Solar systems have been available for residential and commercial use in various forms for a long time. Adoption of modern technologies has led to systems which can be installed on rooftops to deliver a rated 1 kW or 2 kW power output (for example). Likewise, systems can be installed which provide hot water for household use or for heated swimming pools.
Consumers typically must proactively seek their own alternatives to utility-provided electricity. This typically requires a significant investment in time & effort on the part of the consumer to learn about renewables, and then specifically solar options, to seek out providers (installers) and then to select and proceed with purchasing a system. Whether this involves self-installation or installation by a contractor, consumer self-education is a typical requirement.
Solar power and water systems generally do not have a standard design. Given the extreme variations in houses, this is not surprising. However, this means that every installation is unique. Not only is every installation unique, but standard products which may be used time and again on multiple installations are generally not available. Moreover, this leads to interesting and unusual situations, with extension cords snaking across roofs or water pipes running up and down from an external swimming pool to the roof of a house. With every installation a one-off design, economies developed from one design to the next are reduced. Thus, providing a standard design with components which are well organized for varying installations may be useful.
The solar power systems are rated for a specified output, but are not expected to actually deliver that output. Perversely, most government subsidy programs rely on a system rating rather than actual output for incentives. Actual output can have an effect down the road, when the user's power bill comes due, but it is not a significant part of the analysis initially. It may still be useful to develop a system which can be installed with a guarantee of how much power will be output on average.
The present invention is illustrated by way of example by the accompanying drawings. The drawings should be understood as illustrative rather than limiting.
A system, method and apparatus is provided for a solar panel and frame. The specific embodiments described in this document represent exemplary instances of the present invention, and are illustrative in nature rather than restrictive in terms of the scope of the present invention. The scope of the invention is defined by the claims.
Solar panels (solar cell and/or solar heating modules) can be supported by a frame made up of corner supports and potentially other straight internal or edge supports. The frame can be made with interlocking supports and internal support edges of the supports. Such a frame may then be anchored or attached to a surface such as a roof or flat surface of a structure. A solar panel such as a panel of photovoltaic cells, a solar water heating panel (material and water pipes for example), or a thin-film photovoltaic panel may then be supported by the frame. The solar panel may then be integrated into an electrical or water system of the structure or a nearby structure, thereby allowing for conversion of solar energy into a form useful for running electrical appliances or into thermal energy in water.
By using a standard frame design and associated components, a solar panel may be mounted on a roof or other surface in a reasonable and economically feasible way. By requiring minimal customization based on site-specific considerations, expertise can be built up fairly quickly. Moreover, by using electronic databases for research, planning of an installation may be handled expeditiously and inexpensively. Thus, a standard design may be provided which may allow for installation without reinventing the design every time a new installation occurs.
With a solar panel installed, the panel may be monitored remotely and/or locally. When power output or water heating capacity drops unexpectedly, this may be detected automatically, within a system capable of evaluating such a change. In response, on-site observation and maintenance can be requested and performed. All of this reduces or eliminates a requirement of vigilance by the consumer over the lifetime of the solar panel. Moreover, the consumer can find out right away that the system is in need of maintenance, rather than noticing on the next energy bill that something is amiss.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the invention. It will be apparent, however, to one skilled in the art that the invention can be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to avoid obscuring the invention.
Reference in the specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments.
References to a solar panel generally refer to various different types of solar components, both photovoltaic cell panels and solar heating panels. Thus, most installations may involve one or both of a solar photovoltaic cell component and a solar heating component. Similarly, the various structures described may be used with both photovoltaic cells and solar heating elements. Some systems will incorporate both a heating element and a photovoltaic cell, whereas other systems will incorporate only one of the heating element and photovoltaic cell.
Many embodiments are set forth in this document, whether described in connection with figures or as variations of illustrated embodiments. In one embodiment, an apparatus is provided. The apparatus includes a first corner support having an internal support ledge. The apparatus also includes a second corner support having an internal support ledge and coupled to the first corner support. The apparatus further includes a third corner support having an internal support ledge and coupled to the second corner support. The apparatus additionally includes a fourth corner support having an internal support ledge and coupled to the third corner support and the first corner support. The first, second, third and fourth corner supports form a generally rectangular shape. The apparatus also includes a solar panel having edges supported by the internal support ledges of the first, second, third and fourth corner supports.
