Classifications

• • 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
  • 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
  • H02S20/23—Supporting structures directly fixed to an immovable object specially adapted for buildings specially adapted for roof structures
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
  • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
  • F24S25/30—Arrangement 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
  • F24S25/33—Arrangement 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 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
  • F24S25/35—Arrangement 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 forming substantially planar assemblies, e.g. of coplanar or stacked profiles by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
  • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
  • F24S25/30—Arrangement 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
  • F24S25/33—Arrangement 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 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
  • F24S25/37—Arrangement 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 forming substantially planar assemblies, e.g. of coplanar or stacked profiles forming coplanar grids comprising longitudinal and transversal profiles
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
  • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
  • F24S25/60—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules
  • F24S25/63—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for fixing modules or their peripheral frames to supporting elements
  • F24S25/634—Clamps; Clips
  • F24S25/636—Clamps; Clips clamping by screw-threaded elements
• • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
  • F24—HEATING; RANGES; VENTILATING
  • F24S—SOLAR HEAT COLLECTORS; SOLAR HEAT SYSTEMS
  • F24S25/00—Arrangement of stationary mountings or supports for solar heat collector modules
  • F24S2025/80—Special profiles
  • F24S2025/801—Special profiles having hollow parts with closed cross-section
• • 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
  • Y02E10/40—Solar thermal energy, e.g. solar towers
  • Y02E10/47—Mountings or tracking
• • 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

