Patent Application
20140224325
Embodiments generally relate to photovoltaic power sources, and in particular to photovoltaic cell modules.
Photovoltaic installations, for example those appropriate for the residential market, are often installed on residential rooftops or in similar installations. For example, the residential market for solar photovoltaic products typically involves at least: a house with a suitably inclined, non-shaded roof; a home owner willing to undergo a mid-level home renovation project involving contractors and roof penetrations; sufficient capital to cover the costs of the installation; and certain risk tolerance, for example in connection with the possibility of damage or a roof fire over the life of the installation.
A group of people fitting these requirements may generally be said to constitute the current residential market for solar panels, and even where all of the requirements are met, significant hurdles including the sourcing of materials and labor may be necessary to complete a solar installation project. Thus, the current residential market is likely to be significantly smaller than the total proportion of residential units whose occupants may have some interest in a photovoltaic installation, but who lack one or more of the exemplary requirements set forth above.
Attempt to broaden the appeal of photovoltaic installations to a wider segment of society have focused on simplifications to the racking, mounting and wiring to simplify roof top installation for the benefit, for example, of the certified installer. A further attempt has been the development of micro-inverters that allow each module to be controlled and monitored individually, delivering AC power directly from the roof top.
However, in addressing one or another barrier to entry, there has been no comprehensive solution to increasing the versatility of photovoltaic installations or broadening their appeal.
According to various embodiments, a solar power unit including a solar module is disclosed, the solar module defined by a framed, planar solar collection area with at least one photovoltaic cell mounted on the solar collection area and, for example, a junction box electrically connected to the cells.
A support structure is attachable or attached to the solar module. The support structure has at least one leg set having an upper leg and a lower leg. Because of the difference in height of the legs the leg set, the solar module can be secured on a surface at an angle.
According to an aspect of the disclosure, the solar power unit may have at least one hinge for fixing a leg set to the solar module. Additionally, the hinge may allow the leg set to rotate on said first hinge on a first axis parallel to a first side of said frame, for example, the leg set may be rotated from a working position to a flat storage position, such as under the module, depending upon the orientation of the hinge.
According to a further aspect of the disclosure, the support structure may have a second leg set working in conjunction with the first leg set. For example, the second leg set may also include an upper leg and a lower leg, as in the first leg set, the leg sets cooperating to secure the solar module on a surface at an angle.
In such a case, a second hinge may be provided for the second leg set, fixing the second leg set, for example to the frame, for rotating the second leg set under the solar power unit. The hinge for the second leg set may then advantageously be oriented generally parallel to the hinge of the first leg set. In operation, the hinges define axes of rotation of their respective leg sets, permitting rotation from an orientation parallel with the plane of the solar collection area to an orientation perpendicular therewith (and/or, depending on sun angle, parallel to the orientation of incoming solar rays.
According to the present invention the junction box is any kind of electrical connection point connecting the electrical contacts from the module laminate to the external wiring and may include micro inverters, switches, sensors, terminal blocks, bypass diodes and the like or can simply provide electric terminals without bypass diodes.
According to a further aspect of the disclosure, the solar power unit may include a micro-inverter connected to or incorporated in a junction box.
According to a further aspect of the present disclosure, the solar power unit may include a rod or similar contact means for providing electrical soil grounding, the rod contacting a soil surface. The rod may be secured to a leg set, the leg set acting as the grounding means.
According to various embodiments, a support structure rotatably hinged to the solar module having a first and second leg set each having a first upper leg height and a first lower leg height may secure the module to a surface at an angle. The first and second leg sets may each have a unitary structure.
According to an aspect of the disclosure, the unitary structure of each leg set may take a generally convex quadrilateral shape, defined by a first height corresponding to what is referred to as a first and/or second upper leg height and a second height corresponding what is referred to as a first and/or second lower leg height, respectively. Advantageously, the first and second upper leg heights may be the same, and the first and second lower leg heights may be the same.
According to a further aspect of the disclosure, the solar power units may include connectors to link multiple units together.
According to a further aspect of the disclosure, the first and second leg sets may include a securing port for receiving a means for fixing the leg sets to each other. Advantageously, a rigid rod or beam may be used for this purpose, the port having a shape and/or dimension adapted to receive the fixing means.
According to a further aspect of the disclosure, the solar power unit may be adjustable to permit the solar module to be oriented at multiple angles relative to the surface. Moreover, the legs may be folded and snapped into place.