In another embodiment, a method is provided. The method includes reviewing solar days of a site. The method further includes reviewing geographical features of the site. Also, the method includes estimating a guarantee of available solar energy for the site. Moreover, the method includes installing a solar system at the site.
In yet another embodiment, an apparatus is provided. The apparatus includes a means for converting solar energy to a form useful for operation of machines and/or useful for heating water. Additionally, the apparatus includes a first means for supporting a corner of the means for converting. Moreover, the apparatus also includes a second means for supporting a corner of the means for converting. The second means is coupled to the first means for supporting. Also, the apparatus includes a third means for supporting a corner of the means for converting. The third means is coupled to the second means for supporting. Furthermore, the apparatus includes a fourth means for supporting a corner of the means for converting. The fourth means is coupled to the third means for supporting and the first means for supporting.
In still another embodiment, an apparatus is presented. A frame is provided as part of the apparatus. The frame includes a first corner support member with an internal supporting ledge. A second corner support member is coupled to the first corner support member, and the second corner support member has an internal supporting edge. Additionally, a third and fourth corner support member are coupled to the first and second corner support members and to each other, to form a generally rectangular shape. The third and fourth corner support members each have internal supporting ledges. A solar panel is also provided as part of the apparatus, with the solar panel resting on the internal support ledges.
In another embodiment, a method is presented. The method includes reviewing solar days of a site through access of a first database with an identifier of the site. The method further includes reviewing geographical features of the site through access of a second database with the identifier of the site. The method also includes estimating a guarantee of available solar energy for the site based on the solar days and the geographical features. The method additionally includes providing the guarantee to an owner of the site.
In still another embodiment, an apparatus is provided. A frame including interlocking supports and having a rectangular shape is part of the apparatus. The frame includes a first corner support having an internal support ledge and a second corner support having an internal support ledge, with the first corner support coupled to the first corner support. Similarly, the frame includes a third corner support having an internal support ledge and coupled to the second corner support. Additionally, the frame includes a fourth corner support having an internal support ledge, the fourth corner support is coupled to the third corner support and the first corner support. The apparatus also includes a solar panel having edges supported by the internal support ledges of the supports of the frame.
In an embodiment, an apparatus is provided. The apparatus includes a first rail coupled to a second rail, a third rail coupled to the second rail, and a fourth rail coupled to the first rail and the third rail. The apparatus may form a rectangular frame from the four rails. The rails may be coupled through use of corner connectors or may be mitered and coupled through use of brackets in an abutting relationship. Additionally, further rails may be added by interposing the additional rails between a pair of the first, second, third and fourth rails, to extend the frame, and such additions may involve connectors or abutting rails and brackets, for example. The rails may have support ledges. Alternatively, the rails may have slots allowing for support brackets which slide along the slots. Moreover, the rails may be anchored using roof anchoring components to various surfaces. Additionally, the rails may support photovoltaic or other solar panels, and may have caps or top brackets to maintain the position of such solar panels.
Solar arrays or systems can be provided in a variety of forms, provided a standard form is used. The standard form allows for repeatable assembly and installation processes, thereby allowing for economies of scale in manufacturing and installation.
Four corner supports (110, 120, 130 and 140) are used. They are joined at four seams or joints (115, 125, 135 and 145). Thus, the four corner supports (110, 120, 130 and 140) are fixedly attached to each other to form a frame which supports the panel 150 of solar cells. Each corner support includes an internal ledge which supports an edge of panel 150, and the four corner supports (110, 120, 130 and 140) collectively surround the panel 150.
Panel 150 includes photovoltaic solar cells, which are subdivided into six subpanels (160a, 160b, 160c, 160d, 160e and 160f). These subpanels may be components which can be switched out, allowing for repairs of smaller units than an entire panel 150. Panel 150 as a whole may be expected to generate a predictable amount of electric power, based on available solar days, angle of incidence, and nearby obstructions, allowing for prediction of solar generating capacity.
The components of the frame may provide additional details.
Base structure 220 supports the corner support 200 and underlies the beveled external edge 230, top 250, upper ledge 240 and lower ledge 210. In one embodiment, upper ledge 240 is an outer ledge and lower ledge 210 is an inner ledge. Lower ledge 210 provides a shelf upon which the edges of a panel of solar cells (such as plate 150 for example) may rest. Upper ledge 240 may be used to support a component used to secure a panel to lower ledge 210. Such a component may be a bracket or clamp, for example. Alternatively, a panel may be secured using fasteners coupling or connecting the panel to the frame through a through-hole, for example. Also shown are conduits 270, which penetrate base 220. Conduits 270 allow for passage of wires or cables through the structure, and may also allow for passage of fluids such as water around or through the structure.
