WO2016065210A1

WO2016065210A1 - Sensing, interlocking solar module system and installation method

Info

Publication number: WO2016065210A1
Application number: PCT/US2015/057018
Authority: WO
Inventors: Neil Goldberg; Troy Douglas TYLER
Original assignee: Smash Solar, Inc.
Priority date: 2014-10-22
Filing date: 2015-10-22
Publication date: 2016-04-28

Abstract

A solar module system is coupled directly to a fixed structure either individually or collectively as an array. Universal mounting brackets attached to the back of each solar panel module each connect to one or more other brackets of adjacent solar panels and/or to mounting feet that anchor to the fixed structure. Mounting brackets interlock with mounting brackets on adjacent solar modules and include a flexible snap coupling mechanism including a locking feature to selectively flexibly connect to and disconnect from other mounting brackets of adjacent solar panels.

Description

SENSING, INTERLOCKING SOLAR MODULE SYSTEM

AND INSTALLATION METHOD

Inventors: Neil Goldberg and Troy Douglas Tyler

Applicant: Smash Solar, Inc.

PRIORITY AND RELATED APPLICATIONS

[0001] This patent application is a Continuation-in-Part (CIP) application which claims the benefit of priority to United States patent application serial no. 14/521,245, filed October 22, 2014, which is a CIP of United States patent application serial no. 14/054,807, filed October 15, 2013, which claims priority to United States provisional patent application no.

61/712,878, filed October 12, 2012. Each of these priority applications is incorporated by reference.

GOVERNMENT LICENSE RIGHTS

[0002] This invention was made with government support under the SunShot Financial Assistance Award number DE-EE0006457 awarded by the Department of Energy. The government has certain rights in the invention.

BACKGROUND

[0003] Solar panels are widely used in the production of electricity with multiple panels typically connected together as panel assemblies. These assemblies are typically arranged in arrays and mounted on structural racking systems on the roofs of buildings, on the ground or other fixed structures. A fixed structure can include, but is not limited to, existing residential or commercial roof tops, horizontal surfaces or vertical surfaces, existing fences, railings, walls or open ground-mounted areas. These racking assemblies are required to pass loading tests to ensure they can withstand static and dynamic loading anticipated during the life of the installation. These solar racking systems must be custom designed for each application and custom installed by contractors and tradespeople using specialty skills and following the approved drawings. What is needed is a system that meets the loading requirements of solar module racking systems through a configurable design which eliminates expense of custom design and installation activities. [0004] In addition, a number of solar panel manufacturers have released new solar panels with integrated micro-inverters to simplify the electrical installation process and give customers the promise of flexibility: install a small system now and expand in the future.

[0005] Considering the complexity of typical racking systems and the promise of customer flexibility, existing solar mounting systems have a number of problems and limitations that this invention solves.

[0006] Current solar systems on the market are engineered to be custom designed and installed for each application. Each application is typically designed as a maximum size for a single large, complex and custom installation. This custom approach carries inherent costs which customers unknowingly bear. Customers prefer flexibility and control over their power purchases. Installation contractors must either train their workforce or hire specially- skilled solar workers raising their cost of doing business.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 schematically illustrates an embodiment including eight installed solar panels coupled together in 4x2 arrangement.

[0008] Figure 2 schematically illustrates a preassembled solar panel including mounting brackets in accordance with certain embodiments.

[0009] Figure 3 schematically illustrates a mounting foot in accordance with certain embodiments.

[0010] Figure 4 schematically illustrates an anchor including a snap toggle and machine screw in accordance with certain embodiments.

[0011] Figure 5 schematically illustrates a flashing in accordance with certain embodiments.

[0012] Figure 6 schematically illustrates a junction box in accordance with certain embodiments.

[0013] Figure 7 schematically illustrates a pair of end caps in accordance with certain embodiments.

[0014] Figures 8-27 schematically illustrate a method of installing a set of four preassembled solar modules on a roof surface in accordance with certain embodiments.

[0015] Figure 28 schematically illustrates a pair of uncoupled solar panel bracket connectors in accordance with certain embodiments.

