AU2021106499A4

AU2021106499A4 - Mounting apparatus for solar panel installation

Info

Publication number: AU2021106499A4
Application number: AU2021106499A
Authority: AU
Inventors: Matthew Linney
Original assignee: Iberdrola Australia Smart Energy Solutions Pty Ltd
Current assignee: Iberdrola Australia Smart Energy Solutions Pty Ltd
Priority date: 2020-10-12
Filing date: 2021-08-23
Publication date: 2021-11-04
Anticipated expiration: 2029-08-23

Abstract

Mounting apparatus for solar panel installation has a structural mounting rail defining an upper mounting surface against which opposite side attached clamp members can clamp rear frame flanges of adjacent solar panels against the mounting surface in use. 8 2/3 lp r \ 4 Figure 3 Figure 4

Description

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Figure 3

Figure 4

Mounting apparatus for solar panel installation

Field of the Invention

[0001]This invention relates generally to mounting apparatus for solar panel installation.

Background of the Invention

[0002] Solar panels produce electrical energy when light shines on their front surface. DC voltage produced thereby may exceed 30 V and solar panels are increasingly being installed as a source of renewable energy.

[0003] The solar panel typically comprises a photovoltaic (PV) laminate bound by an extruded aluminium frame. These frames typically comprise a rear frame flange supporting a reinforced web having a jaw engaging edges of the panel.

[0004] Solar panels are typically rooftop mounted across horizontal roof mounting rails and attached thereto, typically using top-down clamps bolted to the mounting rails.

[0005] The present invention seeks to provide a mounting apparatus for solar panel installation, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[0006] It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

Summary of the Disclosure

[0007] There is provided herein mounting apparatus for solar panel installation. The mounting apparatus comprises a structural mounting rail defining an upper mounting surface against which opposite side attachment clamp members can clamp rear frame flanges of adjacent solar panels against the mounting surface in use.

[0008] As such, as opposed to prior art top-down clamp arrangements, the present side attachment clamp members engage behind the solar panel frame around edges of the rear frame flanges thereof to allow for installation and maintenance from underneath.

[0009] As such, as opposed to conventional roof mounted installation, the present

apparatus allows for the installation of solar collection shelters without the need for

roof sheet backing wherein the solar panels themselves span adjacently to form a

roof. As such, the present apparatus can be used to quickly and economically erect

various solar collecting shelters, such as for car parks.

[0010] The lack of rear roof sheet backing may allow rear surfaces of bifacial solar

panels to be exposed to collect reflected sunlight, such as from vehicle windshields.

[0011] Each clamp may have a stem flange attachable to a respective side of the rail

and a shorter clamp flange extending orthogonally from an end thereof. The mounting

rail has a width sufficient to reach beyond the extent of the adjacent rear frame

flanges of the adjacent solar panels mounted thereon so that the clamp flanges can

reach around the rear frame flanges to secure the solar panels to the mounting rail.

[0012] Sides of the mounting rail and the stem flange may comprise interlocking teeth

which are orientated along the length of the rail so that clamps can be mounted at

various positions along the rail and which interlock together to resist loosening of the

clamps.

[0013]The present apparatus allows for the installation of solar panels having

conventional frames.

[0014] The mounting rail may comprise side attachment channels through which the

clamps may be quickly and easily attached using the T-headed bolt fasteners.

[0015] The mounting rail may further comprise a central upper locating flange which

stands above the upper mounting surface and which can be used to locate sides of

the adjacent solar panels during installation.

[0016] The present clamp arrangement allows for quick and easy installation and

maintenance of the solar panels from underneath and securely secures the solar

panels without applying excessive force thereto or requiring drilling into the solar

panel frames. The clamps may be independently released to replace individual solar

panels.

[0017] The mounting rail may comprise an underside attachment channel by which

the mounting rail may be attached orthogonally across purlins, either using

attachment brackets or directly thereto.

[0018] The mounting rail may comprise a central upper drain channel recessed

beneath the upper mounting surface which can drain rainwater collected between the

solar panels.