In the drawings, like reference characters generally refer to the same parts throughout the different views. The drawings are not necessarily to-scale, instead generally being intent upon illustrating the principles of various embodiments. In the following descriptions, various embodiments are described with reference to the following drawings, in which:
The following detailed description refers to the accompanying drawings that show, by way of illustration, specific detail and embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the embodiments as disclosed. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the invention. The various embodiments are not necessarily mutually exclusive as some embodiments can be combined with one or more other embodiments to form new embodiments. In the context of this description, the terms “connected” and “coupled” are used to describe both a direct and an indirect connection and a direct or indirect coupling. In the figures, identical or similar elements are provided with identical reference symbols insofar as this is expedient.
Various exemplary embodiments provide a self-contained solar power unit with a built-in support system providing tilt, ground anchoring and an AC micro-inverter connected to wiring that can either plug directly into a suitable mains outlet, or can be wired into the circuit breaker box of a residence.
Module 110, as well as any solar module disclosed in connection with the embodiments described herein may advantageously be any one of a number of well-known solar modules having a plurality of solar cells (shown e.g. in
Junction box/micro-inverter 120, physically secured to frame 112 and/or back sheet 114, is electrically connected to one or more solar cells mounted on/forming part of solar module 110. Junction box/micro-inverter 120 may advantageously include electrical contacts and/or an AC micro-inverter. Ground wires 122 are shown extending from junction box/micro-inverter 120. Alternately, junction box/micro-inverter 120 may be mounted as separate components to frame 112 or back sheet 114 with an electrical connection (not shown) in between.
Legs 136a-b and 138a-b are shown pivotably mounted to hinge plates 132 by hinge pins 134 at a first end, and terminated in foot pads 142 at a second end.
Accordingly, the first leg set (136a/138a) and the second leg set (136b/138b) are shown deployed to support module 110 on surface S. As shown in
Grounding wire 122 is shown extending from module 110, is electrically connected to grounding rod 123 which grounding rod may be a copper pipe or metallic rod extending partially beneath and in electrical or galvanic contact with surface S.
Moreover, grounding rods 123 may serve both the function of electrical grounding as well as for physical anchoring of solar power unit 100 to surface S. Additionally, legs 136 and 138 may individually or both be provided with contact points 140 which may serve to physically attach solar power unit 100 to further units, or contact points 140 may serve additionally as electrical contacts providing electrical contact to an output of junction box/micro-inverter 120.
In operation, the respective lengths of the legs 136 and 138 of the first and second leg sets define an angle which is ideally as close to perpendicular as possible with respect to the average angle of rays of incoming sunlight R as shown in
In this connection, the extension of the respective leg sets may be adjustable, legs 136 and/or 138 being provided, for example with telescoping extensions, or similar means for providing adjustable lengths thereof. This is particularly advantageous for adjusting angle A to compensate for seasonal or geographical changes in solar orientation, or to provide adjustability in case surface S is not level. Additionally, individual adjustability of the lengths of each of legs 136 and/or 138 to each other may be advantageous where surface S is not flat, the unevenness being compensable by adjustments, for example extending one of legs 138 further than the other where necessary to stabilize solar power unit 100 on surface S by maintaining the same angle [A] for each of the first and second leg sets. Note that, for embodiments where the solar module does not include a metal frame around the glass laminate, the legs and hinges may be affixed directly to the edge of the laminate, by fasteners, adhesives or another bonding technique.
As shown in
a and 4b illustrate solar power unit 300 in an operating configuration. In particular, legs 350a-b are shown swung out at 90° to solar module 310, i.e. approximately flush with the side of frame 312. Support rod 337 is shown inserted within and across holes 352 in each of legs 350. Grounding rods 323 are illustrated adjacent to support rod 337, the support rods advantageously providing grounding when inserted for example into surface S, ground wire 322 being electrically connected thereto.
Legs 350a-b are each shown cut in a roughly convex quadrilateral shape, the angle thereof advantageously orienting module 310 at angle [A] relative to surface S. In this sense, it is understood that each of legs 350a and 350b are formed for example as a quadrilateral having a first upper height (h1) and a second, lower height (h2), leg 350a defines a “leg set” for purposes of this disclosure, despite being a unitary structure. Likewise, leg 350b defines a second leg set. These ‘leg sets’ as shown are made of sheet material, such as metal, wood or durable plastic. For weight and/or cost savings, the leg set may not be a solid sheet, but may have cut-outs in various configurations designed to retain strength and stiffness.
