WO2013043599A2 - Système de gestion de fil solaire de conduite pv - Google Patents

Système de gestion de fil solaire de conduite pv Download PDF

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Publication number
WO2013043599A2
WO2013043599A2 PCT/US2012/055916 US2012055916W WO2013043599A2 WO 2013043599 A2 WO2013043599 A2 WO 2013043599A2 US 2012055916 W US2012055916 W US 2012055916W WO 2013043599 A2 WO2013043599 A2 WO 2013043599A2
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WO
WIPO (PCT)
Prior art keywords
conduit
solar
components
array
designed
Prior art date
Application number
PCT/US2012/055916
Other languages
English (en)
Other versions
WO2013043599A3 (fr
Inventor
Jason MAZZONE
Original Assignee
Mazzone Jason
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
Priority claimed from US13/240,693 external-priority patent/US20130075152A1/en
Application filed by Mazzone Jason filed Critical Mazzone Jason
Publication of WO2013043599A2 publication Critical patent/WO2013043599A2/fr
Publication of WO2013043599A3 publication Critical patent/WO2013043599A3/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/02—Details
    • H01L31/02002—Arrangements for conducting electric current to or from the device in operations
    • H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
    • H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S10/00—PV power plants; Combinations of PV energy systems with other systems for the generation of electric power
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S20/00—Supporting structures for PV modules
    • H02S20/20—Supporting structures directly fixed to an immovable object
    • H02S20/22—Supporting structures directly fixed to an immovable object specially adapted for buildings
    • H02S20/26—Building materials integrated with PV modules, e.g. façade elements
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S30/00—Structural details of PV modules other than those related to light conversion
    • H02S30/10—Frame structures
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/30—Electrical components
    • H02S40/34—Electrical components comprising specially adapted electrical connection means to be structurally associated with the PV module, e.g. junction boxes
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B10/00—Integration of renewable energy sources in buildings
    • Y02B10/10—Photovoltaic [PV]
    • Y—GENERAL 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy

Definitions

  • the present invention relates to an integrated conduit for solar power arrays, which is a system of components assembled together for the purpose of organizing, routing and protecting the conductors, connectors, wires and/or tubing originating from a single or plurality of solar modules with a variety of power management hardware. These wires, connectors, and tubes etc. may be originating from a single or plurality of PV modules, hot-water modules, PV module junction boxes, micro-inverters and/or PV module control modules.
  • the invention further relates to a method of installing the conduit systems directly to a variety of solar arrays using a unique system of integrated fasteners that attach the conduit to a solar array.
  • Solar arrays are typically constructed using mounting systems that are comprised of "rails” or “racking” and “module clamp” components that secure the solar modules to the supporting racking or rails.
  • the rails are usually secured, using additional hardware, to a roof or to a structure on the ground, creating a “roof mount” or “ground mount” array.
  • These types of racking systems are well known in the art and contain wiring, tubing and connectors that route the power produced by the solar modules to certain components like storage tanks, combiner boxes, inverters or PV control modules, electricity distribution panels and then, in the case of solar photo-voltaics (PV), to the utility grid.
  • Conventional methods of mounting PV modules include fastening them to the rails using "mid-clamps” and “end-clamps” that install with stainless steel nut and bolt hardware.
  • the wire management system of the present invention comprises multiple components assembled or integrated together in order to create or integrate a conduit or race-way to virtually any solar power array.
  • the invented components are designed to integrate into/onto a solar power array in an assortment of installation locations (Fig 1A) by attaching the conduit to the racking, or rails, module frames, or frameless modules by using the assortment of hardware provided in the invention (Fig 5D).
  • Fig 1A installation locations
  • Fig 5D the hardware in the system changes accordingly to accommodate different environments on the array.
  • conduit and attachment design features of the invented wire management system can be integrated together to enable the installer to easily elevate, attach, organize, protect and route the wires / components of a PV array directly to the array; in a plurality of installation scenarios.
  • This invented system is specifically designed to elevate, route, protect, and attach the PV wires directly to the array, in close proximity to the solar modules, in an aesthetic and architectural manner. This system allows the installer to easily attach a wire management system directly to:
  • a structural "rack” rail typically made of extruded steel or aluminum (1A.2).
  • Certain extrusion profiles of the conduit system interact with certain components of a typical PV array illustrated throughout the drawing set in a new and unique manner. These unique components are designed to be utilized to create a conduit like environment using the least amount of material and labor, efficiently and effectively providing a wire management system.
  • the invented system may be constructed using certain combinations of component features found in the invention as well as in the field of PV installation and the related arts such as solar hot water and natural daylighting systems.
  • the system may be constructed using certain manufacturing techniques such as plastic extrusion, metal extrusion, injection molding, blow molding, etc. and by forming, rolling, bending, stamping, extruding, casting, molding plastic or composite etc. materials.
  • a) 1A.1 depicts a typical solar array,as seen from above in plan view, including a plurality of solar modules 92 fastened onto racking rails 98 using end clamps 94 and mid clamps 93 .
  • Four sectional viewpoint "cut lines" are depicted using dashed lines and arrows indicating the sight line directions. The viewpoints are labeled with the numbers 1,2,3 and 4 inside the arrows.
