This disclosure relates generally to carrier devices and, more specifically, to carrier devices for carrying at least one solar module.
In one specific embodiment, a device includes a handle and at least one attachment device coupled to the handle. The at least one attachment device may include a channel configured for receiving a portion of a frame of a solar module. Further, in one embodiment, each attachment device may include an anti-slip device configured to limit movement of the solar module engaged with the attachment device. In addition, each attachment device may include an engagement device configured to be displaced by the portion of the frame upon the frame being positioned within the channel. The engagement device may be configured to provide a feedback (e.g., audible and/or tactical) upon the frame being engaged with the attachment device.
In another specific embodiment, a device includes a handle and at least one attachment device coupled to the handle and configured to couple to a solar module. Each attachment device includes a channel for receiving a frame of the solar module. Each attachment device may also include an anti-slip device proximate the channel and configured to limit movement of the frame positioned in the channel in a first direction, a second, opposite direction, or both. Moreover, the device may include a harness having at least one strap configured for securing the harness to a user. The harness may also include a latching device configured for attaching to at least one of the handle and the at least one attachment device. The harness may further include a wind force abatement device, which allows the module to align itself in such a way to reduce the force of the wind acting on the user via the harness.
According to another embodiment, a system includes a solar module and a carrier device configured to removably couple to the solar module. The carrier device may include a handle and at least one attachment device coupled to the handle and configured to couple to the solar module. Each attachment device may include at least one of a channel for receiving at least a portion of the solar module and a clamp for securing the solar module.
Other aspects, as well as features and advantages of various aspects, of the present disclosure will become apparent to those of skill in the art through consideration of the ensuing description, the accompanying drawings and the appended claims.
Referring in general to the accompanying drawings, various embodiments of the present disclosure are illustrated to show the structure for a carrier device. Common elements of the illustrated embodiments are designated with like numerals. It should be understood that the figures presented are not meant to be illustrative of actual views of any particular portion of the actual device structure, but are merely schematic representations which are employed to more clearly and fully depict embodiments of the disclosure.
The following provides a more detailed description of the present disclosure and various representative embodiments thereof. In this description, functions may be shown in block diagram form in order not to obscure the present disclosure in unnecessary detail. Additionally, block definitions and partitioning of logic between various blocks is exemplary of a specific implementation. It will be readily apparent to one of ordinary skill in the art that the present disclosure may be practiced by numerous other partitioning solutions. For the most part, details concerning timing considerations and the like have been omitted where such details are not necessary to obtain a complete understanding of the present disclosure and are within the abilities of persons of ordinary skill in the relevant art.
Solar photovoltaic (PV) cells use light energy (photons) from the sun to generate electricity through a photovoltaic effect. A PV solar module includes PV cells mounted behind glass and typically includes a frame at least partially surrounding the edges of the cells and glass. A PV system, which may include a plurality of solar modules and various other electrical components, may be used to generate and supply electricity in utility, commercial and residential applications. The soft-costs of installing a PV system (i.e., costs excluding the cost of the modules, inverters, and other equipment) can be more than half of the entire installation cost (e.g., more than 65% of the total cost of the installation). A large portion of the soft-costs is labor costs, including the cost of injury and accidents and workman's compensation insurance. Solar modules may also be of the type that converts energy from the sun into heat that is captured in a fluid running through collectors mounted behind glass. The heated fluid may then be used, for example, to heat water for use in a home, a pool, or a business. A solar hot water module typically includes a frame at least partially surrounding the edges of the glass and collectors. The labor required in a solar hot water installation is also a significant portion of the cost of a solar hot water system.
Solar installation companies are seeking ways to reduce labor costs. One aspect of installation labor is moving solar modules (e.g., lifting and carrying many modules from a truck to the mounting site). Moving solar modules is a physically tiring process and may require physically strong personnel. For example, a typical residential solar PV installation has around 18 solar modules and, typically, each solar module is approximately 1×1.6 meters in dimensions and approximately 42 pounds in weight. Solar modules are typically carried up a ladder and attached to a roof of a house, which is typically 5 to 8 meters tall. This can put significant strain on a person, who must simultaneously support the awkward shaped and heavy solar module during transportation, especially while ascending a ladder. Further, solar modules may have a sharp edge that is, for example, 1.5-2.5 mm thick and can cut into a hand of the person carrying the solar module. A solar module is often hefted over a person's shoulder and may contact the back of the person carrying the solar module. Accidents may occur as a consequence of fatigue or loss of balance. The Occupational Safety and Health Administration (“OSHA”) requires maintaining three points of contact when climbing a ladder. This presents a challenge when personnel must climb a ladder while carrying a module. Some installation companies today may not be in compliance with the OSHA requirements. Further, pulley systems and/or dedicated solar module lifters require significant time to set-up and add significant cost to the installation process and, thus, are not practical for residential installations.
Various embodiments of the disclosure include a device configured to attach to a solar module and provide an ergonomic, comfortable, and safe means for carrying the solar module. The device may include one or more attachment devices, wherein each attachment device may include a channel for receiving a portion of a frame of a solar module. The device may be attached near the center of an edge of a solar module so that the weight of the solar module is balanced.
