AU2011253866A1 - Cable Support Member - Google Patents

Abstract

A Cable Support Member (10) characterised by a plurality of cradles (12) with a coupling (40) to the structure. The Cable Support Member typically provides cable support and management capabilities for a photovoltaic module's insulated cables and solar array cables but may also be useful for other applications with similar requirements. Fixed cradles permit cables to be managed by looping between the individual cradles. Each fixed cradle can receive, support and grip one or more individual cables depending on cradle depth. Member coupling method varies to suit the structure to which it is fixed. The Cable Support Member (10) also promotes a consistent method of routing (also referred to as "management") of the positive and negative electrical cables of the photovoltaic solar module and return electrical cables used in the installation of photovoltaic solar module arrays, to assist quality control.

Description

1 TITLE OF INVENTION Cable Support Member FIELD OF THE INVENTION The present invention relates generally to the field of cable support, and in one 5 particular aspect to an apparatus and method of securing and supporting cables used in photovoltaic solar arrays. BACKGROUND OF THE INVENTION Photovoltaic solar modules are often mounted on the roofs of buildings using an appropriate metal framework that supports the modules. These metal structures 0 may be fixed onto the roof structure before the modules are installed. The positive and negative direct current (DC) insulated electrical cables of the solar modules are manufactured at set lengths to enable connections to adjacent modules. Generally adjacent modules are connected up in series to form solar strings, and these strings are in turn connected to form a solar array. The ends of 5 the cables are terminated with connectors by the module manufacturer, to enable ease of connection to other modules. Typically after the adjacent cables are connected an excess length of cabling remains. If this excess cabling is not secured it may rest in the troughs of the roofing. This may result in debris, such as leaves and twigs, collecting around the 20 cables over time. The debris retains moisture and the weight of the debris can place a strain on the connectors, which may cause them to separate or loosen. In instances where the connectors are fully or partially separated the risk of short-circuit occurring increases that may further risk combustion of the surrounding material. Furthermore, the portions of cable in contact with the roof surface may deteriorate, 25 risking a short-circuit or a fire as a result of a spark onto dry leaves and twigs. Accordingly in countries such as Australia, safety regulations dictate the need to have the cables secured so that they do not contact with roof surface. Typically cables are secured to the structures that support the solar modules using ties or clips. The cables may also be placed in a tray or conduit to contain and 2 support the cables away from troughs of roofing. There are a number of cable management systems currently available however these suffer from a range of problems, including that they do not take up the excess cable fully, leaving some excess cable unsupported and unsecured that could permit contact between the 5 cable and the roof troughs. Many existing solar system installations inhibit the ease of the cable routing or management, and hence affect the consistent quality of the cable management from module to module. An example is where array structures have integral "slots" or "channels" allowing cables to be tucked therein with no standardised method. 0 Another example is where cables are attached using a variety of ties or clips. The cable can be either over-stretched with sharp-angled bends resulting in break-down or deterioration of the insulation in particular or the cable is not fully supported and the slack contacts the roof. An existing fixing method of using plastic cable ties, require multiple ties to be 5 removed and replaced, in a situation where a routing change or alteration or modification is required. Removal of ties, such as during repair or replacement of a solar module, is usually undertaken by cutting the ties, which may result in accidental damage to cable and/or adjacent structure and equipment, and even cause fatal injury. Furthermore where the cable ties are exposed to sunlight, degradation can '0 result in breakage of the ties, within the life expectancy of the solar module. The existing systems that use trays and conduits may require them to be installed prior to the installation of solar modules. Due to the trays and conduits being partially hidden from the installer when the module is laid over the tray, routing or management of the module cable takes time to ensure cables are correctly placed in the tray and 25 conduits. In some cases, cables are not laid fully into the tray, resulting in the cable being sandwiched between the module and the sharp edge of the tray, with the potential to cause a short-circuit or even a fire. Many existing system such as trays and conduits in use may collect debris and hence retain moisture, increasing the risk 30 of short-circuits at connections of cables due to moisture ingress. Recent changes to legislation also means that each solar panel must be earthed and therefore an earthing cable is required. The term solar panel may also be referred to as module.

