WO2011071489A1 - Mounting system for photovoltaic module - Google Patents

Mounting system for photovoltaic module Download PDF

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Publication number
WO2011071489A1
WO2011071489A1 PCT/US2009/067184 US2009067184W WO2011071489A1 WO 2011071489 A1 WO2011071489 A1 WO 2011071489A1 US 2009067184 W US2009067184 W US 2009067184W WO 2011071489 A1 WO2011071489 A1 WO 2011071489A1
Authority
WO
WIPO (PCT)
Prior art keywords
mounting device
photovoltaic module
support member
notch
supported
Prior art date
Application number
PCT/US2009/067184
Other languages
French (fr)
Inventor
Edward N. Twesme
Ding YU
Matthias Eichelbroenner
Salvatore G. Staiano
Original Assignee
Twesme Edward N
Yu Ding
Matthias Eichelbroenner
Staiano Salvatore G
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Twesme Edward N, Yu Ding, Matthias Eichelbroenner, Staiano Salvatore G filed Critical Twesme Edward N
Priority to PCT/US2009/067184 priority Critical patent/WO2011071489A1/en
Publication of WO2011071489A1 publication Critical patent/WO2011071489A1/en

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Classifications

    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02SGENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00Supporting structures for PV modules
    • H02S20/20Supporting structures directly fixed to an immovable object
    • H02S20/22Supporting structures directly fixed to an immovable object specially adapted for buildings
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/30Arrangement of stationary mountings or supports for solar heat collector modules using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S25/63Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
    • F24S25/632Side connectors; Base connectors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24HEATING; RANGES; VENTILATING
    • F24SSOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
    • F24S25/00Arrangement of stationary mountings or supports for solar heat collector modules
    • F24S25/60Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
    • F24S2025/6002Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by using hooks
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02BCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00Integration of renewable energy sources in buildings
    • Y02B10/10Photovoltaic [PV]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/40Solar thermal energy, e.g. solar towers
    • Y02E10/47Mountings or tracking
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy

Definitions

  • the present invention relates to mounting systems for photovoltaic modules, including frameless photovoltaic modules and methods of mounting photovoltaic modules.
  • Photovoltaic (“pv”) modules and solar cells comprising amorphous silicon (“a-Si”) and doped variants thereof are gaining market share due to their lower cost and improved efficiency.
  • a-Si pv modules are often prepared without a metal frame or other supporting external structure. These frameless modules also frequently have a surface area that is greater than solar cells prepared from other materials, which makes these pv modules susceptible to environmental loads such as wind, snow, rain, ice, etc. It is therefore necessary to mount a-Si pv modules such that they are fully supported without a frame and able to withstand the required loads.
  • a-Si pv modules are particularly attractive for building-integrated applications in which pv modules are utilized as architectural elements such as windows, exterior panels, and/or aesthetic elements.
  • What is needed is a mounting device for pv modules, including frameless pv modules, that provides excellent load-carrying support while also allowing for facile mounting of pv modules from the outward-facing side of a support member such as an architectural element.
  • a mounting device that can be readily integrated with commonly used building materials such as I-bars, H-bars, C-bars, and the like. The present invention fulfills these needs.
  • the apparatus, systems and methods of the present invention allow for improved ease of use (e.g., mounting) while maintaining required stability and load support.
  • the present invention is directed to a supported photovoltaic (“pv") module comprising: a pv module; and a mounting device coupling the pv module to an architectural support, the mounting device including a first surface affixed to a backside of a pv module; and a second surface including a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch coupled with a support member.
  • pv photovoltaic
  • the present invention is directed to a mounting device for affixing a pv module to a support member, the mounting device comprising: a first surface suitable for affixing to a surface of a pv module; and a second surface including a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch suitable for coupling with a support member.
  • the notch includes a mouth portion and a body portion, wherein the mouth portion has a lateral dimension that is less than a lateral dimension of the body portion.
  • the mounting device further includes a long axis, and the notch is substantially orthogonal to the long axis.
  • the protrusion further includes a flexible cantilever element that extends from at least one side of the notch and is suitable for applying pressure to a surface of a support member that is coupled to the mounting device.
  • the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member.
  • the support member includes a groove having a placement and depth suitable for coupling with the flexible cantilever element, and wherein the flexible cantilever element extends a sufficient to fix the position of the mounting device relative on the support member.
  • the protrusion further includes open spaces between the one or more structural elements.
  • the mounting device is prepared from a material selected from: steel, galvanized steel, stainless steel, aluminum, and combinations thereof.
  • the supported pv module has an active region of about
  • the supported pv module is a frameless pv module.
  • the present invention is also directed to an array of pv modules comprising the supported pv module of the present invention.
  • the array has a power output of about 20 kW or more.
  • FIG. 1 provides a cross-sectional representations of a mounting device of the present invention.
  • FIG. 2 provides a three-dimensional schematic representation of a mounting device of the present invention.
  • FIG. 3 provides a cross-sectional representations of a mounting device of the present invention affixed to a surface of a pv module and coupled to a support member.
  • FIGs. 4 and 5 provide three-dimensional schematic representations of a mounting device of the present invention affixed to a back surface of a pv module and coupled to a support member.