While the corner supports may form a rectangular base and potentially support a panel of photovoltaic cells, intervening support members may be useful, too.
Base 310 underlies the cross-bar support 300. Above base 310 is top 320—a top surface of support 300. On top surface 320 are tabs 330 which may guide placement of subpanels of a panel or of multiple panels, for example. Additionally, slot 340 penetrates top 320 and base 310, allowing for drainage or routing of wires at the intersection point of subpanels or panels. Conduits 370 may allow for drainage of fluids (e.g. rainwater) and routing of wires or cables, for example. Cross-bar 300 may be expected to connect to corner support members, such as through an interlocking tab and slot, for example.
A basic rectangular solar cell array may be formed from four corner supports. A wider or longer array may require intervening straight supports.
Base structure 410 underlies straight support 400, and has on top of it a lower ledge 420, upper ledge 430, and top surface 440. Top surface 440 may include a level top surface and/or a beveled edge. Lower ledge 420 may support a solar cell panel or subpanel, and upper ledge 430 may provide a base for components securing a solar cell panel to support 400. Additionally, end pieces 480 and 490 may be similar to connectors 280 and 290, allowing for interconnection with other components.
Internal support for solar cell panels or subpanels may also be useful.
All of these components are likely to be safer if anchored to a structure.
Screw 510 is fit through a through-hole 525 of support 520, and through a through-hole 535 of roof or surface 530, and screwed into nut 540. Thus, support 520 is fixedly attached to surface 530. As may be appropriate, an adhesive may be substituted for screw 510 and nut 540, or a nail may be used, for example.
An assembled frame of support members may provide further insights.
Using cross support members and corner support members, a frame can support a solar cell panel.
Other types of frames may also be used.
Also included are stabilizing platforms 785, which extend out from a central cross-bar portion of cross-bar support 755. Platforms 785 provide further stability, greater surface area in contact with an underlying surface, and space for fasteners attaching to the underlying surface. Slots 793 are apertures through platforms 785, through which a fastener may pass for attachment to an underlying surface. As illustrated, slots 793 provide for placement of a fastener in various locations within the slot 793, allowing for registration tolerances between cross-bar support 755 and an underlying surface. Fasteners may include various different structures, such as those illustrated with respect to
Also illustrated are flanges 791. Flanges 791 are provided at the ends of the cross-bar 755, and define slots into which a corresponding flange of an exterior frame may project. Thus, the exterior frame and cross-bar support 755 may mate, providing a secure fit. Friction fit or various forms of attachment (fasteners or adhesives) may be used, such as nuts and bolts or rivets, for example to secure the mating between cross-bar support 755 and an exterior frame. Through-holes (not shown) may be necessary for some fasteners.
Wider solar cell arrays have been previously discussed, and a schematic diagram may further explain this feature.
Frame 800 includes four corner support members 810, 820, 830 and 840. Depending on design choices, these corner support members may or may not provide sufficient length to support multiple panels of solar cells. Thus, straight support members 850a, 850b, 850c and 850d are interposed between the corner support members, providing an extended frame. Moreover, as falling solar cell panels would be undesirable, internal corner supports 860a and 860b are also provided. Such internal corner supports were illustrated, in one embodiment, in
The solar arrays described above and other embodiments may be provided in a variety of ways. Under some circumstances, incentives may exist for a less efficient distribution process. However, ultimately, providing solar arrays in an efficient manner is likely to be useful.
Process 900 and other processes of this document are implemented as a set of modules, which may be process modules or operations, software modules with associated functions or effects, hardware modules designed to fulfill the process operations, or some combination of the various types of modules, for example. The modules of process 900 and other processes described herein may be rearranged, such as in a parallel or serial fashion, and may be reordered, combined, or subdivided in various embodiments.