During operation, solar radiation R impinges upon the surface of module 310, accordingly angle [A] is advantageously calculated to orient module 310 as closely as possible to perpendicular to the time-averaged direction of the solar radiation. As leg sets 350a-b may be formed of solid material in sheet form such as sheet steel, aluminum, plastic or possibly wood, adjustability in angle A may be effected by trimming one or more sides of legs 350. Advantageously, for example, legs 350 may come pre-marked with cutting lines appropriate for various surface inclinations, and for the geographical latitude at which and/or season during which solar power unit 300 will be used. Alternately, different angles may be manufactured at the factory and delivered to outlets and customers based on geographic location.
The relative orientation of legs 350a-b relative to each other is stabilized by support rod 337 which may be provided with notches or grooves at its ends to securely receive the thickness of the sheet material forming legs 350 and prevent rotation or movement of either leg relative to module 310. Moreover, grounding rods 323 may engage support rod 337 for purposes of further stabilizing solar power unit 300 in addition to providing electrical grounding.
Legs 536 and 538 define an angle relative to a planar surface on which they are placed. This angle (which may be angle [A]) defines the orientation of a solar module supported by it. In this sense, legs 536 and 538 together define a leg set for purposes of this disclosure, the leg set being an integral part of support 500.
For example,
c discloses a screw-down retainer that may be attached to, or form an integral part of, for example support 570 of structure 500. As shown, a cross section of frame 512 of one or two solar modules may be secured in place by screw 562.
As disclosed above, in particular with respect to embodiments disclosing discreet leg structures such as in
The embodiments of the present disclosure, variously described above, may be produced at low price points and may be marketed directly to a consumer, with the result that a professional installer, and associated expense, is not necessarily required to enable a consumer use solar power, including at appropriate mains voltages. One or more of the solar power units variously described herein may be sold commercially in stores marketing appliances and/or electronics, and may be sold in single unit packaging for use alone, or for addition into an array of several units.
Complexity of installation is minimized by advantageously facilitating ground-mounting such as in a yard, an allocation of space similar to a typical vegetable garden. Moreover, although a solar module may be purpose-designed to function with the solar power units disclosed herein, the incorporation of existing solar modules may offer advantages, particularly in terms of standardization, or utilization in conjunction with larger fixed installations.
Legs and other support components may be shipped with the solar module, either pre-installed on the module prior to shipping, or by the end user. Even where already attached, such as to the frame of the solar module, the legs and other support components may be shipped flat, removed upon delivery, and snapped into place, staked into the ground, and/or wiring to adjacent units.
Each of the above embodiments may include side brackets that may also include electrical contacts for purposes of securing units to one another physically and electrically. Contact points 140 of
The solar power units may have a cabling arrangement with both the additive junction box connection and the return line being found on each module, allowing the power to be taken out of one end by an outdoor grade extension cord (such as a ground-fault circuit interrupter enabled outdoor extension, optionally protected by a PVC tube) sold at a standard length. In this sense, the wiring may be similar in some aspects to outdoor lighting.
The angle of incline for the module may be varied by the height of a snap-up strut on the high, or low, side of the solar module, and differently angled products could be sold at stores in different latitudes, or for differently inclined installation surfaces.
Each of the solar power units may be staked to the ground, possibly accomplishing electrical grounding and physical securement in a single step. A user thus has the flexibility to pick a sunny spot and point the array (or individual module) in the optimal direction, with the net effect being similar to a garden patch for harvesting sunlight.
Because of the AC power, the use of the extension cord may be no different than handling other power cords/plugs in a house. The AC micro-inverters may be configured not to deliver power through the cables until grid power is recognized, sometime after they are plugged in, and will stop power delivery if connection to the grid is lost.
The end of a cord connecting the panel to the house can be a standard 110/220V cable, and may plug directly into a house outlet. Alternatively, it may be wired directly into a circuit breaker box.
While the embodiments of the present disclosure have been particularly shown and described with reference to the drawings and the description herein, it should be understood by those skilled in the art that various changes in details of the form may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. The scope of the invention is thus indicated by the appended claims and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced.