  • bottom made herein are for purposes of description and illustration only, and should be interpreted as non-limiting upon the supports, mounting device, substrates, modules, arrays, methods, and products of any method of the present invention, which can be spatially arranged in any orientation or manner.
  • a "lateral dimension” refers to a dimension of an element of a mounting device that is parallel or tangential to the surface of an element.
  • One or more lateral dimensions of an element can be used to defines its three-dimensional shape.
  • Typical lateral dimensions include, but are not limited to: length, width, radius, diameter, and combinations thereof.
  • a vertical dimension is one that can be described by a vector that lies substantially normal to one or more lateral dimensions (e.g., x and y coordinates) suitable for describing the three-dimensional shape of an element.
  • the present invention provides mounting devices and systems for supporting a pv module. While the mounting device, mounting systems and mounting methods of the present invention can be utilized for any pv modules, suitably, the apparatus, systems, and methods are utilized with frameless pv modules.
  • frameless pv modules comprise a solar cell (or a plurality of cells) positioned between support substrates, for example, glass plates that are not surrounded by a frame (e.g., made of metal or another rigid material).
  • Frameless pv modules can include without limitation dot point glazed, metal point glazed, and building integrated pv modules.
  • mounting devices of the present invention are useful for facile and stable mounting of "large area" pv modules (e.g., pv modules having an active area of about 0.5 m 2 or more, or about 0.75 m 2 or more, about 1 m 2 or more, about 1.2 m 2 or more, or about 1.5 m or more).
  • "large area" pv modules e.g., pv modules having an active area of about 0.5 m 2 or more, or about 0.75 m 2 or more, about 1 m 2 or more, about 1.2 m 2 or more, or about 1.5 m or more.
  • a pv module for use with the present invention is semi- transparent (i.e., opaque), and can include a solar cell placed between or on one or more glass panes or sheets.
  • a pv module comprises one or more sheets of soda lime glass.
  • the pv modules for use with the present invention can include without limitation any photovoltaic or solar cell material known to a person of ordinary skill in the art.
  • photovoltaic and solar cell materials for use in a pv module can comprise crystalline silicon, polycrystalline silicon, microcrystalline silicon, nanocrystalline silicon, amorphous silicon, micromorphous silicon, CIS, CIGS, GaAs, Ge, CdTe, and combinations thereof.
  • FIG. 1 provides a cross- sectional schematic representation of a side view of a mounting device, 100, of the present invention.
  • the mounting device, 100 includes a first surface, 110, suitable for affixing to a surface of a pv module, and a second surface, 120 and 121, including a raised portion, 130, protruding from the second surface including one or more structural elements, 131 and 133, suitable for maintaining the raised portion in a fixed position, and a protrusion, 140, extending from the raised portion, wherein the protrusion and the second surface form a notch, 141, suitable for coupling with a support member.
  • the notch includes a mouth portion, 142, having a lateral dimension that is less than a lateral dimension of the body portion, 141.
  • the protrusion further includes a flexible cantilever element, 143, that extends from at least one side of the notch and is suitable for applying pressure to a surface of a support member that is coupled to the mounting device.
  • the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member.
  • the flexible cantilever element locks into a groove in a support member.
  • extending from refers to an element that is attached or otherwise coupled to a surface, element, part, and the like and protrudes therefrom.
  • “extending from” includes embodiments in which elements are monolithic and prepared from the same material (e.g., by molding, machining, rolling, pressing, or otherwise forming) and also includes embodiments in which various elements are prepared from separate materials and bonded, contacted or otherwise adhered to one another (e.g., using an adhesive, a screw, a bolt, a nail, a rivet, a clamp, a weld, a magnetic interaction, a electrostatic interaction, and the like) and embodiments in which a combinations of monolithic and pieced together elements is utilized.
  • an adhesive can be applied to at least a portion of the first surface, 110, suitable for affixing the mounting device (e.g., bonding or adhering) to a surface of a pv module.
  • the first surface can include a recessed portion that can be filled with an adhesive during a mounting process.
  • an adhesive can be applied evenly to the first surface of the mounting device.
  • Exemplary adhesives suitable for use with the present invention include, but are not limited to structural foam tape, and structural adhesives such as silicone-, amino-, silane-, silanol-, or urethane-based adhesives and the like.
  • Exemplary structural adhesives are available from, e.g., Dow Corning Corp., Midland, MI (including without limitation Dow CORNING ® 902, 995, X4-4647 and X4-4643 Silicone Structural Adhesives).
  • the first surface, 110, and second surface, 120 and 121 are opposite one another.
  • opposite refers to an embodiment in an angle of more than 90° is formed between two elements.
  • an angle of 180° is formed between the first and second surfaces.
  • an element aligned opposite to another element can have an angle of more than about 90° to about 270°, about 105° to about 255°, about 120° to about 240°, about 150° to about 210°, about 165° to about 195°, or about 180° between the respective elements (or surfaces).
  • the mounting device is substantially symmetric (i.e., can be transposed by one or more mirror planes).
  • the mounting device can also be asymmetric without limitation.
  • a notch, 141 can optionally comprise a cushion pad attached to a surface thereof.
  • a cushion pad can provide resistance to movement of the mounting device, 100, against an architectural support, enhanced mechanical stability, and combinations thereof.