• Embodiments of the subject matter described herein relate generally to devices and systems from mounting solar modules to fixed surfaces such as roofs.
• Solar photovoltaic systems can employ solar panels made of silicon or other materials (e.g., III-V cells such as GaAs) to convert sunlight into electricity.
• Photovoltaic systems typically include a plurality of photovoltaic (PV) modules (or “solar tiles”) interconnected with wiring to one or more appropriate electrical components (e.g., switches, inverters, junction boxes, etc.).
• PV photovoltaic
• a typical conventional PV module includes a PV laminate or panel having an assembly of crystalline or amorphous semiconductor devices ("PV cells”) electrically interconnected and encapsulated within a weather-proof barrier.
• PV cells crystalline or amorphous semiconductor devices
• One or more electrical conductors are housed inside the PV laminate through which the solar- generated current is conducted.
• PV laminate Regardless of an exact construction of the PV laminate, most PV applications entail placing an array of solar modules at the installation site in a location where sunlight is readily present. This is especially true for residential, commercial or industrial applications in which multiple solar modules are desirable for generating substantial amounts of energy, with the rooftop of the structure providing a convenient surface at which the solar modules can be placed.
• An aspect of at least one of the embodiments disclosed herein includes the realization that certain known mounting systems for mounting solar modules to fixed surfaces such as roofs include excessive components that can be either reduced or eliminated and can require excessive labor for removing and replacing modules.
• one known solar module mounting system is commercially available from Zep Solar.
• the Zep Solar system from mounting photovoltaic modules to a fixed surface such as a roof include three unique parts.
• the Zep Solar system includes splicing interlocks which are used to connect the frames of two adjacent modules together.
• a separate leveling foot is used only in locations where the leveling foot can be attached directly to frame of a module and where it is necessary to include a roof anchor.
• a third device known as a "hybrid interlock" includes both splicing/interlock features for attaching two adjacent modules to each other as well as a connection for anchoring the splicing device to the roof.
• the Zep Solar mounting system noted above also suffers from difficulties.
• the Zep Solar splice device includes a rotatable fastener that extends and rotates about an axis that is generally horizontal.
• the rotatable fastener includes an engagement face for engaging a tool that also must faces horizontally.
• a special tool is needed that includes a fastener engaging portion that extends at a right angle. The tool must be inserted between two adjacent solar modules and moved so that the engagement portion reaches the engagement face of the rotatable fastener. This procedure can be particularly difficult when a worker is attempting to reach solar module that is surrounded by other modules, and thus in a position in which it is difficult to achieve the alignment of the special tool and the engagement face of the rotatable fastener.
• a mounting system for mounting solar modules to a fixed structure such as a roof can be configured to allow solar modules to be removed from an array of solar modules without the need to slide adjacent solar modules off of rails. Further benefits can be achieved by configuring a solar module mounting system such that the engagement portions of the mounting system can be removed by engaging upwardly facing fasteners. Additionally, further benefits can be achieved by configuring a solar module mounting system such that vertical adjustments can be made to the mounting height of solar modules by engaging adjustment mechanism with an upwardly facing engagement portion.
• a height-adjustable roof anchor for solar modules can comprise a base having a hole therein, the hole comprising an inner wall.
• a height adjustment member can have an upper portion configured to engage at least one solar module, the height adjustment member extending from the hole of the base and upwardly away from the base, the height adjustment member having an annular groove formed around the circumference of the rod, the annular groove positioned within the hole.
• a locking portion can engage the annular groove so as to retain the height adjustment member in the hole and allow the height adjustment member to rotate about a rotational axis, wherein the height adjustment member is configured to adjust a height of the at least one solar module during rotation about the rotational axis.
• a method for assembling a height-adjustable roof anchor for solar modules which includes a base having a hole therein, the hole comprising an inner wall and a height adjustment member having an annular groove formed around a circumference of the height adjustment member.
• the method can comprise inserting the height adjustment member in the hole such that the annular groove is positioned within the hole and positioning a locking portion so as to extend into the annular groove.
• a solar array can comprise a plurality of solar modules, each solar module having at least four sides and a frame extending around the four sides of each solar module.
• the plurality of braces supporting at least one side of one of the frames can be shorter than twice a length of one of the sides of one of the frames.
• a plurality of roof anchors can be configured to be mounted to a roof, each roof anchor coupled to one of the plurality of braces.
• a method of assembling a solar array can comprise mounting a plurality of roof anchors to a roof.