[0016] Figure 29 schematically illustrates a pair of coupled and unlocked solar panel bracket connectors in accordance with certain embodiments. [0017] Figure 30 schematically illustrates a pair of coupled and locked solar panel bracket connectors in accordance with certain embodiments.

[0018] Figure 31 schematically illustrates a pair of adjacent preassembled solar panels including two pairs of complementary bracket connectors that are not yet coupled together.

[0019] Figure 32 schematically illustrates four solar panel corners installed as a 2x2 array or subarray that each include a corner bumper that overlaps in two dimensions.

DETAILED DESCRIPTIONS OF THE EMBODIMENTS

[0020] Solar panel modules are provided in embodiments that are not designed to anchor through the roofing membrane into roof rafters. These systems create significant efficiency in the installation process. They reduce work effort and time and personnel for installing the solar panel modular system.

[0021] Solar panel modules have integrated brackets that install with reduced parts count, supply chain burden, logistical cost and installation complexity.

[0022] Solar panel mounting systems are provided that allow users to cost effectively install smaller, more affordable systems and expand them in small increments over time.

[0023] Solar panel modules are provided that installs without aluminum alloy frames nor mounting system members (also primarily made from aluminum alloys) that would otherwise involve more complex electrical equipment grounding for safety.

[0024] An interlocked, modular mounting bracket is provided that is attached to solar panels that significantly streamlines the field installation process using a module with an integral, factory-installed mounting system that is ready to install as soon as it's removed from the package. The interlocking module may have integral sensors which record mechanical and electrical characteristics of the solar installation for instant field verification of a complete and accurate installation and for mobile field inspections for the building inspector.

[0025] Flat plate solar collectors, otherwise known as solar panels, are provided with enhanced efficiency of anchoring to a fixed structure. Aluminum alloy frame, rails and roof standoffs are optional. An interlocking, modular solar panel system is provided that enables a simplified workflow for installing solar panels and provides an electronic measure of the waterproofing and structural integrity of the mounting to the fixed structure.

[0026] A sensing, interlocking module has a structural platform for both connecting solar panels together and anchoring them to a fixed structure. The platform is based on a universal mounting bracket that can be adhered to a plurality of solar panels. This mounting bracket is made from non-conductive materials and mechanically adhered to the back of a solar panel. Each mounting bracket connects to adjacent mounting brackets allowing the interlocking modules to quickly connect to any number of interlocking modules. These brackets structurally support the solar panel without a traditional module frame. These frameless modules rely on the mounting bracket and the connected mounting feet to secure the solar panel to a fixed structure.

[0027] The mounting bracket platform may connect to a plurality of mounting feet for different fixed structure mounting applications. Such applications include rooftop, ground mount and external building envelope such as, but not limited to the following: sloped residential roofs, flat residential roofs, flat commercial roofs, sloped standing seam metal roofs, sloped corrugated metal roofs, vertical walls, fences, railings or other external fixed structures. Each mounting foot contains a number of anchor points each with their own integral waterproofing ring or gasket aligned with the anchor point hole on the bottom of the foot. Standard anchors designed for exposed, external applications will be employed as mechanically driven anchors through one or more anchor point in each mounting foot. Each mounting foot connects to the mounting bracket via a connector that can be quickly and easily released from the top of the mounting foot. This manually activated release connector provides for simple release and reattachment of the interlocking module to the mounting feet for maintenance or upgrades. For composite shingle roofs, the mounting foot also adjusts to align with the specific exposed shingle course dimension which varies by roofing product and manufacturer.

[0028] The mounting feet may contain a radio frequency transmitter and pressure sensor ("mounting sensor") on the bottom of the mounting foot. The mounting sensor is attached adjacent to the anchor point where an anchor is driven through the mounting foot, into the flashing, roofing material and into the roofing substrate. The anchor exerts force against the mounting foot which in turn exerts force against the integral waterproofing ring and roof flashing. The mounting sensor measures the compressive pressure between the mounting foot and the roof flashing to confirm the compliance to the waterproofing and structural anchor installation specifications. With a minimum compressive pressure at each anchor point, waterproofing and structural attachment are assured.

