond between mounting bracket 202 and roof 204 may be broken by passing a metal wire between base portion bottom surface 228 and ridge top surface 230. Alternatively, mounting bracket 202 may be removable by any means that facilitates operation of solar assembly 200 as described herein.
Referring now to
As shown in
Mounting bracket 302 may be constructed of any suitable material for the purposes described herein. In the example embodiment, mounting brackets 302 are made of aluminum. In other embodiments, mounting brackets 302 may be made of any suitable material including, for example, other metals, plastics, fiberglass, composite materials, or any combination thereof. In the example embodiment, each mounting bracket 302 is integrally formed as one piece. More particularly, each mounting bracket 302 is die cast. In other embodiments, each mounting bracket 302 may be formed by any other suitable process including, for example, stamping, machining, and 3D printing.
Mounting block 304 serves as a base of solar assembly 300 and is configured to be coupled between roof 306 and mounting bracket 302. Each mounting block 304 includes a bottom surface 316 positioned proximate a top surface 318 of roof 306. In the example embodiment, structural adhesive compound 308 is applied to at least one of surfaces 316 and 318 to couple mounting block 304 to roof 306 such that surfaces 316 and 318 do not contact each other. Alternatively, in some embodiments, portions of surfaces 316 and 318 may contact each other. In the example embodiment, structural adhesive compound 308 is a substantially liquid adhesive such as, but not limited to, polyurethane or polyether. Alternatively, structural adhesive compound 308 may be any adhesive that facilitates coupling mounting block 304 to roof 306. When applied, structural adhesive compound 308 reacts with moisture in the air to form a high molecular weight cross link polymer that requires approximately 24 hours to cure to approximately 50% of the maximum tensile strength of the structural adhesive compound 308 to allow for rapid installation. Alternatively, structural adhesive compound 308 may require any amount of time to cure to any tensile strength. After curing, structural adhesive compound 308 includes a minimum tensile strength of 100 pounds per square inch. Structural adhesive compound 308 also includes elastic characteristics that enable some displacement of solar module 100 due to wind. As such, structural adhesive compound 308 reduces the shear stress and fatigue loading resulting from wind.
In an example embodiment, structural adhesive compound 308 includes a thickness in a range of between approximately 2 millimeters (mm) to approximately 10 mm. Alternatively, structural adhesive compound 308 may have any thickness that facilitates operation of solar assembly 300 as described herein. Generally, the thickness of structural adhesive compound 308 is based on the materials to be bonded together.
Furthermore, structural adhesive compound 308 is removable such that solar module 100 and mounting blocks 304 may be removed from roof 306 and repositioned at a different location either also on roof 306 or at a different facility. More specifically, the adhesion bond between mounting blocks 304 and roof 306 may be broken by passing a metal wire between block bottom surface 316 and roof top surface 318. Alternatively, mounting block 304 may be removable from roof 306 by any means that facilitates operation of solar assembly 300 as described herein.
Because of the adhesion bond between mounting blocks 304 and roof 306, solar assembly 300 avoids inclusion of a heavy ballast used in known mounting systems to weigh down the solar module to prevent movement due to wind. Moreover, in some embodiments, the adhesion bond is sufficient to hold solar assembly 300 to roof 306 without the use of any weighted ballast at all. In the example embodiment, each mounting block 304 is formed from steel or a lightweight concrete material. In other embodiments, mounting blocks 304 are formed from any material that enables solar assembly 300 to operate as described herein. Each mounting block 304 is formed from a material such that the weight of mounting block 304 is within a range of between approximately 1% to approximately 50% the weight of a known concrete ballast block. More specifically, each mounting block 304 is formed from a material such that the weight of mounting block 304 is within a range of between approximately 10% to approximately 40% the weight of a known concrete ballast block. Use of a relatively lightweight mounting block 304 reduces the weight load on roof 306.
Embodiments of the methods and systems described herein achieve superior results compared to prior methods and systems. For example, the mounting assemblies described herein simplify the installation of solar modules onto the roof of a structure. More specifically, the embodiments described herein use an adhesive to bond a mounting structure to a roof. As such, the mounting assemblies described herein eliminate the need to penetrate a roof with fasteners, and, therefore, do not damage roofs during installation or affect the structural integrity of the roof. The embodiments and methods described above use lightweight mounting structures that either reduce the ballast weight on the roof or eliminate the need for a ballast altogether. As such, time and cost expended calculating proper placement and load limits are saved.
Embodiments of the assemblies may also reduce assembly labor, time, and, therefore, cost of installing the system. The assemblies may also be cheaper due to the elimination of numerous fasteners needed at an installation site. Furthermore, the above-described mounting assemblies enable simple removal of solar modules for installation at a different location. Moreover, the adhesives used in the above-described embodiments have a predetermined modulus of elasticity that enables the adhesive to stretch to account for small displacements of the solar module due to wind. Generally, solar modules installed using embodiments of the mounting brackets may be easier, faster, less expensive, and/or safer to install than solar modules utilizing prior systems.
When introducing elements of the present invention or the embodiment(s) thereof, the articles “a”, “an”, “the”, and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
As various changes could be made in the above without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
This application claims priority to U.S. Provisional Patent Application No. 62/047,965 filed on Sep. 9, 2014, the entire disclosure of which is hereby incorporated by reference in its entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/US2015/049083 | 9/9/2015 | WO | 00 |
Number | Date | Country | |
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62047965 | Sep 2014 | US |