Further, housing 106 may comprise any suitable material. As one example, housing 106 may comprise plastic. According to one embodiment, each attachment device 105 may comprise a hook-shape and include a channel 103 configured to receive a portion of a frame of a solar module. It is noted that although carrier device 100 is depicted as having two attachment devices 105, the present disclosure is not so limited. Rather, carrier device 100 may include one or more attachment devices 105.
It is understood that the carrier device 100 may include any number of attachment devices 105 enabling the carrier to couple to more than one module. For example, the carrier device 100 may include four attachment devices 105 such that it can couple to two separate modules. It is further understood that the handle 101 may enable multiple users to bear the load together or may be of a form that enables convenient coupling to a machine such as a crane, forklift, rope/cable pulley system, or storage rack. In general, handle 101 may be any suitable interface between the carrier device 100 and a separate means of lifting and/or supporting the device. For example, handle 101 may be a simple eye-hole for accepting a hook or a rope or it may be a threaded hole for accepting a variety of attachments or interfaces.
While the vertical offset between the bottom of channel 103 and the center of the handle 101 is short (e.g., as shown in
With reference to
According to one embodiment, attachment device 105 may include an engagement device 107 (see e.g.,
Attachment device 105 may further include an anti-slip device 108 (see e.g.,
According to one embodiment, anti-slip device 108 may comprise one or more sharp edges configured to contact, and possibly penetrate (e.g., “bite into”), at least a portion of an edge of module frame 104. With reference to
Without the anti-slip device, the module frame may have a tendency to slip in the channel in the approximate direction as indicated by arrow 167 in
As noted above, housing 106 may comprise any suitable material, such as, for example only, plastic. In this example, the plastic supporting the threads tips on the far-side from the frame edge yields when first loaded (i.e., after being manufactured), but as the threads penetrate into the plastic, more plastic area is loaded, until equilibrium is reached at a stress level below yield, given that adequate total pin area is provided. Penetration of the threads into the plastic is beneficial in that it prevents the threaded pin from sliding unrestrained relative to the plastic.
The amount that the one or more sharp edges 160 or rod threads 119 penetrate (“bite”) into the module frame edge is not significant to the function or aesthetics of the module. For example, they typically penetrate (e.g., “bite”) in less than 0.1 mm and the penetrations (e.g., “bites”) are on the underside of the module 102 and so will typically not be seen once module 102 is installed in a system.
According to another embodiment, anti-slip device 108 may comprise a clamp configured to secure module 102 to carrier device 100 by pinching the module frame. For example, anti-slip device 108 may include an over-center cam configured to clamp the edge of the module frame (e.g., in response to a lifting force).
In another embodiment illustrated in
With reference to
During one contemplated use, a user may lift handle 101 and module 102 over his/her shoulder and releases it onto the latching mechanism of harness 120. Module 102 is consequently securely attached to the user's back and will not slip off. To remove the module, the user may reach over her/his shoulder or head, and grab and lift handle 101 to release handle 101 and module 102 from harness 120. In one embodiment, harness 120 may include a waist belt 124 instead of, or in addition to, shoulder straps 122.
With reference to
In one embodiment, as illustrated in
In one embodiment, harness 120/120′ may include one or more surfaces 131 (see
If a user is climbing a ladder with carrier device 100 and harness 120 on his/her back, wind may catch the large surface area of module 102 and cause a force that could cause a user to lose his balance or grasp of the ladder. A wind vector coming from the side sees a small module surface area and therefore will have little impact on the user. A wind vector that has a large force component perpendicular to the outer face of module 102 may tend to push the user into the ladder, which may be uncomfortable for the user, but may not be dangerous. However, a wind vector that has a large component perpendicular to the underside of module 102 (i.e., the side of the module facing the user) can tend to push the module and user away from the ladder potentially creating a dangerous condition in which, for example, the ladder pulls away from the roof eve, or the user loses his/her grip on the ladder. In other embodiments, the present disclosure includes a wind force abatement device configured to allow module 102 to align itself at least partially parallel to the wind direction so as to reduce the force of the wind acting on the user via module 102 and harness 120.
With reference to
In addition to module carriers configured for attaching to a frame of a solar module, various embodiments of the present disclosure are related to module carriers configured for attaching to one or more frameless modules (i.e., a module that does not have a frame around an outer edge of the module). As will be understood, frameless modules may include solar cells sandwiched between two pieces of glass. One example frameless modules is a glass-glass module, which includes glass on a top side of the module and glass on an underside of the module, in addition to (or in place of) a typical polymer backsheet.
According to one embodiment, a carrier device may be configured to secure a module by “pinching” the module. Stated another way, for example, a carrier device may create opposing forces on opposite surfaces of a module (e.g., a top major axis surface and bottom major axis surface). In one embodiment, the carrier device may include a compliant material, such as rubber, configured to contact one or surfaces of the module (e.g., to further increase friction).