  • a cushion pad for use with the present invention can comprise without limitation, a plastic, a foam, a polymer, an elastomer, a metal, a wood, and combinations thereof, such as but not limited to alloys thereof, laminates thereof, and composites thereof.
  • the mounting devices of the present invention include a long axis and a short axis.
  • the schematic cross-sectional diagram of FIG. 2 depicts a three-dimensional representation of a mounting device of the present invention. Referring to FIG. 2, the mounting device, 200, includes a short axis, 201, and a long axis, 202.
  • the mounting device has a lateral dimension along a short axis (i.e., the width of the mounting device), 201, of about 20 mm to about 500 mm, about 30 mm to about 300 mm, about 50 mm to about 250 mm, or about 50 mm to about 150 mm.
  • the mounting device has a lateral dimension along a long axis (i.e., the length of a mounting device), 202, of about 25 mm to about 300 mm, about 30 mm to about 280 mm, about 35 mm to about 250 mm, or about 40 mm to about 200 mm.
  • a raised portion, 230 has a lateral dimension, 235, of about 5 mm to about 250 mm, about 10 mm to about 100 mm, or about 20 mm to about 50 mm.
  • a protrusion, 240 has a lateral dimension, 245, of about 10 mm to about 200 mm, about 20 mm to about 150 mm, or about 30 mm to about 100 mm.
  • the mounting device has a length such that the ends of a mounting device protrude a small amount beyond an edge of a surface of a pv module.
  • a mounting device has a length that is about 2 mm or more, about 5 mm or more, about 10 mm or more, or about 20 mm or more than the length of a pv module or solar panel to which the mounting device is attached.
  • a mounting device of the present invention is a formed, machined or extruded material. That is, the mounting device can be prepared from a single piece of material that is shaped to have the recited characteristics and elements provided herein. For example, in some embodiments the mounting device can be machined or milled from a piece of metal such as, but not limited to, steel, galvanized steel, aluminum, stainless steel, and the like.
  • the mounting device can comprise separate pieces of material that are joined together.
  • the separate pieces can be joined via any suitable manner, including adhesives, screws, bolts, clamps, staples, brads, nails, rivets, solder, welds, etc.
  • the mounting device can comprise without limitation, a metal (e.g., aluminum, galvanized steel, stainless steel, roll-formed sheet metal, titanium, etc.), a polymer (e.g., extruded structural plastic), carbon fiber, laminates thereof, alloys thereof, composites thereof, and the like.
  • a mounting device comprises the same material throughout, in other embodiments, separate elements of the apparatus can be prepared from different materials (e.g., different metals or different polymers).
  • a mounting device comprises elements having a minimum tensile strength.
  • a minimum tensile strength can provide for a minimum expected lifetime, a minimum failure rate, or a certification against defect.
  • FIG. 3 provides a three-dimensional schematic representation, 300, of a mounting device of the present invention, 301, affixed to a surface of a pv module, 310, and coupled to a support member, 320.
  • the support member, 320 includes a groove, 321, into which the flexible cantilever element, 343, extends, thereby locking the mounting device in a fixed position on the support member.
  • FIG. 4 provides a three-dimensional schematic representation, 400, of a mounting device of the present invention, 401, affixed to a back surface of a pv module, 410, and coupled to a support member, 420.
  • FIG. 5 provides an exploded image of a portion of FIG. 4, and depicts a three- dimensional schematic representation, 500, of a mounting device of the present invention, 501, affixed to a back surface of a pv module, 510, and coupled to a support member, 520.
  • the support member, 520 includes a groove, 521, into which a flexible cantilever element can extend, thereby locking the mounting device in a fixed position on the support member.
  • a "backside” or “back surface” of a pv module refers to a surface of a pv module closest to a reflective element. It should be noted that the mounting device of the present invention can alternatively be attached to a front surface of a pv module.
  • a support member refers to an element suitable for providing stability for a pv module and can bear the weight of a pv module, as well as any mechanical stress and induced weight a pv module due to external forces (e.g., wind, rain, - 40 - debris, landing birds, and the like).
  • Support members for use with the present invention include any structural member.
  • a support member is an architectural element of a building, wall, deck, roof, and the like.
  • a support member is an architectural element of a structure, such as a house, an office building, a warehouse, a factory, a carport, a garage, a deck, a balcony, and the like or can be a free-standing (and self-supporting) structure such as, but not limited to, a solar- supporting frame.
  • support members include an I-beam, an H- beam, a unistrut, a T-shaped beam, a C-shaped beam, a stock structural support (e.g., a wooden beam), a z-bracket attached to another structure, and any other structural supports or building materials known to a person of ordinary skill in the art.
  • a support member or structural member for use with the present invention includes a material selected from metal, wood, plastic, carbon fiber, combinations thereof, laminates thereof, composites thereof, alloys thereof, and the like.
  • additional stability can be provided, for example, by coupling a mounting device to a support member, and prior to, during, or after the coupling using, e.g., an adhesive, a nail, a screw, a bolt, a weld, a clip, or another suitable mechanism of attachment to secure the coupled mounting device and architectural element.
  • a support member can be movable (e.g., rotatable, tiltable, and the like), for example, to maximize collection of solar energy, aesthetically cover an exterior portion of a building, and the like.
  • the present invention is also directed to methods of mounting a pv module on a support member using the mounting device of the present invention.