  • b) 1A.2 depicts a generic structural rail 90 comprising at least two perpendicular rails which is extruded to varying lengths. These rails may have varying profiles in the field of art, this illustration is intended to show a simplest rail form.
  • c) 1A.3 depicts the edge 99 of a "frameless" PV module 92 which has no additional frame 97 around the perimeter of the module 92.
  • 1A.4 depicts a magnified view of a section of lA. l showing a typical mid clamp
  • e) 1A.5 depicts a magnified view of a section of lA.l showing a typical end-clamp
  • Adjacently depicted above is a section of a solar module 92 with a module frame 97 mounted in its respective location on top of the racking rail 98.
  • g) 1A.7 depicts a section of a solar module 92 frame rail 97 outlined using an oval dashed line.
  • Figure IB depicts a section drawing from viewpoint 1 of lA.l cut at the mid-clamp 93 between two typical solar PV modules 92 mounted on a typical solar racking rail 98.
  • Two preferred models (1B.1, IB.2) of the system are illustrated in their respective installation locations.
  • Two sectional view cut lines are shown using dashed lines and arrows with the number 3 and 4 inside.
  • a) 1B.1 depicts an arc conduit 100 shown installed onto the racking rail 98 using an invented integrated grounding washer 111 integrated into a conduit hanger 110 and then fastened to the array by installing the grounding washer 111 / hager 110 component between the PV module frame and racking rail surface under the mid-clamp 93 using the mid clamp bolt 89 to compress the two surfaces together, thereby mounting the solar module 92, grounding said module to the racking rail 98 and installing a conduit hanger 110. The conduit hanger 110 then cradles and clasps the "arc" shaped conduit 100.
  • IB.2 depicts a second "c" shaped conduit 101 installed onto the frame rail edge
  • This section drawing also illustrates a PV lead wire 106 originating from a PV module junction box 91 being routed into the raceway 103 through the access slit 115 of the "c" shaped conduit 101.
  • Figure 1C depicts a section drawing from viewpoint 3 from lA.l of the rear of a typical solar array with conduit 101 shown installed on the array using fastener 107.
  • a) 1C.1 depicts the racking rail 98 and solar modules 92 installed with the conduit
  • FIG. 1C.2 shows the optional semicircle access holes 116 located along the length of the conduit near the centers of the solar modules to accept the PV leads 106 that originate from the PV module junction boxes 91.
  • Figure ID depicts a section drawing from viewpoint 3 from lA.l of the rear of a typical solar array with conduit 101 shown installed on the array using fastener 107.
  • a) 1D.1 is a magnified portion of ID.3 showing a conduit 101 with an integrated coupler 112 in which the conduit fits directly into the adjacent conduit as shown.
  • ID.2 is a magnified portion of ID.3 showing a conduit 101 installed using an elongated mouth shaped fastener 107 onto the PV module frame rail 97.
  • Figure IE depicts a section drawing from viewpoint 3 from lA.l of the rear of a typical solar array with conduit 101 shown installed on the array using fastener 107.
  • a) 1E.1 is a magnified portion of IE.3 showing a conduit 101 installed using an elongated mouth shaped fastener 107 onto PV module frame rail 97. 1E.1 also illustrates an external coupler 112 designed to install around the C shaped conduit and snap into place, forming a complete raceway between module gaps.
  • IE.2 is a magnified portion of IE.3 showing a conduit 101 installed using an elongated mouth shaped fastener 107 onto the PV module frame rail 97.
  • Figure IF depicts a section drawing from viewpoint 3 from lA.l of the rear of a typical solar array with conduit 100 shown installed on the array using fastener 107.
  • 1F.1 is a magnified portion of IF.3 showing the conduit 100 installed onto
  • Drawing 1F.1 also illustrates the optional semicircle access holes 116 located along the length of the conduit near the centers of the solar modules to accept the PV leads 106 that originate from the PV module junction boxes 91.
  • IF.2 is a magnified portion of IF.3 showing two conduit hangers 110 installed onto the module frame rails 97 of two adjacently located PV modules 92 using the mouth shaped fastener 107 turned perpendicularly and hanging conduit 101. This type of conduit is further detailed in Figure 3C.
  • Figure 1G depicts a section drawing from viewpoint 4 from lA.l of the rear of a typical solar array with conduit 100 shown installed on the rack rail 98 using conduit hangers 110.
  • 1G.1 is a magnified portion of 1G.3 showing the conduit hanger 110 installed at the mid clamp 93 using a bolt and integrated grounding washer 111 to fasten the hanger 110 to the array.
  • 1G.2 is a magnified portion of 1G.3 showing the conduit hanger 110 installed at the end clamp 94 using a bolt to fasten the hanger 110 to the array.
  • Figure 1H depicts four installation scenarios using the various conduit, fastener and grounding hardware provided in the invented system illustrated in axonometric view with the racking rail 98 or module frame rail 97 shown as dashed lines. Additionally, the raceway 103 or wire way 103 created by the conduit is illustrated in the drawings.