• the method can also include coupling a brace to each roof anchor, positioning an edge of a solar module on each brace, and swinging the solar module downward to engage the end of the solar module with the brace.
• a kit for assembling a solar array can include a plurality of roof anchors configured to be coupled to a roof.
• the kit can also include a plurality of braces, each brace configured to support one or more frames of a solar module and configured to couple to one of the plurality of roof anchors, each brace being shorter than twice a length of a side of one of the frames.
• a solar array can comprise a plurality of solar modules, each solar module having at least four sides and comprising a solar module frame extending around at least a portion of the periphery of the solar module.
• At least a first brace member can have a first support surface extending below at least a first solar module frame of the first solar module.
• At least a second brace member can have a second support surface extending over the first solar module frame.
• a first connector can connect the first brace member to the second brace member such that the first solar module is captured between the first and second support surfaces.
• a solar array can comprise at least first, second, third, fourth, and fifth solar modules, each solar module having at least four sides, wherein the first, second, third, and fourth solar modules are respectively disposed adjacent to the four sides of the fifth solar module.
• the array can include braces for removal of the bracing the juxtaposed sides of the solar modules to each other so that the fifth solar module can be disconnected from the first, second, third, and fourth solar modules and lifted upwardly without the need to slide the fifth solar module laterally.
• a brace for connecting solar modules can comprise a body member having first and second sides spaced from each other, a first lip extending outwardly from and along the first side of the body and configured to extend below a frame of a first solar module disposed adjacent to the first side and a second lip extending outwardly from and along a second side of the body and configured to extend below a frame to a second solar module disposed adjacent to the second side.
• the brace can also include at least a first top member configured to be connected to the body member and having a first engagement portion extending outwardly from and along a first side of the top member, the first engagement portion configured to engage in upwardly extending ridge of a first solar module frame, and a second engagement portion extending outwardly from and along a second side of the top member, the second engagement portion configured to engage in upwardly extending ridge of a second solar module disposed adjacent to the first solar module.
• a connector can be configured to connect the first top member to the body member so as to press the frames of the two adjacent solar modules disposed along the first and second sides of the body member between the lips of the body member and the engagement portions of the top member.
• Figure 1A is a perspective view of a solar power array including a plurality of solar modules.
• Figure IB is a schematic diagram of an optional electrical system that can be connected to the array of Figure 1A.
• Figure 1 C is an enlarged sectional view showing a typical cross section of the frame of each of the plurality of solar modules.
• Figure 2A is a perspective view of a first embodiment of a solar module coupler and a detachable height adjustment device.
• Figure 2B is an exploded view of the coupler and detachable height adjustment device of Figure 2 A.
• Figure 2C is a bottom perspective, exploded view of the coupler of Figure 2B.
• Figure 2D is a side elevational view of the coupler and height adjustment device of Figure 2 A connecting two solar modules to each other.
• Figure 2E is a side elevational view of the coupler connected to one solar module and a second solar module tilted relative to the coupler.
• Figure 2F is a side elevational view of the arrangement shown in Figure 2E, with one solar module engaging a hook portion of the coupler and being tilted into an engagement position.
• Figure 2G is a perspective view of the coupler of Figure 2A connecting four solar modules together at their corners.
• Figure 2H is a perspective view of an array of solar modules with one solar module removed.
• Figure 3 is a perspective view of a second embodiment of the coupler of Figure 2A.
• Figure 4A is a perspective view of a third embodiment of the coupler of Figure 2A.
• Figure 4B is an exploded perspective view of the coupler of Figure 4A.
• Coupled means that one element/node/feature is directly or indirectly joined to (or directly or indirectly communicates with) another element/node/feature.
• Adjust means to position, modify, alter, or dispose an element or component or portion thereof as suitable to the circumstance and embodiment.
• the element or component, or portion thereof can remain in an unchanged position, state, and/or condition as a result of adjustment, if appropriate or desirable for the embodiment under the circumstances.
• the element or component can be altered, changed, or modified to a new position, state, and/or condition as a result of adjustment, if appropriate or desired
• FIGS 1 A and I B illustrate a solar power system 10 including a solar array 1 1 having a plurality of solar modules 12.
• Each solar module 12 can include a laminate 14 supported by a frame 13.
• the solar modules 12 can be the same as or similar to the modules disclosed in U. S. Patent Publication No. 2009/0320908, which is incorporated by reference herein in its entirety for all purposes.
• the solar power system 10 can be incorporated into electrical system 40 connected to the array 1 1.