  • the methods of the present invention provide a technique to position a pv module on a single structural element (e.g., a single structural support or single structural member).
  • the methods of the present invention can be easily performed by one or more person, using a minimum number of tools and equipment.
  • positioning has its ordinary meaning of locating in three- dimensional space.
  • moving a mounting device onto a member comprises sliding, pushing, pulling, and the like.
  • a method of the present invention further comprises locking the pv module (and the mounting device) in a fixed position on the structural element or support member.
  • locking include: positioning a fastener in and/or around at least one of the alignment element and the attachment element to contact a surface of the member, positioning a clip in a space between the attachment element and the member, and the like.
  • a protrusion on the mounting device can be used to secure the mounting device to an structural element.
  • Additional methods of mounting a pv module of the present invention include first providing a pv module (e.g., a frameless pv module). At least one mounting device is then attached to the pv module via an interface of a first surface of the apparatus. As described herein, suitably the apparatus is adhered to the pv module using an adhesive. The pv module is then positioned on a support member.
  • a pv module e.g., a frameless pv module.
  • At least one mounting device is then attached to the pv module via an interface of a first surface of the apparatus. As described herein, suitably the apparatus is adhered to the pv module using an adhesive.
  • the pv module is then positioned on a support member.
  • a pv module can be mounted utilizing one ore more mounting devices of the present invention, and suitably, in some embodiments, a pv module can comprise two or more mounting devices (e.g., two, three, four, six or eight mounting devices). When utilizing two mounting devices of the present invention to position a pv module, the mounting devices can be attached to a pv module in one or more aligned rows.
  • the mounting devices and methods dramatically decrease the amount of hardware used to fasten pv modules and/or solar panels to a support member, thereby decreasing cost and installation time. For example, by eliminating threaded fasteners that are typically used for pv module installation, the pv modules can be installed by a single person using minimal tools.
  • the centerline mounting devices of the present invention reduce the potential for over- stressing a pv module or solar panel, thus increasing safety, decreasing cost and minimizing maintenance.
  • the minimal amount of materials used also decreases the overall cost of the mounting system both in terms of base cost and shipping costs associated with transfer of components to an installation site.
  • the mounting device of the present invention is suitable for mounting and supporting a frameless pv module, including pv modules comprising one or more layers of a-Si.
  • a frameless pv module including pv modules comprising one or more layers of a-Si.
  • the ability to mount frameless modules without the use of screws or other attachment pieces, simply by coupling the mounting device to a support structure greatly increases the ease of installation.
  • a support structure e.g., an architectural element
  • a mounting device of the present invention will be attached to a-Si pv module using a structural adhesive (Dow CORNING ® 995 Structural Adhesive) by applying the adhesive to the mounting device and affixing the coated mounting device to an edge of a backside of an a-Si pv module.
  • the structural adhesive will be cured, and the mounted pv module will then be positioned on a support structure (e.g., an I-beam) by aligning the mounting device with and end of the member and coupling the mounting device with the support structure.
  • a support structure e.g., an I-beam

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Abstract

The present invention provides a mounting device suitable for supporting a photovoltaic module, and methods of making and using the same A first embodiment is a mounting device for affixing a photovoltaic module to a support member, the mounting device comprising a first surface suitable for affixing to a surface of a photovoltaic module, and a second surface including a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch suitable for coupling with a support member.

Description

MOUNTING SYSTEM FOR PHOTOVOLTAIC MODULE
BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The present invention relates to mounting systems for photovoltaic modules, including frameless photovoltaic modules and methods of mounting photovoltaic modules.
Background of the Invention
[0002] Photovoltaic ("pv") modules and solar cells comprising amorphous silicon ("a-Si") and doped variants thereof are gaining market share due to their lower cost and improved efficiency. However, a-Si pv modules are often prepared without a metal frame or other supporting external structure. These frameless modules also frequently have a surface area that is greater than solar cells prepared from other materials, which makes these pv modules susceptible to environmental loads such as wind, snow, rain, ice, etc. It is therefore necessary to mount a-Si pv modules such that they are fully supported without a frame and able to withstand the required loads.
[0003] Current methods for mounting frameless pv modules rely on attaching channels or brackets that serve as attachment points to structural supports. Such brackets are typically attached at strategic points on the back of the pv module to maximize the load-carrying capability of the pv module. In some designs a hexagonal head of a ¼ inch machine screw slides into a channel in a bracket such that when a matching nut is applied thereto the pv module becomes affixed securely in place to a mounting support. While such an assembly can secure even large pv modules and pass load testing requirements, the mounting process is labor intensive and time consuming. For example, a bolt head must be carefully aligned in a bracket channel, and the bolt must be maintained in the proper location and alignment during the mounting, which can require personnel both above and below the pv module during the mounting. [0004] a-Si pv modules are particularly attractive for building-integrated applications in which pv modules are utilized as architectural elements such as windows, exterior panels, and/or aesthetic elements.
BRIEF SUMMARY OF THE INVENTION
[0005] What is needed is a mounting device for pv modules, including frameless pv modules, that provides excellent load-carrying support while also allowing for facile mounting of pv modules from the outward-facing side of a support member such as an architectural element. In particular, what is needed is a mounting device that can be readily integrated with commonly used building materials such as I-bars, H-bars, C-bars, and the like. The present invention fulfills these needs.