3 It should be appreciated that any discussion of the prior art throughout the specification is included solely for the purpose of providing a context for the present invention and should in no way be considered as an admission that such prior art was widely known or formed part of the common general knowledge in the field as it 5 existed before the priority date of the application. SUMMARY OF THE INVENTION In one aspect it could broadly be understood that the invention resides in a support member extending between a first and second fixing means, the support member including a plurality of cable securing means for frictional engagement of at 0 least one electrical cable to inhibit said cable contacting an underlying surface. In accordance with another aspect of the invention, but not necessarily the broadest or only aspect, there is proposed a support member including a plurality of cable securing means for frictionally engaging at least one electrical cable of a photovoltaic solar array, the support member being reversibly fastenable to, and 5 extending between, a first and second fixing means, wherein the electrical cable is inhibited from contacting a roof surface to which said solar array is mounted. The first and second fixing means may be a frame on which the solar array is connected to the roof, or may be the edge of a metal-framed solar module of the solar array. It will be appreciated that the solar array comprises a plurality of solar 20 modules, each of which is supplied with an individual support member. The cable securing means may comprise a plurality of upwardly open cradles having opposing upper portions being resiliently flexible and biased inwardly. Wherein the electrical cable can be inserted into the cradle and held therein by the biased upper portions while preventing damage to the cable. In another form, the 25 securing means may comprise at least one coiled spring member having spring tension to capture said electrical cable. The cable securing means may be integral with the said support member. In one form the support member is constructed of a ferrous or non-ferrous metal having a round cross sectional profile of between 2mm to 3.5mm, and more 4 preferably 3mm. The support member is preferably resistant to corrosion, may be constructed from an UV stabilised material and preferably has good thermal stability. In another form the ends of the support member may include coupling means. The coupling means may comprise hooks or a snap-fit configuration for engagement 5 with the respective fixing members. The coupling means may comprise threaded or similar fixings to enable engagement with the respective fixing members and to secure other peripheral parts. The coupling means may be integrally formed with the said support member. The support member may be constructed from a single length of stainless steel 0 wire having a round cross-sectional profile, being 316 or 304 grade or similar. Alternatively the support member may be constructed from spring steel, plated or galvanised steel. In still another form, the support member can also be made from aluminium extrusion profile having the edges rounded or covered by a plastic or synthetic 5 rubber moulding to inhibit cable damage. In yet another form, the support member may be constructed from a plastic or PVC being resiliently flexible, ultra violet resistant and having good thermal stability. The support member may also be made by bending sheet stainless steel, aluminium sheet or galvanised sheet steel and having the edges rounded or covered 20 by a plastic or synthetic rubber moulding. The cradles may be made separately from a different material and attached to the support member. Depending on the design and required operating environment, any material can be used to construct a spring, provided the material has the required combination of 25 yield strength and elasticity. The support member may be used for routing of DC (direct current) cables of photovoltaic solar modules and of solar array of DC cable routing. The cables may be, but is not limited to, electrical DC/AC cables, and data communications cables.