• the electrical system 40 can include the array 1 1 as a power source connected to a remote connection device 42 with power lines 44.
• the electrical system 40 can also include a utility power source, a meter, an electrical panel with a main disconnect, a junction, electrical loads, and/or an inverter with the utility power source monitor.
• the electrical system 40 can be configured and can operate in accordance with the descriptions set forth in U. S. Patent Publication No. 2010/0071744, the entire contents of which are hereby expressly incorporated by reference in its entirety for all purposes.
• each laminate 14 can include an array of solar cells, such as PV cells, configured to convert light into electricity.
• the frame 13 can provide structural support for the corresponding laminate 14 around the peripheral edges of the laminate 14. In some embodiments, the frame 13 can be a separate component that is coupled to the laminate 14.
• FIG. 1 C illustrates the typical cross section of the peripheral members forming the frame 13.
• Each of the members forming the frames 13 can be formed of longitudinally extending the frame members, each having the cross section illustrated in Figure 1 C, and joined at the corners using 45 degree cuts. However, other techniques can also be used.
• the frame 13 includes a first outer member 16 which extends generally perpendicular to the laminate 14.
• the outer member 16 includes an upwardly projecting ridge 18 and a downwardly projecting ridge 20.
• the upper protrusion 18 has a width W.
• the outer member 16 includes an outwardly facing surface 22 which generally forms the lateral, outwardly facing surface of the module 12. Projecting from the inner surface 24 of the outer member 16, the frame 13 can include an upper sealing ledge 26 and a lower sealing ledge 28. The upper and lower ledges 26, 28 are spaced apart such that the laminate 14 can fit therebetween. Optionally, various sealing techniques can be used to seal the edge of the laminate 14 between the upper and lower ledges 28.
• the lower ledge 28 forms part of a stiffening assembly 30 which also extends from the inner surface 24 of the outer member 16.
• the size and shape of the stiffening assembly 30 can be chosen to provide the desired stiffness of the frame 13.
• the stiffening assembly 30 includes a rectangular tubular configuration. However, other shapes can also be used.
• the frame pieces 13 can be extruded from aluminum, other metals or molded from plastic, or other materials.
• the frame 13 is made from aluminum. Other configurations and dimensions can also be used.
• the array 11 includes modules 12 mounted to each other and, collectively, to a roof structure (not shown) with a plurality of brace assemblies 50. Some of the brace assemblies 50 include optional height adjustment devices 52.
• the brace assembly 50 can include a lower portion 54 and an upper portion 56.
• the lower and upper portions 54, 56 can be configured to capture a portion of the frames 13.
• the lower portion 54 can include a central body portion 56.
• the central body portion 56 is in the configuration of a box beam that extends in a generally longitudinal direction.
• the lower portion 54 can include a first lip 58 extending outwardly from and along a lower edge of the main body portion 56.
• the lower portion 54 can include a second lip 60 extending outwardly from and generally along a lower edge of the central body portion 56 on a side opposite from the first lip 58.
• the first and second lips 58, 60 are sized and configured to support a portion of the frame 13.
• the first and second lips 58, 60 are sized to support the lower ridge 20 ( Figure 1 C) of two juxtaposed frames 13.
• the first and second lips 58, 60 include retention ridges 62, 64 that are sized and configured to help retain the lower protrusion 20, for example, by providing for a snap-fit engagement of the frame 13. The engagement of the frame 13 with the ridges 62, 64 is described in greater detail below with reference to Figures 2D - -2F.
• the upper portion 56 of the coupling member 50 can be formed in one or more pieces.
• the upper portion is formed from a first portion 70 and a second portion 72.
• the first and second portions 70, 72 have essentially the same configuration and shape except that they are mirror images of one another.
• first portion 70 is described in detail below, with the understanding that the portions of the second portion 72 which are not expressly described below, are essentially the same as the corresponding components of the first portion 70, except in a mirror image orientation.
• the first portion 70 includes a central elongated portion 74 which extends general longitudinally and parallel to the portion 56 of the lower portion 54.
• a lower surface 76 can include ridges complimentary to the ridges of the upper surface 65 of the lower portion 54.
• the ridges on both the upper surface 65 and the lower surface 76 extend generally longitudinally along the coupling member 50.
• the engagement and electrical coupling between the upper portion 56 and the lower portion 54 is further ensured thereby ensuring reliable electrical grounding between the upper portion 56 and the lower portion 54.
• other configurations can also be used.
• the first portion 74 also includes a first lip 80 extending outwardly from and along an upper edge of the first portion 74 and a second lip 82 extending outwardly from and generally along an upper edge of the first portion 74.
• the first lip 80 is configured to cooperate with the first lip 58 of the lower portion 54 to capture a portion of a frame 13 there between.
• first and second lips 80, 82 are generally hook shaped, extending first, outwardly from the first portion 74, then downwardly toward the lower portion 54.