Process 900 includes receiving a request from a customer, looking up a site, checking days of solar exposure and geographical status, estimating and providing a guarantee, signing a contract, and installing and operating a system. Process 900 begins with receipt of a request from a customer at module 910. At module 920, a site or location for a solar installation is looked up. At module 930, a check into the number of days of solar exposure for the site is made, such as through use of databases of solar exposure keyed to geographical locations. Similarly, at module 940, a check of geographical information about the site is made, such as through geographical databases or satellite photographs of the site. Databases 925 may be used for the lookup and check processes. These checks provide basic information about whether the site is suitable for a solar installation, by determining how much solar exposure occurs, and whether geographical features may detract from available solar exposure. Checking the site geographically may also involve a site visit in some instances, to determine if trees will interfere, for example. Otherwise, these checks (of modules 930 and 940) may be automated—with software querying databases and determining whether initial criteria for solar exposure and geographical features are met.
Based on these checks, at module 950, a guarantee of solar power or heat capacity is estimated. This estimate may be derived automatically from data retrieved from databases 925, with factors for solar exposure and geographical features included in a formula, for example. At module 960, this guarantee, or a guarantee derived from the estimate of module 950, is provided to the customer in response to the request of module 910. If the guarantee is deemed useful by the customer, at module 970, a contract is signed. At module 980, a solar system is installed at the site, and at module 990, the solar system is operated. The solar system may be a solar power system or a solar heating system (or a combination of both), for example.
Further discussion of a method of installation may be useful.
Process 1000 begins at module 1010, with a review of power needs. A home which typically uses 1 kW/h would (potentially) not be a suitable candidate for a large 5 kW solar cell system, for example. Thus, a review of power consumption and the built-in electrical system occurs. This review is potentially automated, by accessing information publicly available such as size of building, records of power requirements, and other similar information. Similarly, at module 1020, roof or other surface space is reviewed, determining where a solar system may be sited. This may include determining which surface faces the sun most often, whether the surface is suitable for attachment of a solar array, and whether any obstructions will interfere with solar power or heat generation. This review may also be automated, based on access of geographical information, for example.
At module 1030, components of the solar array are selected. Preferably, kits may be prepackaged for expected sizes of solar arrays, and such a kit may be selected. Alternatively, standard components may be selected and assembled into a solar array which is ready for installation. At module 1040, the solar array is attached to the roof or other surface. This may involve something as simple as use of fasteners or may involve filling components with ballast material (e.g. sand or water) and adhering the components to the surface. After installation, at module 1050, the solar cell array is integrated into an existing (or new) electrical system. For a heating array, integration with a heating or water system may be in order.
Note that this process may also involve surveying or inspecting a building to determine other opportunities to save power or efficiently use hot water, for example. Thus, an inspection and upgrades may be provided as part of the process of determining what solar array would be helpful and installing the solar array. This inspection may also reveal some details of the amount of power which is likely to be consumed, and whether excess power can be generated, for example.
Various systems may be used in conjunction with evaluation of sites for solar arrays.
Where a solar system is used may be instructive as well.
By way of illustration, two linkages for junction box 1235 are shown. Pole 1250 is linked to junction box 1235, allowing for telephone-line based monitoring of the junction box 1235, and corresponding monitoring of solar array 1215 for electrical performance. If array 1215 suddenly starts providing less power than expected, a signal can travel along a telephone wire to tower 1255, and then to a monitoring station 1260. Alternatively, only raw data is transmitted, and monitoring station 1260 is expected to determine, either manually or automatically, whether the raw data indicates a problem or not. Whether data or a warning is sent out, it may also be done based on a wireless solution. Transmission station 1240 is coupled to junction box 1235, allowing station 1240 to either review incoming communications or to simply pass along incoming communications. Receiver station 1245 is provided near monitoring station 1260, and allows for receipt of data provided over airwaves about the project. A wireless coupling between stations 1240 and 1245 occurs, and information about a particular location and customer may influence collecting such statistics.
Note that the solar array 1215 is illustrated as mounted on the roof of the house 1210. However, the solar array 1215 may be mounted on any structure which provides good sun exposure. Also, the solar array 1215 may be mounted using fasteners or an adhesive to attach the frame to the roof. Alternatively, straps may attach the frame to the roof or other supporting structure if attachment points are not convenient to where the solar array 1215 needs to be attached, for example.
An exemplary installation procedure may be useful for further understanding the solar array and associated processes.
Process 1300 begins with assembly of a frame at module 1310. The frame may be one such as is illustrated in
At module 1320, the frame is attached to the supporting surface. The supporting surface is traditionally the roof of a building which is to use the solar array. However, that supporting surface may be a cover of a carport, a trellis, or some other surface on which the frame may be mounted. Moreover, in some instances, the solar panel and frame may be mounted on a platform which moves to attempt to maximize exposure to the sun.