[0006] The apparatus, systems and methods of the present invention allow for improved ease of use (e.g., mounting) while maintaining required stability and load support.
[0007] The present invention is directed to a supported photovoltaic ("pv") module comprising: a pv module; and a mounting device coupling the pv module to an architectural support, the mounting device including a first surface affixed to a backside of a pv module; and a second surface including a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch coupled with a support member.
[0008] The present invention is directed to a mounting device for affixing a pv module to a support member, the mounting device comprising: a first surface suitable for affixing to a surface of a pv module; and a second surface including a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch suitable for coupling with a support member.
[0009] In some embodiments, the notch includes a mouth portion and a body portion, wherein the mouth portion has a lateral dimension that is less than a lateral dimension of the body portion. [0010] In some embodiments, the mounting device further includes a long axis, and the notch is substantially orthogonal to the long axis.
[0011] In some embodiments, the protrusion further includes a flexible cantilever element that extends from at least one side of the notch and is suitable for applying pressure to a surface of a support member that is coupled to the mounting device. In some embodiments, the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member. In some embodiments, the support member includes a groove having a placement and depth suitable for coupling with the flexible cantilever element, and wherein the flexible cantilever element extends a sufficient to fix the position of the mounting device relative on the support member.
[0012] In some embodiments, the protrusion further includes open spaces between the one or more structural elements.
[0013] In some embodiments, the mounting device is prepared from a material selected from: steel, galvanized steel, stainless steel, aluminum, and combinations thereof.
[0014] In some embodiments, the supported pv module has an active region of about
0.5 m or greater.
[0015] In some embodiments, the supported pv module is a frameless pv module.
[0016] The present invention is also directed to an array of pv modules comprising the supported pv module of the present invention. In some embodiments, the array has a power output of about 20 kW or more.
[0017] Additional features and advantages of the invention will be set forth in the description that follows, and in part will be apparent from the description, or may be learned by practice of the invention. The advantages of the invention will be realized and attained by the structure and particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0018] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.
[0020] FIG. 1 provides a cross-sectional representations of a mounting device of the present invention.
[0021] FIG. 2 provides a three-dimensional schematic representation of a mounting device of the present invention.
[0022] FIG. 3 provides a cross-sectional representations of a mounting device of the present invention affixed to a surface of a pv module and coupled to a support member.
[0023] FIGs. 4 and 5 provide three-dimensional schematic representations of a mounting device of the present invention affixed to a back surface of a pv module and coupled to a support member.
[0024] One or more embodiments of the present invention will now be described with reference to the accompanying drawings. In the drawings, like reference numbers can indicate identical or functionally similar elements. Additionally, the left- most digit(s) of a reference number can identify the drawing in which the reference number first appears.
DETAILED DESCRIPTION OF THE INVENTION
[0025] This specification discloses one or more embodiments that incorporate the features of this invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s). The invention is defined by the claims appended hereto.
[0026] The embodiment(s) described, and references in the specification to "one embodiment," "an embodiment," "an example embodiment," etc., indicate that the embodiment(s) described can include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is understood that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
[0027] References to spatial descriptions (e.g., "above," "below," "up," "down," "top,"
"bottom," etc.) made herein are for purposes of description and illustration only, and should be interpreted as non-limiting upon the supports, mounting device, substrates, modules, arrays, methods, and products of any method of the present invention, which can be spatially arranged in any orientation or manner.
[0028] As used herein, a "lateral dimension" refers to a dimension of an element of a mounting device that is parallel or tangential to the surface of an element. One or more lateral dimensions of an element can be used to defines its three-dimensional shape.
Typical lateral dimensions include, but are not limited to: length, width, radius, diameter, and combinations thereof.
[0029] As used herein, a vertical dimension is one that can be described by a vector that lies substantially normal to one or more lateral dimensions (e.g., x and y coordinates) suitable for describing the three-dimensional shape of an element.
Photovoltaic Modules
[0030] The present invention provides mounting devices and systems for supporting a pv module. While the mounting device, mounting systems and mounting methods of the present invention can be utilized for any pv modules, suitably, the apparatus, systems, and methods are utilized with frameless pv modules. Generally, frameless pv modules comprise a solar cell (or a plurality of cells) positioned between support substrates, for example, glass plates that are not surrounded by a frame (e.g., made of metal or another rigid material). Frameless pv modules can include without limitation dot point glazed, metal point glazed, and building integrated pv modules.
[0031] In particular, mounting devices of the present invention are useful for facile and stable mounting of "large area" pv modules (e.g., pv modules having an active area of about 0.5 m 2 or more, or about 0.75 m 2 or more, about 1 m 2 or more, about 1.2 m 2 or more, or about 1.5 m or more).
[0032] In some embodiments, a pv module for use with the present invention is semi- transparent (i.e., opaque), and can include a solar cell placed between or on one or more glass panes or sheets. In some embodiments, a pv module comprises one or more sheets of soda lime glass.
[0033] The pv modules for use with the present invention can include without limitation any photovoltaic or solar cell material known to a person of ordinary skill in the art. For example, photovoltaic and solar cell materials for use in a pv module can comprise crystalline silicon, polycrystalline silicon, microcrystalline silicon, nanocrystalline silicon, amorphous silicon, micromorphous silicon, CIS, CIGS, GaAs, Ge, CdTe, and combinations thereof.