• first and second lips 80, 82 can provide a further advantage in simplifying a method for connecting a frame 13 to the coupling device 50, described in greater detail below with reference to Figures 2D - 2F.
• the first portion 74 can also include notches 84, 86 in the first and second lips 80, 82, respectively.
• the notches 84, 86 can have a width 88 that is at least as wide as the width W of the upper ridge 18 of the frame 13 ( Figure 1 C).
• the coupler 50 can be connected to a frame 13 at a corner, wherein one part of the frame 16 extends perpendicular to the coupler 50, and another side where the frame extends parallel to the coupler 50.
• the upper portion 56 can include centrally positioned notches 90, 92 on the first and second lips 80, 82.
• the notches 90, 92 have a width 94 that is greater than the width 88.
• the width 94 can be about the same size as or greater than a thickness 96 of the central portion 56 plus two times the width W of the upper ridge 18 ( Figure 1 C). Sized as such, the notch 94 can allow more flexibility in the placement of the coupler 50, and in particular, can allow the coupler 50 to be used in a position attaching the corners of two modules 12 and straddling the corner. This arrangement is described in greater detail below with reference to Figure 2G.
• each of the first and second portions 80, 72 can be attached to the lower portion 54 in any known manner.
• threaded fasteners 98 extend through apertures 100 to secure the first and second portion 70, 72 to the lower portion 54.
• the upper portion 56 can include a height adjustment aperture 102. In the illustrated embodiment, because the upper portion 56 is formed of two portions 70, 72, each of the first and second portions 70, 72 form approximately half of the aperture 102. However, other configurations can also be used.
• the height adjustment aperture 102 can be size to accommodate the insertion of a tool, from a position above the coupler 50, and down into the interior of the coupler 50, to engage the height adjustment device 52.
• the height adjustment device 52 can include a base portion 110, a rotatable height adjuster 112 which cooperates with a fixed threaded member 114 which can be fixed to the coupler 50.
• the base portion 110 can be formed in any configuration designed for a fixed connection to a structure such as a roof.
• the base portion 110 can be configured to be connectible to a roof stud, or other structural member, with a threaded fastener such as a lag screw or the like.
• the base portion includes a mounting plate portion 116 with an elongated slot 118.
• the elongated slot 118 is preferably sized to receive an appropriately sized lag screw, designed for the engagement of a roof structure and/or a roofing stud.
• the base portion 110 can also include a receiver portion 120 for engagement with the rotatable adjuster 112.
• the receiver portion 120 is generally block shaped with an upper aperture 122.
• the rotatable adjuster 112 can include a threaded body portion 130, an upwardly facing engagement surface 132, and a neck portion 134.
• the neck portion 134 can be in the form of an annular groove disposed on the outer surface of the rotatable adjuster 112.
• the rotatable adjuster 112 can be swaged into the block portion 120.
• the rotatable adjuster 112 can be inserted through the aperture 122 into the block 120.
• a portion of the block 120 can be pressed inwardly such that an inner wall of the aperture 122 extends into the necked portion 134, thereby trapping the rotatable adjuster 112 within the block 120, but allowing the rotatable adjuster 112 to freely rotate relative to the base 1 10.
• the base portion and the block portion 120 can be made from aluminum, the swaging of which is well known in the art.
• the engagement surface 132 is in the form of a female alien wrench head. However, other engagement surfaces can also be used. [0068] With the rotatable adjuster 1 12 mounted as such, the threads of the rotatable adjuster 1 12 can cooperate with internal threads on the coupler 50, so as to allow the coupler 50 to be moved upward and downwardly relative to the base 1 10. In some embodiments, as noted above, an internal thread member 1 14 can be directly formed in the lower portion 54.
• the internal thread member 1 14 can extend through an aperture 140 extending through the lower portion 54.
• the lower portion 54 can include an anti-rotation recess 142 configured to cooperate with a portion of the internal thread member 114 such that the thread member 114 can be fixed relative to lower portion 54.
• the internal threaded member 114 can include an anti-rotation aperture 144 configured to receive a fastener (not shown) extending through the aperture 144 and into the anti-rotation recess 142 so as to prevent any relative rotation between threaded member 114 and the lower portion 54.
• the rotatable adjuster 112 when the rotatable adjuster 112 is rotated relative to the lower portion 54, and thus relative to the internal thread member 114, the rotatable adjuster 112 operates as a jack screw, as the rotatable adjuster 1 12 is rotated clockwise or counter clockwise.
• Other configurations can also be used.
• the threaded sleeve can also include a feature (not shown) that allows the threaded sleeve to be snapped into the base, but that will prevent the threaded sleeve from being removed unintentionally, such as by wind forces.
• the feature can be a spring-loaded detent, barb formed in the sleeve, or any other suitable mechanism.
• the first and second lips 80, 82 can optionally include one or more ridges, teeth, or spikes on the distal end thereof.
• the first and second lips 80, 82 include a sharpened edge 130, 132 so that when they are pressed into engagement with a frame 13, the sharpened edges 130, 132 penetrate the outermost surface of the frame 13, to thereby provide better electrical contact with the frame 13.