5 The support member may also be used to support pneumatic or fluid hose. In another aspect of the invention there is proposed a cable management method of routing cables connected to a photovoltaic solar array having a plurality of solar modules, including the steps of: 5 attached a frame to a roof structure; fastening a cable attached to a solar module to a support member having a plurality of cable securing means for frictionally engaging said cable; attached said solar module to said frame; connecting the electrical cable attached to a solar module to an electrical cable of an 0 adjacent solar module wherein said electrical cables are inhibited from contacting said roof surface. The support member may be attached to said frame or to the solar module. It should be appreciated that the order of the above steps may be changed. In one example the step of attached the solar module to the frame may precede the 5 step of fastening the cable to the support member. The cables generally include a copper core or cores, with electrical insulation surrounding the core, and connectors. In one particular aspect the invention relates to the retention and support and the method of management of the positive and negative direct current (DC) insulated electrical cables of the photovoltaic solar 20 modules and of the return or extension electrical cables used in the installation of photovoltaic solar module arrays. The cable management method may also be used to secure loose electrical and data communication cables in other applications. In another broad aspect the present invention relates to a support member for 25 retention and support of direct current (DC) insulated electrical cables of photovoltaic solar panel and solar array, a method of managing the cables, a method of attaching the managed cables to the module or to the structure supporting the modules thus integrating the invention into the solar array system.

6 Although discussed with particular reference to solar arrays it will be appreciated that the support member may be used for managing routing of electrical insulated cable used in a range of applications, such as, but not limited to computing, home entertainment systems, telecommunications or any other application that uses 5 insulated cabling. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate implementations of the invention and, together with the description, serve to explain the advantages and principles of the invention. In the 0 drawings: Figure 1 is a side perspective view of a first embodiment of the support member of the present invention; Figure 2a is a side view of the support member of figure 1; Figure 2b is a side view of the support member of figure 1 illustrating the 5 attachment of the solar modules; Figure 2c is a side view of the support member of figure 1 illustrating the attachment of the solar modules and adjacent support members; Figure 3a is a side view of the support member of figure 1; Figure 3b is a side view of the support member of figure 3a attached to the frame 20 of the solar array; Figure 4a is a side view of a second embodiment of the support member; Figure 4b is a side view of the support member of figure 4a attached to the edge of a solar module; Figure 5a is a side view of a third embodiment of the support member; 25 Figure 5b is a side view of the support member of figure 5a attached to the edge of a solar module; 7 Figure 6 is a side view of a fourth embodiment of the support member; and Figure 7 is a side view of a fifth embodiment of the support member. DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS There are numerous specific details set forth in the following description. 5 However, from the disclosure, it will be apparent to those skilled in the art that modifications and/or substitutions may be made without departing from the scope and spirit of the invention. In some circumstance specific details may have been omitted so as not to obscure the invention. Similar reference characters indicate corresponding parts throughout the drawings. 0 Referring to the drawings for a more detailed description, a support member 10 is illustrated, demonstrating by way of examples arrangements in which the principles of the present invention may be employed. In a first embodiment, as illustrated in figures 1 to 3b, there is shown a support member 10 including a plurality of cable securing means 12 for frictionally engaging an electrical cable 14 of a 5 photovoltaic solar array 16, the support member 10 being reversibly fastenable to, and extending between, first and second fixing means 18, 20, wherein the cable 14 is inhibited from contacting an underlying roof surface 22 to which said solar array 16 is mounted. As illustrated in figure 1 the solar array 16 includes adjacent solar modules 24, 20 26, 28, attached to and supported on fixing means 18, 20 being a framework that is attached to the roof. Cable 14 attached to the solar module junction box 30 of module 26 include male/female connectors 32, 34 that engage corresponding male/female connectors 36, 38 of adjacent modules 24, 28. As illustrated in figure 1 the ends of the support member 10 include respective 25 coupling means 40 for engagement with the framework fixing means 18, 20. Figure 2a illustrates the support member 10 attached to the fixing means 18, 20. The framework fixing means 18, 20 are attached (not shown) to the surface of the roof 22. The solar modules 24, 26, 24 are attached to the framework fixing means 18, 20 using mounts 42 and the cable 14 is engaged with a number of the 8 securing means 12. As further illustrated in figure 2c the cables 14a, 14b of the adjacent modules 24, 28 are supported on corresponding support members 10a, 10b. Furthermore the return cable 44 also engages the securing means 12 to inhibit them coming into contact with surface 22. 5 The cables 14 may be connected to the support member 10 prior to attachment of the modules to the framework 18, 20. This reduces strain on the user's back since the cable 14 can be looped though the cable securing means 12 while the module is in the upright position. After attachment of the module to the framework, the return cable 44 can be then looped through the cable securing means 12 and the 0 support member may be slid along framework 18 and 20 with cables 14 and 44 secured to a position beneath the module. It should however be appreciated that the cables 14 may be connected to the support member 10 after attachment of the modules to the framework 18, 20. It is envisage that the support member 10 will be constructed of a ferrous or 5 non-ferrous metal wire having a generally round cross-sectional profile of between 2mm to 3.5mm however the reader will appreciate that other materials and profiles could be used. As illustrated in figure 3a the ends of the support member 10 include coupling means 40 for attachment to fixing means 18, 20. The coupling means 40 include an O upper portion 46 and a depending biased leg 48. As further illustrated in figure 3b the upper portion 46 rest upon the top of the fixing means 18, 20 and the depending leg 48 impinges on the outer side of the fixing means 18, 20 to frictionally engage the fixing means 18, 20. The configuration of the coupling means 40 ensures that the support member 25 can be slid along the rails into the desired installed position, which is under the solar module 26, once the connection of cables to adjacent modules are made. In another embodiment, as illustrated in figure 4a, the coupling means 40 located at the ends of support member 10 include upwardly and inwardly projecting hooks 50, being configured to engage aperture 52 in the margin 54 of solar module 30 56. As illustrated in the enlarged portions of figure 4b the hook at one end of the 9 support member is set at an angle, when viewed along the longitudinal axis of the support member, to the opposing hook. This inhibits disengagement from the apertures thereby forming a snap-fit configuration held firmly by torsion through the support member for engagement with the fixing means. 5 Figures 5a and 5b illustrate another embodiment of the coupling means 40 including a hook member 58. The hook member at one end of the support member is set at an angle, when viewed along the longitudinal axis of the support member, to the opposing hook. This inhibits disengagement from the apertures thereby forming a snap-fit configuration held firmly by torsion through the support member for 0 engagement with the fixing means. As the reader will now appreciate the support member 10 provides a plurality of cable securing means 12 or gripping cradles for engagement with the insulated electrical cable 14. The cable can be direct current, alternate current, communications cables and the like, having single or multiples cores of copper wire, 5 to be gripped or pinched with a low force that is able to retain or stop the cable 14 from becoming detaching from the securing means 12. A securing means 12 provides a spring-loaded action and friction characteristics to flex open and allow the insulated electrical cable to be pushed into the base of the securing means 12 and flexes back to a narrower opening to stop the O insulated cable from disengaging. This frictional engagement reduces wear on the cable due to repeated movement as a result of wind. The distance between each cradle is such that the looping, or management of cable and the bending radius of the cable is not compromised. In general, the securing means 12 will be in equal depths. In another form, the 25 securing means 12 may be deeper than illustrated to accommodate multiple cables. In another form, the support member may be made of two parts that are joined by welding or by mechanical fixing. This joint feature allows parts to be joined resulting in a selection of lengths to suit different solar modules having different widths and lengths.