  • a) 1H.1 depicts a racking rail 98 with conduit 100 shown fastened using an
  • 1H.2 depicts a racking rail 98 with conduit 101 shown fastened using conduit hanger 110 with grounding washer 111. As illustrated, the bolt is inserted through the grounding washer hole (typically centrally located). The grounding washer is placed under two adjacent PV modules 92 and compressed using the bolt to clamp the module frames 97 down. The grounding washer 111 has "tooth" components that scratch or bite throught the anodized module frames to form a conductive bond between module frames 97 and racking rail 98.
  • c) 1H.3 depicts a solar module frame rail 97 with conduit 101 installed using
  • 1H.4 depicts a solar module frame rail 97 with conduit 100 installed using
  • Figure II depicts six installation scenarios using conduit 101 and 102 integrated with fastener 107 to attach the conduit onto racking rail 90 or PV module 92, 99.
  • a) 11.1 depicts an axonometric view of conduit 101 installed onto module edge 99 creating raceway 103. Additionally, an optional bead of adhesive 117 is shown meant to reinforce the bond between fastener and rail.
  • b) 11.2 depicts an elevation view of the installation scenario illustrated in 11.1.
  • c) 11.3 depicts an axonometric view of conduit 101 installed onto rack rail edge 90 creating raceway 103. Additionally, an optional bead of adhesive 117 is shown meant to reinforce the bond between fastener and rail.
  • d) 11.4 depicts an elevation view of the installation scenario illustrated in 11.3.
  • e) 11.5 depicts an axonometric view of conduit 102 with integrated conductors 104 installed onto frameless module edge 99 with integrated connector 130.
  • a two part snap fitting 113, 125 is provided to clasp the flexible arc conduit 100 closed.
  • f) 11.6 depicts an elevation view of the installation scenario illustrated in 11.5.
  • Figure 1J depicts a conduit 102 with integrated conductors 104, 135 and arc component 100 which creates raceway 103 installed onto frameless PV module edge 99 using fastener 107.
  • a) 1J.1 depicts an elevation view of conduit 102 installed onto a solar module edge 99 with integrated connector 130 relaying current produced by PV layers 96 of PV module 92.
  • 1J.3 depicts an axonometric view of the conduit of 1J.1 and splice / connector components of 1J.2 shown in their respective installation scenarios with arrows indicating the direction in which they would be assembled together.
  • Figure 2A depicts three section drawings from viewpoint 2 showing installation scenarios of conduit 101 mounted on racking rail 98 using various fasteners.
  • a) 2A.1 depicts a conduit 101 cradled by a conduit hanger 110 that is fastened to the racking rail 98 with a compressing tab 109 that is installed into the top rail channel 95 directly at any point along the channel 95.
  • 2A.2 depicts a similar conduit and hanger of 2A.1 installed on a side rail channel
  • 2A.3 depicts a racking rail 98 that is extruded using a different profile. In this installation, there is no channel 95 provided in the side of the rail 98.
  • the conduit is attached using a flat tab 108 fastener that is integrated or extruded into the conduit 101 profile and fastened to the rail 98 using a screw 88.
  • Figure 2B depicts three section drawings from viewpoints 1 and 2 showing installation scenarios of conduit 101 mounted on racking rail 98 using various fasteners and integrated grounding components.
  • a) 2B.1 depicts a section drawing from viewpoint 2 of racking rail 98 with two channels 95 shown as being used to fasten the conduit hanger 110 to the rail 98 using a plurality (two) elongated tabs 109.
  • the conduit hanger 110 cradles and secures a conduit 101.
  • b) 2B.2 depicts a section drawing from viewpoint 1 of racking rail 98, conduit 101 fastened to the rail with a conduit hanger 110 that is secured by inserting a bolt 89 in channel 95 and through a provided hole on the top flat portion of the hanger 110 that mates with the top of the rail 98. The installer then clamps the hanger down by tightening the nut.
  • 2B.3 depicts a section drawing from viewpoint 1 of a similar installation scenario as 2B.2, however the top of the conduit hanger 110 has been replaced with a grounding washer 111 of figure 1H.2 .
  • Figure 2C depicts three section drawings from viewpoint 1 and 2 of three installation scenarios of conduit 100 mounted on racking rail 98 using various fasteners and integrated grounding components.
  • a) 2C.1 depicts a section drawing from viewpoint 2 of racking rail 98 with conduit
  • conduit 100 installed using a conduit hanger 110 fastened using a bolt and nut as shown.
  • the conduit 100 and hanger 110 components illustrated herein have integrated two part snap fittings 125,113 that create a fully enclosed raceway 103 once snapped shut.
  • FIG.3 depicts a section drawing from viewpoint 1 of racking rail similar to 2C.2 however the top portion of the hanger 110 has been replaced with an integrated grounding washer 111 and the top snap fitting has been removed.
  • Figure 2D depicts three section drawings from viewpoint 1 of three installation scenarios of conduit 100,102,126 integrated onto/into racking 98 using various fasteners, grounding and integrated conductor / connector components.