• the frame 13 can be aluminum with a anodized outer coating. As such, the sharpened edges 130, 132 can help pierce the outermost anodizing of the frame 13, and thereby provide better electrical contact between the coupler 50 and the frame 13.
• the sharpened edges 130, 132 can also be further beneficial where the coupler 50 is made from a different material than the frame 13, for example, but without limitation, where the coupler 50 is made from stainless steel and the frame 13 is made from aluminum.
• the above configuration can accommodate two different methods for attaching coupler 50 to a module 12. Firstly, as is apparent from the above description, the upper portion 56 of a coupler 50 can be removed, the frame of the module can be placed such that the upper ridge 18 of a frame engages the hook shaped lip 80 with the lower protrusion 20 of the frame supported by the lower lip 58. The upper portion 56 can be secured to the lower portion 54 of the coupler with the threaded fasteners 98.
• the above configuration of the coupler also allows a module 12 to be connected to the coupler 50 by a "hook and swing motion. "
• the coupler is fully assembled with the upper portion 56 attached to the lower portion 54.
• a solar module 12A is illustrated in the position in which it is tilted relative to coupler 50.
• the module 12A can be manually moved into a position in which the upper protrusion 18 is engaged with the hook shaped lip 82. Then, the module 12A can be tilted downwardly, in the direction of arrow T until the module 12A reaches the orientation illustrated in Figure 2F.
• the lip 60 can include a ridge 64 configured to cooperate with the lower protrusion 20 of the frame 13 so as to provide a snap fit.
• a ridge 64 configured to cooperate with the lower protrusion 20 of the frame 13 so as to provide a snap fit.
• the minimum distance between the uppermost portion of the ridge 64 and the uppermost portion of the inner surface of the hook shaped lip 82 can be slightly closer than the overall vertical Height of the outer portion 16 of the frame 13.
• the inherent elasticity of the coupler 50 and in particular the hook shaped lip 82 and the lip 60 can allow the lips 82, 60 to slightly spread apart as the lower protrusion 20 passes over the ridge 64, then due to their elasticity, snap back to their original spacing, thereby trapping the outer member 16 of the frame 13 in the position illustrated in Figure 2F.
• the lips 58, 80 and ridge 62 can be configured in essentially the same manner such that solar modules 12, 12A can be attached to both sides of the coupler 50 without the need for moving the lips 80, 82 relative to the lower lips 58, 60.
• the solar modules 12, 12 A are spaced apart such that the inwardly facing surfaces of their respective upper ridges 18 as defined by the width 200.
• the width 200 in the illustrated configuration, is approximately the width 96 of the central portion of the coupler 50 plus two times the width W of the outer portion 16 of the frames 13. This spacing is about the same as or less than the width 94 of the notch 92 ( Figure 2A) described above.
• the width 94 of the notch 92 allows the notch 92 to straddle the spaced apart upper ridges 18 of two adjacent modules 12.
• the laminates 14 of the solar modules illustrated in Figure 2G have been removed for purposes of illustration.
• the width 88 of the notches 86 also allow the coupler 50 to be positioned near a corner of a module 12, but not straddling the spacing between two adjacent modules 12. Rather, the notches 86 could be aligned with single upper ridge 18 of a frame 13.
• the couplers 50 can accommodate further advantageous methods for removing and reinstalling a solar module 12 from an array of solar modules. As shown in Figure 2H, the upper portions 56 of two couplers 50 have been removed and the module 12 ( Figure 1 A) has been removed by lifting and tilting the module 12 out of the fully assembled couplers 50B.
• one edge of the solar module 12 can be lowered into position, into the orientation illustrated in Figure 2E, such that in upper protrusion 18 of the frame 13 of the solar module 12 engages the hook shaped lip 82 of the couplers 50B.
• the lower protrusion 20 can engage with the ridge 64 of the couplers 50B.
• the lower protrusion 20 eventually comes to rest on the first lip 58 of the couplers 5 OA.
• the lowering of the solar module 12 can be accomplished using suction cups (not shown) temporarily attached to the upper surface of the laminate 14, or other techniques.
• the upper portions 56 of the couplers 50A can be replaced, thereby returning the array 1 1 into the state illustrated in Figure 1 A.
• FIG. 1 illustrates another embodiment of the coupler 50, identified by the reference numeral 1050.
• the components of the coupler 1050 that are the same or similar to the coupler 50, are identified with the same reference numeral, except that 1000 has been added thereto.
• the coupler 1050 can include an upper portion 1056 that is made from a single piece instead of two separate pieces 70, 72 of the coupler 50.
• the remaining components of the coupler 1050 as well as the use and operation, are essentially the same as the coupler 50.
• the coupler 1050 can be formed such that the upper portion 1056 is permanently affixed to the lower portion 1054.
• the coupler 1050 could be made from a single piece of material into a monolific body.
• the coupler 1050 could be made from two separate pieces such as the lower and upper portions 1054, 1056, but permanently affixed to one another.
• Such an integrated design for the coupler 1050 can further reduce costs of such a system, by reducing the part counts, and reduce manufacturing costs.