10 The insulated cable can be looped or snaked as illustrated in figure 1 to take up excess length which would normally drop down onto the roof surface. The quantity of cradles is decided by how much length of the excess of cable is required to be taken up, what distance is required as a gap between the cable and the roof surface, 5 and what the minimum bending radius is permissible for the cable. Eight securing means 12 are illustrated in the figure to allow the positive and negative cables to be supported, and allow the excess cable to be managed. The securing means 12 allows for the "return" cable for each solar string to be managed, in a typical connection of photovoltaic solar modules in "series". Additional securing means 12 0 may also be used to manage additional necessary cables as required such as earthing cables. The support member 10 may be made of a singular homogeneous material which integrates a securing means 12 arranged to grip the positive and negative electrical cables of the photovoltaic solar module and return electrical cables used in 5 the installation of photovoltaic solar modules and of solar arrays to simultaneously position and support the positive and negative electrical cables of the photovoltaic solar module and return electrical cables used in the installation of photovoltaic solar module arrays. The skilled addressee will now appreciate the many advantages of the '0 illustrated invention. The support member 10 is suited for routing and management of electrical cables and the like for a range of applications including the installation of photovoltaic solar arrays, data communication cabinets, personal computer workstations and home entertainment centres. Various features of the invention have been particularly shown and described 25 in connection with the exemplified embodiments of the invention, however, it must be understood that these particular arrangements merely illustrate and that the invention is not limited thereto. Accordingly the invention can include various modifications, which fall within the spirit and scope of the invention. It should be further understood that for the purpose of the specification the word "comprise" or 30 "comprising" means "including but not limited to".