[0019] A box gutter may be attached along a lower edge of a structure using a gutter

bracket attached to the undersurface attachment channel of the mounting rails.

[0020] Sealing gaskets may interface the mounting surface and the rear side flanges

of the solar panels to prevent water leaking from the drain channel.

[0021] Other aspects of the invention are also disclosed.

Brief Description of the Drawings

[0022] Notwithstanding any other forms which may fall within the scope of the present

invention, preferred embodiments of the disclosure will now be described, by way of

example only, with reference to the accompanying drawings in which:

[0023] Figure 1 shows an underside perspective view of a solar collection shelter in

accordance with an embodiment;

[0024] Figure 2 shows a top perspective view of the solar collection shelter;

[0025] Figure 3 shows a cross-sectional elevation view of mounting apparatus for

solar panel installation in accordance with an embodiment;

[0026] Figure 4 shows an exploded representation of a mounting rail and opposite

side attached clamp members of the apparatus;

[0027] Figure 5 shows a side elevation view illustrating the manner by which the

mounting rail can be attached to a purlin; and

[0028] Figure 6 shows a side elevation view illustrating the manner by which a box

gutter may be attached to the apparatus to collect run-off.

Description of Embodiments

[0029] Mounting apparatus 100 for solar panel 101 installation comprises a structural

mounting rail 102. The mounting rail 102 may be generally rectangular in cross section and of uniform cross-section along the length thereof. The mounting rail 102 may be manufactured from an extrusion process and may comprise metal, typically aluminium.

[0030] The mounting apparatus 100 is used for mounting adjacent solar panels 101.

With reference to Figure 3, a solar panel 101 comprises a frame 105 typically

comprising a jaw 106 holding an edge of a PV laminate 107, the PV laminate 107

typically comprising toughened glass, Ethylene-vinyl acetate (EVA), a plurality of

solar cells and a backsheet. A rubber seal may interface the jaw 106 and the PV

laminate 107.

[0031] The frame 105 typically also has a rear frame flange 109 and a reinforced web

108 interfacing the jaw 106 and the rear flange 109.

[0032] The frame 105 is typically aluminium and may have a continuous longitudinal

cross-section made from an extrusion process.

[0033] The mounting rail 102 defines an upper mounting surface 103 against which

to rear frame flanges 109 of adjacent panels 101 can lie side-by-side in the manner

shown in Figure 3. The mounting surface 103 may be planar as shown.

[0034] The apparatus 100 has opposite side clamps 104 which clamp the rear frame

flanges 109 of the adjacent solar panels 101 against the mounting surface 103 in use.

[0035] Each clamp 104 may have a stem flange 110 attachable to a respective side

111 of the mounting rail 102 and a shorter clamp flange 112 extending orthogonally

from an upper distal end thereof. The shorter clamp flange 112 may bear downwardly

on the respective rear frame flange 109 to mount the respective solar panel 101

against the mounting rail 102.

[0036] As is shown in figure 3, the mounting rail 102 may comprise a width sufficient

to extend beyond the adjacent rear frame flanges 109 so that the clamps 102 can

reach around the rear frame flanges 109

[0037] Sides 111 of the mounting rail 102 may comprise side attachment channels

113 running along the length of the mounting rail 102. The clamps 104 may have

corresponding apertures through the stem flanges so that the clamps 104 are attachable to the sides 111 of the mounting rail 102 using fasteners 114 in the manner shown in Figure 3.

[0038] Each channel 113 may defined by edges 115 forming an entrance into a

relatively larger interior 116 thereof. As such, the fastener 114 may comprise a T-bolt

comprising a head 117 narrow enough to fit through the entrance of the side

attachment channel 113 which can then be rotated out of alignment to catch against

the edges 115. A stem 118 of the fastener 114 may be secured with a locknut 119.

[0039] Sides 111 of the mounting rail 102 and interior surfaces of the stem flanges

110 may comprise interlocking teeth 120. The interlocking teeth 120 are orientated

along the length of the rail 102 so that clamps 104 may be located at various positions

along the rail 102 but, when pressed together by the fastener 116, interlock to resist

release of the rear frame flanges 109. The teeth 120 of the clamps 104 may be angled

downwardly whereas the teeth 120 of the mounting rail 102 may be angled upwardly.