• such as single piece coupler 1050 can be connected to a fixed solar module by hooking the lip 1080 to an upper ridge 18 of a solar module 12, then tilting the coupler 1050 relative to the solar module 12, until the lower protrusion 20 of the frame 13 of the solar module engages the ridge 1062.
• an adjacent solar module 12 can be connected to the coupler 1050 by hooking the corresponding upper protrusion 18 of a solar module 12 into the hook shaped lip 1082 of the coupler 1050, then tilting the solar module 12 downwardly, in the direction of RT of Figure 2E, until the lower protrusion 20 engages the ridge 64 and is oriented in the position shown in Figure 2F.
• a single piece coupler 1050 can be used without removing the upper portion 156.
• Figure 4 A illustrates another embodiment of the coupler 50, identified by the reference numeral 2050.
• the components of the coupler 2050 that are the same or similar to the couplers 50 or 2050 are identified with the same reference numeral, except that 2000 has been added thereto.
• the coupler 2050 can include a lower portion 2054 and an upper portion 2056.
• the lower portion 2054 includes the lip 82 and an upper mounting surface 2402 for receiving the upper portion 2056.
• the upper portion 2056 can be made from one or more parts.
• the upper portion 2056 can include a lip only on one side, in the illustrated embodiment, the lip 2080.
• the coupler 2050 can be engaged with a solar module 12 by hooking and tilting the coupler relative to solar module 12 as described above with reference to Figure 3. Additionally, the coupler 2050 can be connected to and removed from engagement with solar modules by removing the fasteners 98 and the upper portion 2056. As such, the upper portion 2056 can be removed while the other side of the coupler 2050, including the upper lip 82 can remain engaged with a solar module, thereby maintaining the coupler 2050 in its position.
• the coupler 2050 can remain securely engaged with an adjacent solar module because the lip 2082 remains fixed relative to the lower lip 2060.
• the solar module 12 which is removed and/or reinstalled can rest against the lower lips 2058 of the coupler 2050, during the reinstallation process.
• Embodiments may also include:
• Embodiment 1 A height- adjustable roof anchor for solar modules, the roof anchor comprising a base having a hole therein, the hole comprising an inner wall, a height adjustment member having an upper portion configured to engage at least one solar module, the height adjustment member extending from the hole of the base and upwardly away from the base, the height adjustment member having an annular groove formed around the circumference of the rod, the annular groove positioned within the hole and a locking portion engaging the annular groove so as to retain the height adjustment member in the hole and allow the height adjustment member to rotate about a rotational axis, wherein the height adjustment member is configured to adjust a height of the at least one solar module during rotation about the rotational axis.
• Embodiment 2 The roof anchor of Embodiment 1, wherein the height adjustment member comprises a rod with a threaded portion and a non-threaded portion, the annular groove formed in the non-threaded portion.
• Embodiment 3 The roof anchor of Embodiment 2, wherein the threaded portion of the rod extends out of the hole, and wherein at least part of the non- threaded portion is positioned within the hole.
• Embodiment 4 The roof anchor of Embodiment 3, the non-threaded portion comprising a plurality of annular grooves formed around the circumference of the rod and the inner wall comprising a plurality of locking portions, each locking portion extending into a corresponding annular groove.
• Embodiment 5 The roof anchor of Embodiment 4, wherein the locking portion of the inner wall is swaged into the annular groove.
• Embodiment 6 The roof anchor of Embodiment 1 , wherein the locking portion of the inner wall is configured to substantially prevent the height adjustment member from being removed from the hole.
• Embodiment 7 The roof anchor of Embodiment 6, wherein the locking portion of the inner wall is configured to allow rotation of the height adjustment member about a longitudinal axis of the height adjustment member.
• Embodiment 8 The roof anchor of Embodiment 1 , wherein the base comprises a mount configured to mechanically couple to a roof and an extruded foot, the hole being formed in the extruded foot.
• Embodiment 9 The roof anchor of Embodiment 8, wherein the base is made of aluminum and the height adjustment member is made of steel rod.
• Embodiment 10 The roof anchor of Embodiment 8, the mount comprising a slot configured to receive a coupling member for securing the roof anchor to the roof.
• Embodiment 1 1.
• Embodiment 12 The roof anchor of Embodiment 11, wherein the sleeve is configured to prevent rotation of a brace relative to the sleeve.
• Embodiment 13 The roof anchor of Embodiment 12, wherein the sleeve is configured to positively locate the brace relative to the sleeve, and wherein the sleeve is configured to be removed when a detent or latching mechanism is engaged.
• Embodiment 14 A method for assembling a height-adjustable roof anchor for solar modules which includes a base having a hole therein, the hole comprising an inner wall and a height adjustment member having an annular groove formed around a circumference of the height adjustment member, the method comprising inserting the height adjustment member in the hole such that the annular groove is positioned within the hole and positioning a locking portion so as to extend into the annular groove.
• Embodiment 15 The method of Embodiment 14, wherein positioning the locking portion comprises swaging the inner wall into the annular groove.