  • a) 2D.1 depicts a section drawing from viewpoint 1 of racking rail 98 with a
  • conduit 100 and conduit hanger 110 with integrated grounding washer 111 and snap fittings 113,125 The drawing attempts to illustrate how the grounding washer component may be integrated into the hanger by over-molding the hanger material around the washer 111 to reinforce the hole in which the bolt 89 is inserted through, giving the hanger more structural support.
  • 2D.2 depicts a section drawing from viewpoint 1 showing the versatility of the hanger 110 profile, adapting to an irregular racking rail profile 98. There is an additional snap fitting 113, 125 component as well, to provide a fully enclosed raceway.
  • 2D.3 depicts a section drawing from viewpoint 1 showing a PVC or composite racking rail 126 with integrated connectors 132 and conductors 129 designed to accept and mate with provided PV module 92,99 connectors 130 which plug directly into the rail connectors 132 through a weatherproof grommet 136.
  • the module is clamped down using similar bolt and nut components 89 found throughout the system.
  • Certain PV components 120,127,106 may be installed inside the integrated raceway 103 of the racking rail 102.
  • the raceway is accessible through the flexible conduit 100 which is opened and closed using the two part snap fitting 113, 125.
  • Figure 2E depicts three section drawings from viewpoints 1 and 2 of three installation scenarios of racking rail 126 using various integrated conduit profiles, conductors and connectors.
  • a) 2E.1 depicts a section drawing from viewpoint 1 showing a racking rail 126 with conduit 101 integrated into the extrusion profile. Furthermore, the grounding washer 111 has been adapted to connect and bond to a connector 131 which electrically and structurally bonds to a wire conductor 104 embedded or co- extruded into a rail 126 profile.
  • 2E.2 depicts a section drawing from viewpoint 2 showing a racking rail 126 with conduit 100 integrated into the extrusion profile. Furthermore, the embedded conductors 104, 135, 122 are illustrated showing two part connectors 131 that are designed connect and bond electric circuits / leads 106 originating from PV system components to conductors 104, 135, 122 embedded, isolated and insulated in the rail 126.
  • c) 2E.3 depicts a section drawing from viewpoint 2 showing a racking rail 98, 126 with integrated conduit hanger or "lip" 126. This drawing further illustrates a shelf for a variety of PV components 120. From the PV component, originates a PV lead 106 that is routed to a two part connector 131 designed to route the lead 106 to conductors embedded in the rail 126. The lead 106 and conductors 104 may be used as a ground, positive, negative, neutral or communication cable intended for a variety of system functions.
  • Figure 2F depicts two section drawings from viewpoints 1 and 2 of two installation scenarios of racking rails 98 and 126 using various integrated conduit profiles, conductors and connectors.
  • a) 2F.1 depicts a section drawing from viewpoint 1 of a racking rail 98 that has a conduit component 102 installed using a hanger 110 with integrated connectors 132 and conductors 129.
  • the hanger connectors 132 are designed to accept and bond the PV module junction connectors 130 through the protection of a weatherproof grommet 136.
  • the integrated conductors 129 of the hanger are routed from the module 92 to another connector 132 which is designed to attach or connect to PV leads which may be routed to a variety of PV power management components 120 located in the raceway 103 provided.
  • the raceway is created by the conduit 100 component that is illustrated being secured to the hanger using snap-fitting 113, 125.
  • the entire unit illustrated is shown being clamped together using the nut and bolt assembly.
  • the nut and bolt assembly 89 may be located anywhere on the module.
  • a hole may be drilled through the module 92 to allow this unit to be located under the module 92 instead of at a mid-clamp 93 location,
  • 2F.2 depicts a section drawing from viewpoint 1 of a racking rail 98 with conduit
  • FIG. 1A depicts a section drawing from viewpoint 3 showing a two versions of conduit model 101 installed on a solar module frame 97 using an elongated mouth shaped fastener with teeth features and a reinforcing clip 114.
  • Figure 3B depicts a section drawing of a variety of conduit models with integrated mouth shaped fasteners 107.
  • a) 3B.1 depicts manufacturing profiles of a conduit 101 and conduit hanger 110 model beings separated and sat side by side in elevation.; where said mouth shaped fastener component 107 of the conduit is formed or extruded in a closed position so that upon opening while being pushed/installed onto a rail 97,90,99 the mouth 107 exerts a clamping force because the plastilene is flexed open and wants to return to its original form.
  • the drawing further illustrates the nominal thickness of certain parts of the components 101,110 necessary to achieve flexibility and rigidity in the appropriate tolerances to function under duress.
  • 3B.2 depicts a similar installation scenario as 3B.1, however in this drawing the model has an integrated mouth fastener 107 profile extruded along the entire length of the conduit 101.
  • a similarly shaped conduit 101 coupler 112 is provided that snaps snugly into place and continues the partially enclosed raceway 103 across module 92 gaps.
  • Fig 3C depicts a conduit hanger 110 model that has the mouth fastener 107 turned ninety degrees in a perpendicular fashion. This is intended to universally attach to the module frame rails 97 of common PV modules that are perpendicular to the racking rails. This model is, of course, applicable in many installation scenarios to hang a conduit across a gap in a solar array or other areas of the industry.
  • 3C.1 is an axonometric view of said ninety-degree hanger 110 and conduit 101.