Mounting device
[0034] FIG. 1 provides a cross- sectional schematic representation of a side view of a mounting device, 100, of the present invention. Referring to FIG. 1, the mounting device, 100, includes a first surface, 110, suitable for affixing to a surface of a pv module, and a second surface, 120 and 121, including a raised portion, 130, protruding from the second surface including one or more structural elements, 131 and 133, suitable for maintaining the raised portion in a fixed position, and a protrusion, 140, extending from the raised portion, wherein the protrusion and the second surface form a notch, 141, suitable for coupling with a support member.
[0035] In some embodiments, the notch includes a mouth portion, 142, having a lateral dimension that is less than a lateral dimension of the body portion, 141.
[0036] In some embodiments, the protrusion further includes a flexible cantilever element, 143, that extends from at least one side of the notch and is suitable for applying pressure to a surface of a support member that is coupled to the mounting device. In some embodiments, the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member. In some embodiments, the flexible cantilever element locks into a groove in a support member.
[0037] As used herein, "extending from" refers to an element that is attached or otherwise coupled to a surface, element, part, and the like and protrudes therefrom. As used herein, "extending from" includes embodiments in which elements are monolithic and prepared from the same material (e.g., by molding, machining, rolling, pressing, or otherwise forming) and also includes embodiments in which various elements are prepared from separate materials and bonded, contacted or otherwise adhered to one another (e.g., using an adhesive, a screw, a bolt, a nail, a rivet, a clamp, a weld, a magnetic interaction, a electrostatic interaction, and the like) and embodiments in which a combinations of monolithic and pieced together elements is utilized.
[0038] Referring to FIG. 1, in some embodiments, an adhesive can be applied to at least a portion of the first surface, 110, suitable for affixing the mounting device (e.g., bonding or adhering) to a surface of a pv module. In some embodiments, the first surface can include a recessed portion that can be filled with an adhesive during a mounting process. Alternatively, an adhesive can be applied evenly to the first surface of the mounting device. Exemplary adhesives suitable for use with the present invention include, but are not limited to structural foam tape, and structural adhesives such as silicone-, amino-, silane-, silanol-, or urethane-based adhesives and the like. Exemplary structural adhesives are available from, e.g., Dow Corning Corp., Midland, MI (including without limitation Dow CORNING® 902, 995, X4-4647 and X4-4643 Silicone Structural Adhesives).
[0039] Referring to FIG. 1, the first surface, 110, and second surface, 120 and 121, are opposite one another. As used herein, "opposite" refers to an embodiment in an angle of more than 90° is formed between two elements. For example, in FIG. 1, an angle of 180° is formed between the first and second surfaces. In some embodiments, an element aligned opposite to another element (or a surface aligned opposite to another surface) can have an angle of more than about 90° to about 270°, about 105° to about 255°, about 120° to about 240°, about 150° to about 210°, about 165° to about 195°, or about 180° between the respective elements (or surfaces).
[0040] In some embodiments, the mounting device is substantially symmetric (i.e., can be transposed by one or more mirror planes). The mounting device can also be asymmetric without limitation.
[0041] Referring to FIG. 1, in some embodiments a notch, 141, can optionally comprise a cushion pad attached to a surface thereof. A cushion pad can provide resistance to movement of the mounting device, 100, against an architectural support, enhanced mechanical stability, and combinations thereof. A cushion pad for use with the present invention can comprise without limitation, a plastic, a foam, a polymer, an elastomer, a metal, a wood, and combinations thereof, such as but not limited to alloys thereof, laminates thereof, and composites thereof. [0042] In some embodiments, the mounting devices of the present invention include a long axis and a short axis. The schematic cross-sectional diagram of FIG. 2 depicts a three-dimensional representation of a mounting device of the present invention. Referring to FIG. 2, the mounting device, 200, includes a short axis, 201, and a long axis, 202.
[0043] Referring to FIG. 2, in some embodiments the mounting device has a lateral dimension along a short axis (i.e., the width of the mounting device), 201, of about 20 mm to about 500 mm, about 30 mm to about 300 mm, about 50 mm to about 250 mm, or about 50 mm to about 150 mm. In some embodiments, the mounting device has a lateral dimension along a long axis (i.e., the length of a mounting device), 202, of about 25 mm to about 300 mm, about 30 mm to about 280 mm, about 35 mm to about 250 mm, or about 40 mm to about 200 mm.
[0044] Referring to FIG. 2, in some embodiments a raised portion, 230, has a lateral dimension, 235, of about 5 mm to about 250 mm, about 10 mm to about 100 mm, or about 20 mm to about 50 mm.
[0045] Referring to FIG. 2, in some embodiments a protrusion, 240, has a lateral dimension, 245, of about 10 mm to about 200 mm, about 20 mm to about 150 mm, or about 30 mm to about 100 mm.
[0046] In some embodiments, the mounting device has a length such that the ends of a mounting device protrude a small amount beyond an edge of a surface of a pv module. For example, in some embodiments a mounting device has a length that is about 2 mm or more, about 5 mm or more, about 10 mm or more, or about 20 mm or more than the length of a pv module or solar panel to which the mounting device is attached.