At module 1330, solar panels are attached to the frame. The solar panels may be photovoltaic cells, heating elements, or some combination of the two. A combination may be, for example, a photovoltaic cell with an underlying water pipe which allows for heat transfer to water in the pipe.
At module 1340, solar cells are connected or coupled to the electrical system. Such a coupling may involve routing electrical energy through an inverter, for example. Moreover, in coupling the solar array to a junction box, some form of automatic switch may be installed, with the switch triggering when the external power grid loses power (brownout or blackout), and thereby allowing the house to retain solar power without attempting to power the grid from the solar array.
Likewise, at module 1350, solar heating pipes may be connected to an existing water system, allowing for supply of hot water when solar heating is available. This may involve connecting or coupling through a pump, for example, to allow water to get to or from the solar array. Additionally, at module 1360, monitoring hardware may be installed. Monitoring hardware may detect current generated by the photovoltaic cells or temperature and pressure of water for solar heating panels and record data related to these detections. The monitoring hardware may also provide such data to a local system such as a computer, or to a transmission station for transmission to a remote monitoring facility (or both).
With the system installed, a process for operating the system may also be useful.
Process 1400 initiates with installation of the solar installation at module 1410. Installation may be handled through a process such as process 1300 of
Monitoring of the system may result in continued operation at module 1420, or in disengagement of the system for maintenance at module 1475. If the system is disengaged, this will typically be responsive to maintenance personnel acting to disengage the system. Then, at module 1480, the system will be maintained—necessary repairs, adjustments or replacements may be made without fear of an electrical shock from an external power grid or a rush of hot water from a water heater. The system may then be re-engaged or reconnected at module 1485, once the system is believed to be ready to operate.
Determining whether to repair a system may be done locally or remotely, based on measured performance.
Process 1440 begins with module 1445 and receiving measurements from a solar array. At module 1450, the measurements (data) are compared with historical data. At module 1455, the received measurements are also compared to calculated data, such as expected solar power output or efficiency, for example. The calculated data may be related to or derived from a calculated guarantee of solar power output, for example.
At module 1460, a determination is made as to whether the solar array is operating properly. This determination may indicate that the solar array has experienced a sudden and unexpected drop in power or heat output. Alternatively, it may indicate the solar array is not performing up to par with regard to a guaranteed level of performance. If the solar array is performing adequately, the process returns to receiving measurements at module 1445. If the solar array is not performing adequately, at module 1465, an operator of a system is alerted as to the situation. The system is then maintained, such as through dispatch of a maintenance person or crew to the solar array, at module 1470. Thus, maintenance may be invoked automatically based on remote monitoring.
Note that this process may further include monitoring whether an installed solar system is delivering power adequate to needs of a house, for example. Thus, a system may have been installed to deliver 1 kW, but the needs of the house may prove to be greater, in the range of 1.5 kW, thus resulting in the house always drawing power from an external grid. This may point toward installing an enlarged system if the owner so desires. Similarly, if the house consistently uses more hot water than is supplied, that may be recorded and the owner notified. When consumption outstrips supply, this may indicate a problem, either a malfunctioning appliance which consumes excess power or a water leak, for example. Thus, increase in supply may not be necessary where demand may be decreased.
In some embodiments of the various systems, it may be useful to add on a cooling component.
Pancake fan 1500 may be used with a solar array and frame to provide ventilation and cooling as necessary. In some systems, pancake fan 1500 may be mounted at or near a slot 280 of a corner support 290 of
Similarly, air gaps or other structural features in the frame may be placed to create a chimney effect or continuous air current, to cool photovoltaic panels and increase performance. In another embodiment, the skirt may be perforated, allowing air flow which may cool the panels or dry out the system after rain, without requiring a fan. The skirt refers to the outer surface of the frame, however perforations would typically be extended through holes in the inner surface of the rail as well.
Another aspect of various embodiments that may provide further understanding is the cross-section of some components.
In contrast, another cross-section can be used with essentially the same components in other embodiments.