[0029] A mobile electronic device (such as a mobile phone, tablet or specialty radio frequency reader) can read each transmitter and confirm the compressive pressure meets a minimum value for the specific application. The sensors and mobile devices can use one communication protocol or a plurality of communication protocols including but not limited to high frequency (HF), ultra-high frequency (UHF) or Bluetooth standards. The software code or application ("MOUNTING APP") on the mobile device will collect user entered information, photographic images, the longitudinal and latitudinal location from the mobile device global positioning system sensor, the radio frequency transmitter signals including compressive pressure compliance, a unique identifier for each transmitter and any other relevant information. The information collected by the mobile device will be communicated to remote computing devices and machines using Internet protocols - either in real-time (if a network signal exists on the mobile device) or at a later time (when the network signal is available or when the mobile device is connected to an Internet connected computer).

[0030] These and other features are provided in various embodiments of the sensing, interlocking solar module system. Certain embodiments eliminate the time, cost and complexity of anchoring to roof rafters with a mounting foot that can be installed directly to the roof membrane with standard metal flashing anchored through the roof substrate

(plywood sheeting).

[0031] Certain embodiments significantly reduce the number of loose parts involved in installation of a solar panel array through a factory-assembled interlocking mounting system.

[0032] Certain embodiments streamline the system design and installation process especially for smaller system sizes, giving customers an affordable small solar option through its modular, all-in-one design.

[0033] Certain embodiments use non-conductive, composite materials, eliminating the equipment grounding requirement.

[0034] Certain embodiments include mounting brackets that are designed to structurally support the frameless module eliminating special panel designs (e.g. thicker glass) intended to strengthen or stiffen the panel when the frame is removed.

[0035] Certain embodiments involve a factory-installed mounting system that simplifies the installation process reducing in field decision making, eliminating specialty skills and human error potential.

[0036] Certain embodiments eliminate the need to precisely layout and install roof connectors at the roof rafters.

[0037] Certain embodiments reduce the size of the crew involved in installing a solar array, which can be installed with one or two workers in only a matter of hours.

[0038] Certain embodiments mitigate the risk of a failed anchor installation - in which the anchor is over tightened and strips out the underlying roof substrate using a compressive pressure sensor that will confirm the physical connection meets minimum compliance levels. [0039] Certain embodiments include a radio transmitter and pressure sensor and array installation monitor that gives installers and system owners data on their system installation that are not available today.

[0040] Certain embodiments reduce the number of roof penetrations compared to a direct attachment system since the mounting feet are shared across interlocking modules.

[0041] Certain embodiments include an anchoring mounting foot for composite shingle applications that addresses the shingle course exposure variability with an adjustable connection between mounting foot and mounting bracket, allowing the alignment of the mounting foot and the open shingle course.

[0042] Certain embodiments include a connection between the mounting bracket and mounting feet that accept the angular variation between the roof membrane and roofing plane. The mounting feet may be always adjusted to lay flat against the roof flashing to create a strong waterproofing seal and/or any angular variation is absorbed in the connector between the mounting foot and mounting bracket.

[0043] Certain embodiments create a simplified installation process which reduces worker stress and strain typical in traditional solar array installations.

[0044] LOCKING MECHANISM (FOR BRACKET TO BRACKET COUPLINGS)

[0045] Bracket to bracket coupling is achieved when a pair of complementary bracket connectors, one protruding from each of two adjacent mounting brackets of two adjacent solar panel modules, are snapped together. That is, the coupled bracket configuration is one of stable equilibrium. This is achieved in certain embodiments by coupling a tranverse protrusion component of one of the pair of complementary mounting bracket connectors to a recess component of the other of the pair of bracket connectors. The snapping together that occurs when the protruding component centers within the recess in achieved in certain embodiments using flexible material such as a durable polymer that has a hardness that permits flexing sufficient for the protrusion component of one bracket connector to traverse the raised outer region that defines the recess of the other bracket component, by bending and thereby displacing the end of the protrusion by a distance equal to the distance between the bottom of the recess and its outer region.