Claims (20)

1. A member for supporting insulated electrical cables, said member being substantially as hereinbefore described with reference to the accompanying drawings.

2. A member for supporting insulated electrical cables, the member comprising coupling means for engagement to the structure; and a number of securing means or gripping cradles for engagement with the insulated electrical cable adapted to predetermined selective positions within the member.

3. The member of claim 2, according to any preceding claim, in which the quantity of the securing means can vary to take up excess lengths or numbers of cables as necessary.

4. The member of claim 2, according to any preceding claim, in which the depth of the securing means may be increased to secure more than one cable.

5. The member of claim 2, according to any preceding claim, in which the securing means provide a spring-loaded action to flex open and allow the insulated cable to be pushed into the base of the securing means or cradles and flexes back to a narrower opening to stop the insulated cable from disengaging.

6. The member of claim 2, according to any preceding claim, in which the securing means provide friction characteristics such that the frictional engagement reduces wear on the cable due to the repeated movement as a result of wind.

7. The member of claim 2, according to any preceding claim, in which the distance between each securing means or cradle such that the looping, or management of cable and the bending radius of the cable is not compromised.

8. The member of claim 2, according to any preceding claim, in which the coupling means include an upper portion and a depending biased leg, therefore provide a spring-loaded action, which impinges on the outer side of the mounting frame to frictionally engage the mounting frame.

9. The member of claim 2, according to any preceding claim, in which the coupling means located at the ends of the support member include upwardly and inwardly projecting hooks, therefore provide a spring-loaded action, being configured to engage apertures in the margins or edges of solar module.

10. The member of claim 2, according to any preceding claim, in which the coupling means located at the ends of the support member include upwardly, and laterally projecting hooks opposite with respect to each other, therefore provide a spring loaded action, being configured to engage apertures in the margins or edges of solar module.

11. The member of claim 2, according to any preceding claim, in which the coupling means located at the ends of the support member include threaded ends or similar fixings to enable engagement with the respective fixing members and may also secure other peripheral parts.

12. The member of claim 2, according to any preceding claim, can be retained to photovoltaic solar array structure or framework allowing easy and quick removal from the structure or framework.

13. The member of claim 2, according to any preceding claim, can be retained to margins of photovoltaic solar module allowing easy and quick removal of the module from the array of modules.

14. The member has filleted securing means without sharp edges that avoids damage to cable insulation .

15. The member may be used simultaneously as an element of an earthing system.

16. A method of cable management, said method being substantially as hereinbefore described with reference to the accompanying drawings.

17. A method of cable management in several embodiments allow the routing of cable to be managed without tools.

18. A method of cable management to allow repeatability of the cable routing or management, and hence provide consistent cable installation quality.

19. A method for easy and quick reinstallation of an installed photovoltaic solar module in situations that require a module to be lifted or moved with re-use of the member.

20. A method that allows module cable routing and visibility for inspection to be completed on the ground prior to modules being placed on the structures. DATED this Seventh Day of December, 2011 Semkat Pty Ltd