  • 3C.2 is an elevation view showing certain basic dimensions of both conduit 101 and conduit hanger 110 in relationship to each other.
  • SC.3 is a section view from viewpoint 3 showing the relationship between two hangers 110, a single conduit 101 spread over a gap between two solar modules 92.
  • Fig 4A depicts four section drawings from viewpoints 5 and 6 of four different versions of conduit models 101,102,126 shown as a conduit that is designed install onto a plurality of solar modules mounted adjacently to each other.
  • the conduits uses the mouth fastener 107.
  • This fastener may be used to mount the solar module on a building fa ade, and mate with said building fa ade.
  • the conduits illustrated work to align, mate and bond said modules together in an array form or building integrated application.
  • the conduit may or may not have integrated conductors / connectors. If no integrated conductors are present, as in 4A.3 and 4A.4, the conduit offers a wire way for said system leads 106.
  • a) 4A.1 depicts a section drawing from viewpoint 6 of two adjacently located PV modules 99 with integrated conductors 130, 132 and an additional wire way 103 provided by conduit 101.
  • the conduit is separated into two parts and may be majorly assembled from below or inside a building.
  • the conduit may contain certain connectors 104,134,135 designed to integrate the modules and system component 120 leads 106 together.
  • 4A.2 depicts a section drawing from viewpoint 5 of two adjacently located PV modules 99 installed into one conduit 102 with integrated conductors 104 and connecter 132 and providing raceway 103.
  • 4A.3 depicts a section drawing of a conduit model from a similar viewpoint as the previous 4A.1 and 4A.2.
  • this drawings illustrates a model of conduit with no integrated conductors.
  • the conductors and connectors are integrated into the PV module 99 only.
  • the elongated mouth fastener 107 and module 99 have one half of a snap-fitting integrated into them, so that they may mate together and secure the conduit 107 to the modules 99.
  • 4A.4 depicts a similar section drawing as 4A.3 of similar invented system
  • Fig 4B illustrates four different versions of a model of conduit 101 installed onto a frameless PV module 99 with and without integrated conductors 104.
  • the drawings on this sheet are intended to illustrate the various conduit 101 forms.
  • FIGS. 5A, 5B and 5C depict a plan drawing of three different solar PV arrays as seen from below the array.
  • the drawings illustrate the variable location and circuit design of certain components of certain types of system designs using the conduit with integrated conductors as described.
  • a) 5A illustrates an array of modules connected in string series.
  • the circuit of energy from the modules is illustrated being routed through the module junction box 91 connector 130 to a connector in the rail 132 through the integrated raceway 103 or conductors 104 of the conduit 101 to a junction box 120, inverter 120 or control module management unit 120.
  • Section viewpoint 6 is illustrated as a dashed line showing the cut line with an arrow indicating the direction of view.
  • b) 5B illustrates an array of modules connected together using splicing connectors
  • This type of array can be described as being comprised of module junction boxes 91 that may have integrated DC control modules 119 or micro-inverters 119.
  • the cables illustrated are shown to connect to various control modules 91 or micro-inverters 91 located throughout the system in the modules 99 or integrated in the conduit 102.
  • the cable or circuit of power generated by the array is illustrated leading directly to a power management unit 120 or inverter etc.
  • c) 5C illustrates an array of modules 92 connected together using splicing connectors 133,134 and connectors 130,132 in a combined circuit that combines the power generated by each module 92, 99 into one cable of multiple conductors 104 from multiple circuits including the positive, negative, neutral, ground, and communication conductors 104 necessary to the function of said PV components.
  • This type of array can be described as being comprised of DC control modules or micro-inverters.
  • the circuit illustrated is shown to lead to various control modules 91 or micro-inverters 91 located throughout the system in the modules 99 or conduit 102.
  • the power generated by the array is illustrated leading directly to a power management unit 120 or inverter etc.
  • Section viewpoint 6 is illustrated as a dashed line showing the cut line with an arrow indicating the direction of view.
  • Figure 5D illustrates a simple concept drawing of the versatility of the system components.
  • This drawing attempts to illustrate the various combination of fasteners 107,108,109,110,111 and basic conduit forms 100,101,102 with optional integrated conductors 104 135 and connectors 130,132.
  • the basic function of the conduit invented system is to provide an integrated raceway 103 to contain and route the PV leads 106 and/or integrated conductors 104,135 in a plurality of component combinations creating a multitude of installation scenarios described and illustrated herein.
  • the PV conduit system provided is designed to be easily installed and to assist in constructing a safe, aesthetically pleasing solar array in a stand alone or building integrated manner. It is an object of the present invention to provide a wire / conductor management system or integrated conduit that elevates, organizes, routes, protects, contains and/or retain the wires/conductors found in a typical solar array. In a solar PV array, this creates an organized installation in which the wires are elevated off the rooftop or ground in a neatly secured fashion using the integrated conduit.