Also, in relationship to the various components of different embodiments, it should be noted that these components may be made of a variety of materials. These components may be molded or otherwise formed as single pieces of such materials as plastics or metals (e.g. aluminum). Likewise, these components may be assembled from various materials, such that the components may be made from plastic, metal, wood, or any other material which is expected to withstand the environment in which the system is deployed. Manufacturing cost and tolerances will play a part in choosing materials, but the components are generally intended to be interchangeable to allow for ease of assembly and use.
Also of potential interest is an alternate structure for a single panel system.
Additional alternative components may be used to substitute for parts of a frame, or to provide an alternate embodiment of a frame entirely.
While the rail is shown with a skirt as part of a unitary unit, other options exist for assembly of such a frame. For example, a frame may be made up of rails with a rectangular cross-section, to which a skirt with a more aesthetically pleasing appearance is bolted or otherwise attached. Thus, while unitary components are described and illustrated, it should be borne in mind that these components may be subdivided or combined in various embodiments, while still providing an embodiment within the spirit of that which is described.
A cap may be used with rail 1800.
Also potentially useful with rail 1800 is an underside support.
Various components are described separately, but those components collectively combine to form a frame for solar panels.
As indicated in
Pivot 2230 is also coupled to pivot 2270 through pin 2235. A through-hole 2255 is used to connect pin 2235 to pivot 2270. Similarly, through-hole 2277 of pivot 2270 is used to connect pin 2235 to pivot 2270, and thereby to rotatably couple pivot 2230 to pivot 2270. Through-hole 2238 of pin 2235 receives fastener 2245, which retains pin 2235 within through-hole 2255. Additionally, set-screw 2260, with adjustment wheel 2262, may force pin 2235 against an internal side of through-hole 2255 for a friction-based hold of pin 2235. Base 2234 retains pin 2235 within through-hole 2277 of pivot 2270. Pivot 2270 includes cylindrical portion 2275 (through which through-hole 2277 passes) along with through-hole 2285. Pin 2280 passes through through-hole 2285, and may then be used to attach to a roof, or some component attached to a roof such as a bracket (not shown). Head 2290 retains pin 2280 within through-hole 2285. With the other end of pin 2280 fastened elsewhere (on a roof for example), this is sufficient to maintain the connection. The components of fastener 2200 provide a highly flexible pivot component which can slide along a rail. With several options for pivoting the component, and the ability to slide the component along the rail, an initial anchor location can be much more flexible when a rail or frame must be moved slightly to accommodate other aspects of an installation.
A snap rail may also be used to hold a solar panel in place.
The side rails form the frame, but must be joined together to accomplish this task.
The sliders 2430 can then mate with slots of a pair of rails 1800 to couple the two rails 1800 together.
Given the size of frames used, a center rail may also be necessary.
One such component is a support spring. With top surface 2610 extending out from the rest of rail 2600, a top for a solar panel is provided, and a supporting spring can then frictionally sandwich in the solar panel.
The center rail may also need to be attached to the roof.
The L-brackets of
Various options exist for connecting a series of rails or a set of rails in a corner configuration.
End 3150 closes the end of the connector 3100, and would be inserted into a rail 1800. To avoid having the connector slide all the way through the rail and to provide an approximately uniform exterior, ridge 3190 is raised at approximately the midpoint of the connector 3100. Ridge 3190 preferably approximates the outer surface of a rail 1800, such that a rail 1800 mating with ridge 3190 provides a relatively smooth transition. Thus, when each end 3150 of connector 3100 is inserted into a separate rail 1800, the joined set of three pieces appears from outward observation to be a single unitary piece.
Connector 3100 may be fastened to a rail 1800 through a variety of ways. For example, fasteners such as screws or similar components may be used. Alternatively, a friction or press-fit may be used. Other examples of known options for fastening components may similarly be substituted in the device.
Along with coupling rails together in an abutting relationship, it may be useful to couple rails in a corner configuration, such as for a rectangular or square solar array configuration.
This allows for main rails with flat ends perpendicular to the sides of the rail, rather than requiring rails that are mitered at a 45 degree or other custom angle. Additionally, note that no V-slots are illustrated in this particular embodiment. However, such V-slots may be provided in some embodiments, or the connector may be designed to only fit into other parts of the main rail (e.g. along the curved surface, top surface and bottom surface, for example).
Similarly, interior corner connectors may be useful in some situations—where a solar array conforms to a non-rectangular rooftop space, for example.