[0046] The protrusion climbs the outer region of the recess in a direction transverse to the coupling direction of the brackets until the protrusion falls into the recess thereby snapping into a stable coupling configuration. In order to do that, a space is provided for the protruding component to bend or flex into during the coupling of the brackets. In order to prevent the bending or flexing to occur in reverse in an undesired bracket to bracket decoupling event, an advantageous locking mechanism is provided in accordance with certain embodiments. Nonexhaustive example embodiments are provided particularly at Figures 28- 30. The locking mechanism is configured to be actuated, e.g., by sliding or alternatively lifting and setting or perhaps rotating, from an unlocked position to a locked position. During this actuation from unlocked to locked position, a spacer is moved into the flex space so that the protruding component cannot flex therein thereby locking the complementary bracket connectors together in a strong coupling arrangement.

[0047] In certain embodiments, a visual queue is apparent to installation personnel when the locking mechanism is unlocked (e.g., a bright colored spot or symbol) and becomes hidden or otherwise noticeably changes its appearance when the locking mechanism is locked. When the installation of all of the solar panel modules of a system or array of modules is completed, all of the locking mechanisms should be in the locked position.

[0048] The locking mechanism is only actuated back to the unlocked position when a solar panel module is to be replaced or otherwise removed from the sunlight receiving surface upon which it has been mounted. To release a bracket to bracket coupling, a pair of recesses formed in protrusion components may permit them to be squeezed with a plyer tool or the recess components may have recess that can be pulled apart with a same or similar tool.

[0049] STIFFENERS

[0050] In certain embodiments, one or more stiffeners are mounted to the underside of each solar panel module in preassembly to support the solar panels, particularly when in certain embodiments the solar panels are frameless and therefore do not have the mechanical support that a frame could otherwise provide. The stiffeners, in alternative embodiments, are placed close to the edges of the solar panels or inset from the edges of the solar panels. The

Stiffeners taken together form in certain embodiments a rectangular shape having same or similar perspective ratio length to width as the solar panel to which the stiffeners are mounted. Alternatively, a set of one or more stiffeners can form an other than rectangular shape, such as may be formed with more or less than four straight components as in a triangle, pentagon, hexagon, octagon, etc., or a shape including one of more curved segments or even an ellipse or partial ellipse, or a shape that is not closed such as a U, X or H shape. Moreover, the stiffeners can form a rectangular shape that has other than the same

perspective ratio length to width as the solar panel to which they are mounted.

[0051] In fact, a frame is typically understood by definition to be provided at the outer edge of whatever is being framed to provide structural support, and in some cases to protect the edges from fraying or warping or being damaged by contact with the ground, a roof surface or any other object. A set of stiffeners could be placed at the edges of the solar panels in certain embodiments and in this sense function in some ways more similar to a frame than the stiffeners that are inset from the edges in alternative embodiments. The advantageous stiffeners provided herein in accordance with certain embodiments are disposed away from the edges closer to the center and are mounted to the underside of the solar panels such as to not overlap the solar panel edges in either of the two flat dimensions of the solar panel.

[0052] Stiffeners perform further functions in certain embodiments. Stiffeners can be shaped in cross section to provide ease of gripping with human hands. Stiffeners may have electrical wiring clamped or otherwise coupled thereto. The cross sectional height of the stiffeners is less than the height of the mounting brackets that have mounting feet coupled thereto, so that the feet can reach, contact and be anchored via the flashing on the roof or other mounting surface during installation.

[0053] The stiffeners are metallic or otherwise conducting or semiconducting and coated with insulating material in certain embodiments. Alternatively, the stiffeners may be fabricated from durable polymeric material or another material that is electrically insulating.

[0054] FASTENING MECHANISM

[0055] In certain embodiments, a fastening mechanism similar to that described at US patent no. 6,161,999, which is incorporated by reference, is used for anchoring a mounting foot to the roof or other installation surface. In certain embodiments, a snap toggle component may be rectangular or otherwise elongated such as to be configured to be rotatable after penetrating a drill hole only slightly larger than the short dimensions of the rectangular or otherwise elongated component. The rectangular or otherwise elongated component may be configured with teeth or another mechanism for gripping the underside of the roof or other mounting surface which may comprise wood. The teeth or other gripping configuration prevent the rectangular or otherwise elongated component from rotating excessively and/or otherwise causing for example damage to the underside of the roof or instability in the anchoring of the feet to the roof.