  • ARRAY WIRES / COMPONENT CONDUCTORS / PV CONNECTORS (104,105,106):
  • the conductors found currently in the field of art that this system integrates with and manages can be described as the conductors, wires or leads 106 that are fastened and bonded to a single or plurality of PV components that make up a solar array. These conductors are most often attached to solar modules from the factory and the wires that the installer must connect to the factory solar module wires. These wires are necessary to complete a photo-voltaic array and are commonly referred to as PV wires, module wires, trunk cables, high and low voltage conductors and/or home-runs.
  • These wires carry the electrical current produced from the solar modules through a series of special weatherproof outdoor DC rated PV connectors 105 through and from the solar array to a combiner box(es) or junction box, inverter, micro-inverter, PV control module, power management unit etc. or any other component 120 that accepts these conductors for whatever functional purpose.
  • these conductors 104 may be integrated or embedded into the conduit.
  • TWO-PIECE SYSTEM This wire management system is essentially a two piece system that may be separate or integrated together into one component. This two-piece system is comprised of the conduit component 100,101,102,103 and the fastener 107,108,109,110,111 component. In addition to these components, each model may have additional and optional components described in the drawing set and specification.
  • conduit is designed to be modularly mounted in an adjacent and/or parallel fashion onto the array in a multitude of scenarios or installation locations, for example :
  • a first scenario is to fasten a conduit directly onto and along the inside or
  • a second scenario is to fasten a conduit directly onto and running next to the "rack" or “rail” 90,98 that structurally supports the solar modules.
  • the conduit is running under the array, parallel to the rail 90,98. It is understood that the fastener features may be scaled up or down to
  • a third scenario is to fasten a conduit directly onto a "frameless" solar PV
  • a frameless module is basically a solar panel with the frame removed.
  • the resin or glass "back-sheet" of the panel may be clear or transparent instead of the typical white or black. This clear back-sheet allows the solar module to be used as a window or glass fa ade or building integrated photovoltaic (BIPV) module.
  • BIPV building integrated photovoltaic
  • a fourth scenario is to fasten and mate a conduit with integrated conductors and connectors onto a frameless solar module or typical solar module in order to eliminate the need for wires, increasing aesthetic appeal and the associated additional labor of installing said wires 106.
  • the basic (no integrated conductors) wire management conduit 100,101 is tailor-able to the specific project array components 90,92,97,98.
  • the installer may choose to route the wires 106 along the module supporting rail(s) using one of the models described in this document (illustrated in drawing set) or he / she may choose to install the conduit 100,101 on each individual solar PV module/panel frame 97 in a series along the array (illustrated in drawing set).
  • SYSTEM ADAPTABILITY The system components are available in different designs that attach in different scenarios throughout the array. The specific hardware or components available are based upon certain scenarios that in turn depend upon certain design criteria, for example: the installer's preference, project budget, the location on the array where the installer would like to attach the conduit, the manufacturer or model of certain components in the PV array, preferred materials, whether the installer wants to hang the conduit and ground the modules to the rails in one operation (using a conduit -hanger 110 with integrated grounding washer 111 that mounts between the module and rail, thereby bonding the two together once installed.
  • the conduit is installed in the manner in which it was designed; using the attachment features or hardware accordingly.
  • the PV array wires, conductors and/or connectors are located to the conduit access holes 116 or access "slit" 115, the conduit 100,101 may be flexed outward or open to accept the wires and/or connectors.
  • the wires and connectors 106,95 are then routed into the conduit 100,101 in an organized manner (2D).
  • the conduit is ideally installed as close to the PV module junction boxes 91 (source of module wires) as possible. After the PV conduit is installed, the installer will then thread, feed, push or route the wires 106 into the PV conduit.
  • the electrical leads originating from a PV module may be shortened and connected to a connector 130 that is mated and bonded to another connecter 132 of inverse shape embedded in the conduit 102.
  • Connector 132 may be bonded using embedded foil or wire 129 to various conductors 104 adapted to route the electrical current to various system components 120.
  • These embedded connectors / conductors should be designed and manufactured to existing UL listed solar electrical connectors which are designed to conduct the electricity produced from the PV array modules 92,99 and route it into an elongated conductor or wire 104 that is factory integrated or easily integrated onsite into the conduit 102.
  • RAIL CONDUCTOR SPLICE (133,134): In order to provide a continuous circuit, certain electrical splice connections may be necessary to bond adjacently located conductors 104 embedded in the conduit 102.
  • PV conduit 102,124,126 may contain integrated, pre-terminated electrical conductors with PV connectors that are designed to create a safe, weatherproof electrical bond between an assortment of PV system components using a UL listed connector, thereby forming a weather- tight, secure connection between any two of the following PV components 119,120:
  • PV conduit 102 systems conduit with integrated conductors and connectors, contains pre-terminated conductors and connectors that are designed to mate and bond certain PV connectors and/or other PV system components together.
  • PV conduit 102 may fasten directly to the PV module 92,99 or racking rail to form a single or plurality of UL listed electrical connections. Additional grounding, communication and high voltage conductors 135 may be integrated into the conduit.
  • the PV conduit may be scaled larger and/or have certain design features that allow for certain PV system components to be integrated or attached to the provided raceway 103 or outside surface of the PV conduit 102.
  • LINEAR FASHION, COUPLERS (112) Certain conduit models are designed to be butted and mounted next to one another in a linear, adjacent, modular fashion forming a wire-way, raceway or conduit.