In one example, each arm 205 may be configured to rotate about handle 201. More specifically, one or more arms 205 may be rotated to enable module 202 to be positioned between arms 205. Further, one or more arms 205 may be rotated to “pinch” module 202 (i.e., between two or more arms 205). As will be appreciated, each arm 205 may be configured to apply a pressure against a surface of module 202. More specifically, for example, arm 205A may be configured to apply pressure in a first direction (i.e., as indicated by arrow 206A), and arm 205B may be configured to apply pressure in a second, opposite direction (i.e., as indicated by arrow 206B).
Fastening device 209 may be configured for securing a position of arms 205 relative to one another to maintain an adequate amount of pressure one each surface of module 202. Collectively, arms 205, and possibly fastening device 209, may be referred to herein as an “attachment device.”
Another carrier device 300 is illustrated in
As will be understood by a person having ordinary skill in the art, a frameless module may be susceptible to damage, especially at the corners. Another embodiment includes a carrier device that may provide protection to a module. With reference to
Embodiments of the present disclosure include a relatively low-cost device that may relieve stress, strain, and safety risks associated with carrying solar modules. Further, embodiments of the present disclosure may reduce the labor costs associated with moving solar modules. Further, the embodiments described herein may enable a user to carry a module up a ladder while maintaining three points of contact, as recommend by OSHA.
Although the foregoing description contains many specifics, these should not be construed as limiting the scope of the disclosure or of any of the appended claims, but merely as providing information pertinent to some specific embodiments that may fall within the scopes of the disclosure and the appended claims. Features from different embodiments may be employed in combination. In addition, other embodiments may also be devised which lie within the scopes of the disclosure and the appended claims. The scope of the disclosure is, therefore, indicated and limited only by the appended claims and their legal equivalents. All additions, deletions and modifications to the disclosure, as disclosed herein, that fall within the meaning and scopes of the claims are to be embraced by the claims.
This application claims the benefit of and priority to U.S. Provisional App. No. 62/106,850, filed Jan. 23, 2015, which is incorporated herein by reference.
Number | Name | Date | Kind |
---|---|---|---|
1082446 | Rodman | Dec 1913 | A |
1251278 | Porter | Dec 1917 | A |
2430142 | Roberts | Nov 1947 | A |
2651441 | Rau | Sep 1953 | A |
2776856 | Ingram | Jan 1957 | A |
3336068 | Renfroe | Aug 1967 | A |
3374024 | Le Roy Reynolds | Mar 1968 | A |
3524670 | Ilich | Aug 1970 | A |
4013202 | Russo | Mar 1977 | A |
4098442 | Moore | Jul 1978 | A |
4113160 | Spiers | Sep 1978 | A |
4135655 | Brown | Jan 1979 | A |
4177911 | Griffin | Dec 1979 | A |
4190278 | Jancik, Jr. | Feb 1980 | A |
4463977 | Wyatt | Aug 1984 | A |
4483380 | Beran | Nov 1984 | A |
4630838 | Stockton | Dec 1986 | A |
4993953 | Stein | Feb 1991 | A |
5226688 | Russo | Jul 1993 | A |
5257843 | Nunn | Nov 1993 | A |
5397158 | Brass | Mar 1995 | A |
6113167 | Mattis | Sep 2000 | A |
6220638 | Carroll | Apr 2001 | B1 |
6412838 | Malamud | Jul 2002 | B1 |
6494513 | Worthington | Dec 2002 | B2 |
6857673 | Lang | Feb 2005 | B2 |
8087633 | Vargo | Jan 2012 | B2 |
9114932 | Majni | Aug 2015 | B1 |
9675166 | Mick | Jun 2017 | B2 |
D812905 | Olsen | Mar 2018 | S |
20020148866 | Dent | Oct 2002 | A1 |
20030122389 | Urbanovic | Jul 2003 | A1 |
20030132641 | Ponec | Jul 2003 | A1 |
20040178240 | Bauer | Sep 2004 | A1 |
20070046047 | Ehrhardt | Mar 2007 | A1 |
20080057804 | Watanabe | Mar 2008 | A1 |
20080185409 | Kellenberger | Aug 2008 | A1 |
20090230707 | Scherger | Sep 2009 | A1 |
20090321481 | Licausi | Dec 2009 | A1 |
20100019114 | Vargo | Jan 2010 | A1 |
20100096420 | Holmer | Apr 2010 | A1 |
20100187274 | Chock, Jr. | Jul 2010 | A1 |
20110241366 | Hamblin | Oct 2011 | A1 |
20120181762 | Skijus | Jul 2012 | A1 |
20140360951 | Ilzhoefer | Dec 2014 | A1 |
Number | Date | Country |
---|---|---|
000334920 | Mar 1921 | DE |
334920 | Mar 1921 | DE |
WO-2007034565 | Mar 2007 | WO |
Number | Date | Country | |
---|---|---|---|
20160214798 A1 | Jul 2016 | US |
Number | Date | Country | |
---|---|---|---|
62106850 | Jan 2015 | US |