[0040] The mounting rail 102 may define a central upper drain channel 121 recessed

beneath the upper mounting surface 103. As can be seen from Figure 3, rainwater

falling between the adjacent solar panels 101 could collect in the drain channel 121

and run-off along the length of the rail 102.

[0041] Figure 6 shows an embodiment wherein a box gutter 126 connected to a

downpipe 122 is attached to a lower end of mounting rails 102 using a gutter bracket

121. With reference to Figure 4, the mounting rail 102 may comprise an underside

attachment channel 124 against which an attachment flange 123 of the gutter bracket

121 may similarly be attached with a T-headed fastener 114.

[0042] The apparatus 100 may comprise longitudinal sealing gaskets 125 (such as of

EPDM rubber) which seal against the rear frame flange 109 to prevent rainwater

seeping from the drain channel 121. A pair of parallel gaskets 125 may be adhered

along the upper mounting surface 103 for each respective rear frame flange 109.

[0043] The mounting rail 102 may comprise a central upper locating flange 127 to aid

location of the sides of the solar panels 101 during installation. The locating flange

127 may comprise a vertical web 128 widening to a rail 129 which stands above the

upper mounting surface 103.

[0044] Figures 1 and 2 show a solar collection shelter 130 built using the apparatus

100.

[0045] The shelter 130 may comprise vertical posts 134, rafters 131 and the purlins

132 thereacross. The rafters 131 may be horizontal but are preferably angled to

provide a sun facing aspect and to aid rainwater run-off.

[0046] With reference to Figure 2, a lower edge of the shelter 130 may comprise the

aforedescribed box gutter 126 and downpipe 122.

[0047] With reference to Figure 5 mounting rails 102 may be mounted orthogonally

across purlins 132 using U-shaped attachment brackets 136. In the embodiment

shown, the purlin 132 is metallic and C-channel shaped and wherein the attachment

bracket 136 surrounds the purlin 132 and has side flanges 133 through which

fasteners 114 engage the underside attachment channel 124 of the mounting rail 102.

In alternative embodiments, the mounting rail 102 may be attached directly to the

purlin 132 using a fastener 114 going through an aperture of a side flange 135 of the

purlin 132.

[0048] The foregoing description, for purposes of explanation, used specific

nomenclature to provide a thorough understanding of the invention. However, it will

be apparent to one skilled in the art that specific details are not required in order to

practise the invention. Thus, the foregoing descriptions of specific embodiments of

the invention are presented for purposes of illustration and description. They are not

intended to be exhaustive or to limit the invention to the precise forms disclosed as

obviously many modifications and variations are possible in view of the above

teachings. The embodiments were chosen and described in order to best explain the

principles of the invention and its practical applications, thereby enabling others

skilled in the art to best utilize the invention and various embodiments with various

modifications as are suited to the particular use contemplated. It is intended that the

following claims and their equivalents define the scope of the invention.

[0049] The term "approximately" or similar as used herein should be construed as

being within 10% of the value stated unless otherwise indicated.

Claims

Claims 1. Mounting apparatus for solar panel installation, the mounting apparatus

comprising a structural mounting rail defining an upper mounting surface against

which opposite side attached clamp members can clamp rear frame flanges of

adjacent solar panels against the mounting surface in use.
2. Apparatus as claimed in claim 1, wherein the clamps have stem flanges

attachable to respective sides of the rail and shorter orthogonally extending clamp

flanges which clamp the rear frame flanges in use and wherein the mounting rail has

a width sufficient so that the clamping flanges can reach around the rear frame

flanges in use.
3. Apparatus as claimed in claim 3, wherein the mounting rail defines side

attachment channels to which the clamps may be attached at various positions

therealong using T-headed fasteners inserted therein.
4. Apparatus as claimed in claim 1, wherein the mounting rail has a central upper

drain channel recessed beneath the upper mounting surface.
5. Apparatus as claimed in claim 1, wherein the mounting rail comprises a central

locating flange which stands above the upper mounting surface.