  • CONDUIT PROFILE ADAPTABLITY The conduit profiles of the invented system are designed to adapt to different racking or modules using certain and non-certain illustrated and described extrusion profiles with integrated or separate attachment features and/or hardware that work together to install a functioning wire-way. There are two major conduit profile shapes 100,101 disclosed in the preferred model of the invention. They are described as “C” 101, "arc” 100 shaped). This conductor management system can adapt according to certain project demands. CONDUIT PROFILE SCALABILITY: It is understood that the conduit profiles of the invented system can alter slightly in scale or dimension to accommodate the future demands, dimensions and specifications of certain products coming to market in the future.
  • CONDUIT PROFILE SHAPE VARIATION It is understood that the invented conduit profile may have many shapes that create the wire-way.
  • the invention is a claiming to be a combination of said profiles and fasteners. In the preferred model of the system, there are two main shapes.
  • the first is an "arc” or “L” or linear shaped conduit 100 that uses the rail surface to create a partially enclosed wire-way.
  • the second is a "c","u” or “v” shaped conduit 101 that is a partially enclosed wire-way by itself.
  • the "arc" shaped conduit 100 form creates create a raceway 103 by using an "arc” shaped conduit component.
  • This conduit 100 extrusion profile works in combination with the surfaces of neighboring array components such as the module frames and the racking rails.
  • the raceway is formed when the "arc" conduit is installed onto certain components of the PV array specifically the PV module(s), racking, stanchions, rails, framing and/or along the racking, module frames.
  • the enclosure is created when the conduit is installed adjacent onto the surfaces, corners or recesses of the neighboring array components
  • conduit may be scaled up to be large enough to work as a race way 103 that may contain certain PV components 120 and the associated wiring. In the future it is expected that these components will become smaller (i.e. PV control modules, micro-inverters etc) and may be embedded directly into the raceway provided or the solar module.
  • COMPONENT MATERIALS All PV conduit system components are to be formed of various plastic, metal or composite materials that are known to withstand UV exposure and other extreme environmental factors well. For example PVC and ASA.
  • each of the plastic components may include a ultra-violet (UV) coating to provide protection against the harmful effects of the ultra-violet rays.
  • UV ultra-violet
  • the metal components may be painted, galvanized and/or anodized etc. to further protect them.
  • CONDUIT ACCESS SLIT / HOLES (115,116):
  • the conduit profiles are designed to allow wires to be inserted into the conduit at any point along its length, due to the "slit” 115 that is formed, created by the "arc” conduit 100, or by the slit 115 that is molded into or extruded into or cut along the "c" shaped conduit 101 components.
  • All conduit models may have access holes 116 that are punched out or cut out from the conduit to allow wires 106,135 to be fed into the conduit from array electrical components 92,99,120,127.
  • these access holes 116 are semi-circle in shape and are located directly adjacent the PV module junction boxes 91 and PV leads 106, usually at the top of the conduit. It may also have no "factory cut” openings so that the installer may cut or snip or punch openings exactly where they want them for aesthetic / functionality purposes.
  • Each model of conduit may be adapted to a specific location on the array where the installer prefers to route the PV wires 106 using a conduit component and an attachment feature or hardware.
  • the system can be designed using many different variations of the model that are designed to attach to either the modules 92, 99, module frame rails 97 or the racking rails 98 found in most solar arrays.
  • the major factor that will determine the wire management system design is whether the conduit will be mounted onto the frame or edge of a PV module, or whether the conduit will be mounted onto the supporting rack or rails.
  • the conduit may be easily co-extruded into the racking or rails or module rails as illustrated in drawings 2D.3,2E.1,2E.2,2E.3.
  • the conduit may be co-extruded, embedded, pre-assembled or integrated into the racking, rail or module components in the manufacturing setting.
  • MOUTH CLAMP FASTENER (107) This "mouth clamp” fastener is made using a profile that is integrated or extruded into the conduit or conduit hanger at different scales to accommodate the various dimensions of different components found in the field of art.
  • This clamp component may also be surrounded with a single or multiple reinforcing clips 114 that are constructed of weather resistant composite or metal to further secure the conduit and/or conduit hanger component to the rail that it is being fastened to.
  • TAB / COMPRESSING FASTENER (108) If the installer is installing the conduit on the rails using a channel 95 that may be integrated into the manufacturers' rail 98 extrusion profiles.
  • the tab fastener component is designed to slide or push directly into the channel 95 commonly located along most racking rails. The tab is integrated to the conduit extrusion profile or hanger profile. The tab component is then used to hang or affix the conduit to the array.
  • the independent hanger component is designed to cradle and secure the conduit to the array.
  • the hanger component can be fastened using said system fasteners and/or additional hardware like screws 88 or bolts 89.
  • the hanger 110 can accommodate multiple types of existing conduits in the field, and an ever expanding range of rail
  • the grounding hanger component can effectively ground PV modules to module mounting rails using an integrated, thin conducting metal washer that is textured and upon compression, scratches the finish coating typically found on an aluminum PV module frame and it supporting rail, thereby establishing a conductive bond between the two metal components of a typical PV array.