Ends 3330 may abut main rails, such that surfaces 3310 and 3320 provide a near continuous appearance. Ends 3340 cap the connector 3300, at the end of interior curved surface 3350 and interior top surface 3360 on each leg of the connector 3300. Thus, surfaces 3350 and 3360 can mate with corresponding surfaces on the inside of a main rail, allowing for some form of friction fit or fastener. Note that the various connectors discussed here may be manufactured in a variety of ways to provide the desired aesthetic and functional structures.
Use of these various connectors allows for a variety of configurations.
Other shapes may also be provided.
Note that not all of the rails 3410 need be cut to the same length—the corner and abutting connectors allow for the rails to be cut to a desired length as long as the end of the rail is essentially perpendicular to the sides of the rail. Also, not shown are interior or center rails which would likely be used to provide further support and anchorage to the solar panels 3450 and 3455. Such center rails may be rails such as those illustrated in
Other shapes may also be appropriate.
Center rails can be important or even vital parts of a solar array, providing interior support and potentially making a frame more rigid.
Main rails in such a system have been previously described, but other embodiments may also be employed.
Note that with the cap 3820 and similar caps, a feature is potentially available which can ease installation and maintenance. Namely, the cap 3820 may be removed from the rest of the assembly, without requiring disassembly of the entire frame. This then potentially allows for access to the panels held in by the cap 3820, and to wiring and components underneath the panels, without requiring any attempt to remove the frame from the roof or remove the anchors from the roof, for example.
Other embodiments of rails and caps may be appropriate in various embodiments of arrays and systems.
Additionally, viewing rails 3950 and 3900, it becomes apparent that curved surface 1810 need not necessarily be curved in some embodiments. A purpose of the solar array, in some embodiments, is to provide an aesthetically pleasing design, unlike some of the objectively displeasing installations to be found already. Thus, the frame is preferably constructed, in some embodiments, to allow for a design similar to a skylight, with sloped or curved sides, which provide a pleasing appearance to observers viewing such an installation from a road or other nearby location. The exact profile of the rails is thus designed for aesthetic purposes. Additional functional aspects may be incidental, such as allowing for better shedding of water or vegetable matter (e.g. leaves).
Installation of these arrays may take on many forms, with various processes available.
Process 4000 initiates with identification of an intended location of a solar array at module 4005. At module 4010, a rough location of various components is estimated, such as main rails (sides of the array), center rails, and associated connectors. At module 4020, location of roof components occurs, such as finding underlying rafters or other structures for anchor purposes. At module 4030, a first rail (a main rail) is positioned in a final position. This final position is essentially correct, and is based on how the rail will be anchored to the roof or other underlying surface. However, the nature of the roof mounting components of
With the first rail in position, the end rails are then mounted at module 4040, connecting or coupling them to the first rail, and anchoring the end rails to the roof. For the simplest of mountings, as is assumed for this process, there is a first rail, two end rails, and another main rail forming the rectangular frame of the array. Thus, the two end rails are coupled to the first rail through corner connectors. At module 4050, another main rail (a second rail) are mounted, with the second main rail completing the rectangle defined by the first rail and the two end rails. In other installations, modules 4040 and 4050 may include additional rails mounted in line with the first rail, or module 4030 may include mounting a set of first rails which provide a first side of a solar array.
Furthermore, installations may include center rails which are fastened at intermediate points within the frame in more complicated embodiments. Moreover, in some embodiments, frames may also be assembled such that all rails are coupled together before any component is anchored to a support structure such as a roof. In such an instance, the assembled frame may be moved to account for variations in the surface or for aesthetic reasons, for example, and then anchored in place. The adjustable anchor components may potentially provide additional flexibility in such instances, too.
With the rails in place, and the frame essentially assembled, the solar or photovoltaic panels are added at module 4060. This typically would include placement of the panels, addition of any supporting brackets, wiring of the panels, and connection or coupling of panel wiring to external wiring and components such as an inverter or power junction. With the panels in place, the frame is then adjusted against the roof at module 4070. This may involve removing panels temporarily to get at underlying components. Moreover, this is expected to include adjusting the roof mounting components such as those of
At module 4080, supports for the solar panels are adjusted. This may involve simply sliding supports to new locations and fastening them, or it may involve additional supports added in as part of this array. Moreover, adjustment may be minimal or unnecessary in some instances. Top caps are then installed at module 4090. The top caps may be snapped in or placed and fastened as appropriate. With the top caps in place, the solar array is complete, and the installers may then exit the roof or other location.