[0047] In some embodiments, a mounting device of the present invention is a formed, machined or extruded material. That is, the mounting device can be prepared from a single piece of material that is shaped to have the recited characteristics and elements provided herein. For example, in some embodiments the mounting device can be machined or milled from a piece of metal such as, but not limited to, steel, galvanized steel, aluminum, stainless steel, and the like.
[0048] In other embodiments, the mounting device can comprise separate pieces of material that are joined together. The separate pieces can be joined via any suitable manner, including adhesives, screws, bolts, clamps, staples, brads, nails, rivets, solder, welds, etc. The mounting device can comprise without limitation, a metal (e.g., aluminum, galvanized steel, stainless steel, roll-formed sheet metal, titanium, etc.), a polymer (e.g., extruded structural plastic), carbon fiber, laminates thereof, alloys thereof, composites thereof, and the like. In some embodiments, a mounting device comprises the same material throughout, in other embodiments, separate elements of the apparatus can be prepared from different materials (e.g., different metals or different polymers).
[0049] In some embodiments, a mounting device comprises elements having a minimum tensile strength. Not being bound by any particular theory, a minimum tensile strength can provide for a minimum expected lifetime, a minimum failure rate, or a certification against defect. For example, it is important that architecturally mounted pv modules have an expected failure rate sufficiently low to provide for safe expected use.
[0050] FIG. 3 provides a three-dimensional schematic representation, 300, of a mounting device of the present invention, 301, affixed to a surface of a pv module, 310, and coupled to a support member, 320. The support member, 320, includes a groove, 321, into which the flexible cantilever element, 343, extends, thereby locking the mounting device in a fixed position on the support member.
[0051] FIG. 4 provides a three-dimensional schematic representation, 400, of a mounting device of the present invention, 401, affixed to a back surface of a pv module, 410, and coupled to a support member, 420.
[0052] FIG. 5 provides an exploded image of a portion of FIG. 4, and depicts a three- dimensional schematic representation, 500, of a mounting device of the present invention, 501, affixed to a back surface of a pv module, 510, and coupled to a support member, 520. The support member, 520, includes a groove, 521, into which a flexible cantilever element can extend, thereby locking the mounting device in a fixed position on the support member.
[0053] As used herein, a "backside" or "back surface" of a pv module refers to a surface of a pv module closest to a reflective element. It should be noted that the mounting device of the present invention can alternatively be attached to a front surface of a pv module.
[0054] As used herein, "a support member," refers to an element suitable for providing stability for a pv module and can bear the weight of a pv module, as well as any mechanical stress and induced weight a pv module due to external forces (e.g., wind, rain, - 40 - debris, landing birds, and the like). Support members for use with the present invention include any structural member. In some embodiments, a support member is an architectural element of a building, wall, deck, roof, and the like. In some embodiments, a support member is an architectural element of a structure, such as a house, an office building, a warehouse, a factory, a carport, a garage, a deck, a balcony, and the like or can be a free-standing (and self-supporting) structure such as, but not limited to, a solar- supporting frame. Non-limiting examples of support members include an I-beam, an H- beam, a unistrut, a T-shaped beam, a C-shaped beam, a stock structural support (e.g., a wooden beam), a z-bracket attached to another structure, and any other structural supports or building materials known to a person of ordinary skill in the art.
[0055] In some embodiments, a support member or structural member for use with the present invention includes a material selected from metal, wood, plastic, carbon fiber, combinations thereof, laminates thereof, composites thereof, alloys thereof, and the like.
[0056] While it is not required to rigidly affix a mounting device to a support member, additional stability can be provided, for example, by coupling a mounting device to a support member, and prior to, during, or after the coupling using, e.g., an adhesive, a nail, a screw, a bolt, a weld, a clip, or another suitable mechanism of attachment to secure the coupled mounting device and architectural element.
[0057] In some embodiments, a support member can be movable (e.g., rotatable, tiltable, and the like), for example, to maximize collection of solar energy, aesthetically cover an exterior portion of a building, and the like.
[0058] The present invention is also directed to methods of mounting a pv module on a support member using the mounting device of the present invention. In some embodiments, the methods of the present invention provide a technique to position a pv module on a single structural element (e.g., a single structural support or single structural member). In some embodiments, the methods of the present invention can be easily performed by one or more person, using a minimum number of tools and equipment.
[0059] As used herein, "positioning" has its ordinary meaning of locating in three- dimensional space. In some embodiments, moving a mounting device onto a member comprises sliding, pushing, pulling, and the like.
[0060] In some embodiments, a method of the present invention further comprises locking the pv module (and the mounting device) in a fixed position on the structural element or support member. Non-limiting examples of locking include: positioning a fastener in and/or around at least one of the alignment element and the attachment element to contact a surface of the member, positioning a clip in a space between the attachment element and the member, and the like. In some embodiments, a protrusion on the mounting device can be used to secure the mounting device to an structural element.
[0061] Additional methods of mounting a pv module of the present invention include first providing a pv module (e.g., a frameless pv module). At least one mounting device is then attached to the pv module via an interface of a first surface of the apparatus. As described herein, suitably the apparatus is adhered to the pv module using an adhesive. The pv module is then positioned on a support member.
[0062] A pv module can be mounted utilizing one ore more mounting devices of the present invention, and suitably, in some embodiments, a pv module can comprise two or more mounting devices (e.g., two, three, four, six or eight mounting devices). When utilizing two mounting devices of the present invention to position a pv module, the mounting devices can be attached to a pv module in one or more aligned rows.