  • the conduit hanger 110 with integrated grounding washer 111 can effectively perform two tasks in the construction of a PV array, grounding the PV modules 92,99 to the racking 90,98 and cradling / clasping the PV conduit 100,101,102.
  • Each of the conduit-like components may be installed with structurally enhancing hardware like retaining clips, screws etc to work in combination with the conduit to secure the conduit to the array. All of the conduit models may be installed by simply attaching the conduit components to the array, rails or underneath the module frames by using cable ties or by securing them with other mechanical fasteners commonly used in the associated trades.
  • ADHESIVES (117): Certain adhesives may be used to assist in long term bonding between conduit fasteners and certain rails of the installation scenario.
  • conduit profiles may be retro-fitted with an integrated component that allow a single or plurality of cable ties to be fed through the adapter (or holes punched in conduit) and then wrapped around a large variety of rails/racking commonly used in the industry.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Civil Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Energy (AREA)
  • Sustainable Development (AREA)
  • Supports For Pipes And Cables (AREA)
  • Laying Of Electric Cables Or Lines Outside (AREA)

Abstract

La présente invention porte sur une conduite intégrée à conducteurs et connecteurs incorporés facultatifs, spécifiquement conçue pour être intégrée dans un générateur solaire moderne ou jouer son rôle. Ce système de conduite ou « conduite solaire » ou « conduite PV » est conçu pour organiser, contenir, protéger et router les fils, conducteurs, tubes, composants et/ou connecteurs couramment présents dans un générateur solaire, en particulier un générateur photovoltaïque (PV) solaire.
PCT/US2012/055916 2011-09-22 2012-09-18 Système de gestion de fil solaire de conduite pv WO2013043599A2 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US13/240,693 US20130075152A1 (en) 2011-09-22 2011-09-22 Photo-voltaic (pv) wire management system or pv conduit
US13/240,693 2011-09-22
US29/402,704 2011-09-26
US201129402704 2011-09-26
US201213357471A 2012-01-24 2012-01-24
US13/357,471 2012-01-24

Publications (2)

Publication Number Publication Date
WO2013043599A2 true WO2013043599A2 (fr) 2013-03-28
WO2013043599A3 WO2013043599A3 (fr) 2013-09-12

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10243505B1 (en) 2016-03-07 2019-03-26 Raceway Racking, Inc. Wire management racking system for photovoltaic solar modules
EP3769414A4 (fr) * 2018-03-19 2022-03-02 Lumeta, LLC Appareil et procédé pour panneau solaire avec gestion intégrée de câbles
WO2023217334A1 (fr) * 2022-05-10 2023-11-16 Alumero Systematic Solutions Gmbh Agencement de module photovoltaïque pliable comprenant deux modules photovoltaïques

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6084180A (en) * 1993-11-15 2000-07-04 Debartolo, Jr.; Joseph V. Multi-channel duct for power and tel/com conductors
US6465724B1 (en) * 1998-07-28 2002-10-15 Bp Solar International Llc Photovoltaic module framing system with integral electrical raceways
US6768050B2 (en) * 2001-02-17 2004-07-27 The Lamson & Sessions Co. Conduit connector apparatus
US20060086382A1 (en) * 2004-02-13 2006-04-27 Plaisted Joshua R Mechanism for mounting solar modules
US7297874B2 (en) * 2002-05-29 2007-11-20 Yazaki Corporation Fixture for long member
US7638712B2 (en) * 2006-07-28 2009-12-29 Yazaki Corporation Protector
US7845126B2 (en) * 2008-09-23 2010-12-07 Architectural Glass And Aluminum Corporation, Inc. UL compliant building integrated photovoltaic conversion system

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6084180A (en) * 1993-11-15 2000-07-04 Debartolo, Jr.; Joseph V. Multi-channel duct for power and tel/com conductors
US6465724B1 (en) * 1998-07-28 2002-10-15 Bp Solar International Llc Photovoltaic module framing system with integral electrical raceways
US6768050B2 (en) * 2001-02-17 2004-07-27 The Lamson & Sessions Co. Conduit connector apparatus
US7297874B2 (en) * 2002-05-29 2007-11-20 Yazaki Corporation Fixture for long member
US20060086382A1 (en) * 2004-02-13 2006-04-27 Plaisted Joshua R Mechanism for mounting solar modules
US7638712B2 (en) * 2006-07-28 2009-12-29 Yazaki Corporation Protector
US7845126B2 (en) * 2008-09-23 2010-12-07 Architectural Glass And Aluminum Corporation, Inc. UL compliant building integrated photovoltaic conversion system

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10243505B1 (en) 2016-03-07 2019-03-26 Raceway Racking, Inc. Wire management racking system for photovoltaic solar modules
EP3769414A4 (fr) * 2018-03-19 2022-03-02 Lumeta, LLC Appareil et procédé pour panneau solaire avec gestion intégrée de câbles
WO2023217334A1 (fr) * 2022-05-10 2023-11-16 Alumero Systematic Solutions Gmbh Agencement de module photovoltaïque pliable comprenant deux modules photovoltaïques

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