Yet another embodiment of a frame may be used as part of a solar array.
Main rail 4100 has a top surface 4135 in which a T-slot 4125 is formed. Side surface 4110 descends from top surface 4135 to shelf 4105. Shelf 4105 may provide a supporting shelf for a solar panel, for example. Shelf 4105 mates with corner piece 4120. Corner piece 4120 has T-slots formed in both its vertical and horizontal surfaces. Corner piece 4120 also meets bottom 4115, which forms a bottom surface which may support rail 4100. Bottom 4115 is connected to curved outer side 4130, which in turn is connected to top surface 4135. At this junctions of bottom 4115 with outer side 4130 and outer side 4130 with top surface 4135, curved hollows 4140 are formed within the material, allowing for use of dowels or pegs, for example, to couple rails. Note that rail 4100 may be formed through an extrusion process—where reference is made to connections or meetings of parts of rail 4100, this may refer to a transition from one part of an extruded rail to another part of an extruded rail, for example.
Top cap 4155 is coupled to main rail 4100 through use of fasteners such as fastener 4150. Top cap 4155 is illustrated as a flat metal piece which is coupled to main rail 4100 and projects out beyond top surface 4135 to cover part of shelf 4105. This projection allows top cap 4155 to hold a solar panel in place against shelf 4105. Also illustrated is bracket 4160, which has a vertical surface 4165 and a horizontal surface 4170 joined at a right-angle joint. Vertical surface 4165 has two through-holes in this embodiment, through which fasteners 4150 couple bracket 4160 to a T-slot 4125 of rail 4100. Horizontal surface 4170 has a through-hole through which a screw assembly 4170 or similar fastener may be inserted. Screw assembly 4170 may be used to couple with a roof attachment bracket such as that shown in
Also, note that the embodiment of
Some arrays may require internal support along with the exterior support of the rails 4100.
Putting the main rails of
A similar attachment mechanism is provided between a main rail 4100 and a center rail 4300. Again, a corner bracket 4410 couples a main rail 4100 to a center rail 4300 through use of fasteners 4150 attached to through-holes of sides 4420 and T-slots of main rail 4100 (T-slot 4125) and center rail 4300 (T-slot 4320). Not illustrated is a second corner bracket 4410 attached to the other side of center rail 4300 and a corresponding main rail 4100. Also illustrated is top cap 4155 coupled to center rail 4300 on one side of center rail 4300—allowing for secure mounting of a solar panel within the confines of the main rails 4100 and center rail 4300, with the panel supported by shelf 4310 of center rail 4300 and by the shelves 4105 of main rails 4100. Note that the top caps 4155 of main rails 4100 are mounted to the main rails 4100 and also meet at a 45 degree angle. Also shown is bracket 4160 mounted to center rail 4300 by attachment of two fasteners 4150 through vertical surface 4165 to T-slot 4320 of center rail 4300.
Installation has been discussed with respect to mounting a frame or array on a roof top. Other surfaces may be suitable, such as a carport, or trellis-style mount. Similarly, ledges may extend from a building on which solar arrays may be mounted. Moreover, ground-mounting may be appropriate in some circumstances. For example, a ground mount may involve poles sunk in the ground, with the array attached to the poles in a relatively conventional manner, or with the array attached to a platform attached to a pole or poles, for example. Moreover, poles (or a more direct connection) may be used to attach a solar array to a structure which does not necessarily have a fixed location, such as a boat or yacht, for example.
One skilled in the art will appreciate that although specific examples and embodiments of the system and methods have been described for purposes of illustration, various modifications can be made. For example, embodiments of the present invention may be applied to many different types of structures and customers and to many different types of databases, systems and application programs. Moreover, features of one embodiment may be incorporated into other embodiments, even where those features are not described together in a single embodiment within the present document. Similarly, embodiments illustrated in this document may be implemented without all of the features or aspects illustrated or described.
This application is a continuation of PCT application no. US06/26968, filed Jul. 11, 2006, which claims priority to U.S. Provisional Patent Application No. 60/778,771, filed Mar. 2, 2006 and U.S. Provisional Patent Application No. 60/698,385, filed Jul. 11, 2005, which are hereby incorporated herein by reference.
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Number | Date | Country | |
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Number | Date | Country | |
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Parent | PCT/US2006/026968 | Jul 2006 | US |
Child | 12013328 | US |