[0063] The mounting devices and methods dramatically decrease the amount of hardware used to fasten pv modules and/or solar panels to a support member, thereby decreasing cost and installation time. For example, by eliminating threaded fasteners that are typically used for pv module installation, the pv modules can be installed by a single person using minimal tools.
[0064] Moreover, the centerline mounting devices of the present invention reduce the potential for over- stressing a pv module or solar panel, thus increasing safety, decreasing cost and minimizing maintenance. The minimal amount of materials used also decreases the overall cost of the mounting system both in terms of base cost and shipping costs associated with transfer of components to an installation site.
[0065] As noted herein, the mounting device of the present invention is suitable for mounting and supporting a frameless pv module, including pv modules comprising one or more layers of a-Si. The ability to mount frameless modules without the use of screws or other attachment pieces, simply by coupling the mounting device to a support structure (e.g., an architectural element) greatly increases the ease of installation. - 42 - EXAMPLES
Prophetic Example 1
[0066] A mounting device of the present invention will be attached to a-Si pv module using a structural adhesive (Dow CORNING® 995 Structural Adhesive) by applying the adhesive to the mounting device and affixing the coated mounting device to an edge of a backside of an a-Si pv module. The structural adhesive will be cured, and the mounted pv module will then be positioned on a support structure (e.g., an I-beam) by aligning the mounting device with and end of the member and coupling the mounting device with the support structure. Such an arrangement is graphically depicted in FIGs. 4 and 5.
CONCLUSION
[0067] These examples illustrate possible embodiments of the present invention. While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. It will be apparent to persons skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.
[0068] It is to be appreciated that the Detailed Description section, and not the Summary and Abstract sections, is intended to be used to interpret the claims. The Summary and Abstract sections can set forth one or more, but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.
[0069] All documents cited herein, including journal articles or abstracts, published or corresponding U.S. or foreign patent applications, issued or foreign patents, or any other documents, are each entirely incorporated by reference herein, including all data, tables, figures, and text presented in the cited documents.

Claims

WHAT IS CLAIMED IS:
1. A mounting device for affixing a photovoltaic module to a support member, the mounting device comprising:
a first surface suitable for affixing to a surface of a photovoltaic module; and a second surface including
a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and
a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch suitable for coupling with a support member.
2. The mounting device of claim 1, wherein the notch includes a mouth portion and a body portion, wherein the mouth portion has a lateral dimension that is less than a lateral dimension of the body portion.
3. The mounting device of claim 1, wherein the mounting device further includes a long axis, and the notch is substantially orthogonal to the long axis.
4. The mounting device of claim 1, wherein the protrusion further includes a flexible cantilever element that extends from at least one side of the notch and is suitable for applying pressure to a surface of a support member that is coupled to the mounting device.
5. The mounting device of claim 4, wherein the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member.
6. The mounting device of claim 1, wherein the protrusion further includes open spaces between the one or more structural elements.
The mounting device of claim 1, wherein the mounting device is prepared from a material selected from: steel, galvanized steel, stainless steel, aluminum, and combinations thereof.
A supported photovoltaic module comprising:
a photovoltaic module;
a mounting device coupling the photovoltaic module to a support member, the mounting device including
a first surface affixed to a backside of a photovoltaic module; and
a second surface including
a raised portion protruding from the second surface including one or more structural elements suitable for maintaining the raised portion in a fixed position, and
a protrusion extending from the raised portion, wherein the protrusion and the second surface form a notch coupled with a support member.
The supported photovoltaic module of claim 8, wherein the notch includes a mouth portion and a body portion, wherein the mouth portion has a lateral dimension that is less than a lateral dimension of the body portion.
The supported photovoltaic module of claim 8, wherein the mounting device further includes a long axis, and the notch is substantially orthogonal to the long axis.
The supported photovoltaic module of claim 8, wherein the protrusion further includes a flexible cantilever element that extends from at least one side of the notch and applies pressure to a surface of the architectural element that is coupled to the mounting device.
The supported photovoltaic module of claim 11 , wherein the flexible cantilever element extends from and occludes at least a portion of the notch prior to coupling with a support member.
13. The supported photovoltaic module of claim 1 1, wherein the support member includes a groove having a placement and depth suitable for coupling with the flexible cantilever element, and wherein the flexible cantilever element extends a sufficient to fix the position of the mounting device relative on the support member.
14. The supported photovoltaic module of claim 8, wherein the protrusion further includes open spaces between the one or more structural elements.
15. The supported photovoltaic module of claim 8, wherein the mounting device prepared from a material selected from: steel, galvanized steel, stainless steel, aluminum, and combinations thereof.
16. The supported photovoltaic module of claim 8, wherein the supported photovoltaic module has an active region of about 0.5 m2 or greater.
17. The supported photovoltaic module of claim 8, wherein the supported photovoltaic module is a frameless photovoltaic module.
18. An array of photovoltaic modules comprising the supported photovoltaic module of claim 8.
19. The array of claim 18, wherein the array has a power output of about 20 kW or more.
PCT/US2009/067184 2009-12-08 2009-12-08 Mounting system for photovoltaic module WO2011071489A1 (en)

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