• Embodiment 16 The method of Embodiment 15, wherein the base comprises an aluminum mount and an extruded foot at an end of the mount.
• Embodiment 17 The method of Embodiment 16, wherein swaging the locking portion comprises applying pressure to opposing faces of the extruded foot to deform the inner wall.
• Embodiment 18 The method of Embodiment 17, wherein swaging the locking portion further comprises applying heat to the extruded foot when applying pressure to the opposing faces.
• Embodiment 19 The method of Embodiment 14, wherein the rod comprises a threaded portion and a non-threaded portion, and wherein the annular groove is formed in the non-threaded portion.
• Embodiment 20 The method of Embodiment 14, further comprising applying a sleeve over the rod.
• Embodiment 21 A solar array, the array comprising a plurality of solar modules, each solar module comprising at least four sides, a frame extending around the four sides of each solar module, a plurality of braces, each brace supporting at least one side of one of the frames, each brace being shorter than twice a length of one of the sides of one of the frames and a plurality of roof anchors configured to be mounted to a roof, each roof anchor coupled to one of the plurality of braces.
• Embodiment 22 The solar array of Embodiment 21, wherein the solar array does not include rails that are longer than twice a length of one of the sides of the frames and that extend parallel to and engage a plurality of the frames.
• Embodiment 23 The solar array of Embodiment 21, further comprising a first brace supporting a first frame and slidably coupled to a first roof anchor.
• Embodiment 24 The solar array of Embodiment 23, further comprising a second brace supporting a second frame and a third frame adjacent the second frame,
• Embodiment 25 The solar array of Embodiment 24, wherein said second brace is not coupled to a roof anchor.
• Embodiment 26 The solar array of Embodiment 24, wherein said second brace is slidably coupled to a second roof anchor.
• Embodiment 27 The solar array of Embodiment 24, wherein the second brace supports a fourth frame and fifth frame on a side of the second brace opposite the second frame and the third frame.
• Embodiment 28 The solar array of Embodiment 24, wherein the second brace is coupled to a corner of the second frame and a corner of the third frame, the second brace maintaining separation between the corner of the second frame and the corner of the third frame.
• Embodiment 29 A method of assembling a solar array, the method comprising mounting a plurality of roof anchors to a roof, slidably coupling a brace to each roof anchor, positioning an end of a solar module on each brace and swinging the solar module downward to engage the end of the solar module with the brace.
• Embodiment 30 The method of Embodiment 29, wherein slidably coupling the brace comprises snapping the brace to a sleeve on the anchor such that the brace is secured to the sleeve.
• Embodiment 31 The method of Embodiment 29, further comprising adjusting the height of each roof anchor to controllably mount the solar modules to the braces.
• Embodiment 32 The method of Embodiment 29, further comprising coupling a first solar module and a second solar module adjacent the first solar module to a first brace, wherein the first brace maintains separation between a corner of the first solar module and a corner of the second solar module.
• Embodiment 33 The method of Embodiment 32, wherein the first brace is not coupled to a roof anchor.
• Embodiment 34 The method of Embodiment 32, further comprising slidably coupling the first brace to a first roof anchor.
• Embodiment 35 The method of Embodiment 29, further comprising coupling a third solar module to a second brace, wherein said second brace is not coupled to a roof anchor.
• Embodiment 36 A kit for assembling a solar array, the kit comprising a plurality of roof anchors configured to be coupled to a roof and a plurality of braces, each brace configured to support one or more frames of a solar module and configured to slidably couple to one of the plurality of roof anchors, each brace being shorter than twice a length of a side of one of the frames.
• Embodiment 37 The kit of Embodiment 36, further comprising a plurality of the solar modules, each solar module comprising a frame mounted around edges of each solar module.
• each roof anchor comprises a base having a hole therein, the hole comprising an inner wall, a rod inserted in the hole of the base, the rod having an annular groove formed around the circumference of the rod, the annular groove positioned within the hole, wherein a locking portion of the inner wall extends into the annular groove.

Landscapes

• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Physics & Mathematics (AREA)
• Life Sciences & Earth Sciences (AREA)
• Sustainable Development (AREA)
• Sustainable Energy (AREA)
• Thermal Sciences (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• General Engineering & Computer Science (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)
• Photovoltaic Devices (AREA)

Priority Applications (4)

Applications Claiming Priority (6)

Publications (1)

Family

ID=49783762

Family Applications (1)

Country Status (5)

Cited By (8)

Families Citing this family (1)

Citations (5)

Family Cites Families (12)

• 2013
  • 2013-06-21 AU AU2013280828A patent/AU2013280828B2/en not_active Ceased
  • 2013-06-21 JP JP2015518600A patent/JP2015527855A/ja not_active Ceased
  • 2013-06-21 KR KR20157001598A patent/KR20150034733A/ko not_active Application Discontinuation
  • 2013-06-21 WO PCT/US2013/046992 patent/WO2014004279A1/en active Application Filing
  • 2013-06-21 EP EP13809479.2A patent/EP2865014A4/en not_active Withdrawn

Patent Citations (5)

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events