[0056] The rectangular or otherwise elongated component of the snap toggle anchoring system may include one or more components that serve to strengthen the fastening mechanism so that it can better withstand lateral or transverse forces. In certain

embodiments, steel threads are provided. In another embodiment, a brace is provided that serves to prevent buckling of the rectangular or otherwise elongated component. One or more elongated brace components may be coupled to the rectangular or other otherwise elongated component of the snap toggle anchoring mechanism, for example, at the interior of the "U" when the rectangular or otherwise elongated component has a U-shape cross-section or other shape that permits coupling the brace component at an empty area of the cross- section.

[0057] FLASHING

[0058] The flashing may be generally rectangular and flat such as to fit under a roof shingle. The flashing may be without any holes drilled in it before placement on the roof, or a drill hole may be formed in the flashing during preassembly. The drill hole in the flashing is used for inserting the shape toggle anchoring mechanism therethrough (and through an

overlapping hole in the roof) in order to secure the solar panel modules at the mounting feet to the roof. The flashing may have a dome indentation formed around the drill hole at the time of installation or in preassembly, which serves to divert water that may otherwise tend to flow down the drill hole and erode the anchoring stability that is advantageously achieved at the time of installation in accordance with certain embodiments such as the snap toggle anchoring components described above and at the 6,161,999 patent incorporated by reference above.

[0059] The dome shaped protrusion may be used to self-align a mounting foot during installation. That is, a mounting foot may be configured with a cutout section or other protrusion or indentation or shape in certain embodiments so that a mounting foot rests most stably in the two dimensions of the flashing when the mounting foot is aligned properly in those two dimensions with the drill hole in the flashing and roof.

[0060] Mounting feet may be tightened in coupling to mounting brackets using a foot to bracket latching mechanism such as any of a variety of known coupling mechanisms that first loosely coupled two things together followed by a step of tightening them. In one

embodiment, a U-shaped cam-lock connector component is rotated to tighten the foot to the bracket. A buckling mechanism may also be used. A mounting foot may be slid across a bracket section until it reaches a latched coupling position. A mounting foot may be snap coupled to a mounting bracket, e.g., along similar general lines as the bracket to bracket snap coupling mechanism that is described above and below herein. In certain embodiments, mounting feet and coupled to mounting brackets in preassembly or at least prior to anchoring a solar panel module to a roof via one, two or four mounting feet. However, in other embodiments, mounting feet may coupled to the roof via the flashing before the mounting bracket is coupled to the mounting foot to secure the solar panel module to the roof. [0061] Installed solar panel modules of a system or array may be spaced edge to edge by between 10 mm and 120 mm, e.g., 1.5 inches. The solar panels are spaced from the surface of the roof when installed between 2-12 inches, e.g., 4 inches in certain embodiments.

[0062] Wind, water and/or thermal flow blocking or shaping components may be installed along with an array of solar panel modules in certain embodiments depending on the environment and characteristics of the setting within which the solar panel modules are being installed.

[0063] The complementary bracket to bracket connector pair coupling mechanism illustrated schematically at Figures 28-30 in certain embodiments is configured such that brackets may be coupled together by relative movement in more than just the plane of the solar panel modules or horizontally if we take the plane of the roof as horizontal for this discussion. A bracket connector component of a next module to be installed in the array may approach the other one of the complementary pair at an angle that is less than 90 degrees to vertical and could be vertical or near vertical or any angle in between. Moreover, a solar panel module may be moved in the direction that is normal to the plane such that the bracket connectors actually slide toward their relative snap coupling positions as much as 90 degrees displaced around the closed outer region that defines the recess for one of the pair of bracket connectors and as much as 90 degrees in the opposite direction around the periphery of the protrusion component of the other of the bracket connectors that form the complementary pair. In short, adjacent solar panel modules in accordance with certain embodiments may be relatively moved toward each other in a relative direction that is any of a wide range of combinations of horizontal and vertically movements in the plane of the next solar panel module to be installed, and of movements of the solar panel module normal to the plane of the flat solar panel surface of the module.

[0064] BUMPERS

[0065] Bumpers are provided in certain embodiments at each of the four corners of a solar panel module to protect the edges of the solar panel, particularly for embodiments that include frameless solar panels. The bumpers are preassembled to solar panel modules in accordance with certain embodiments to prevent edge contact with the ground or the roof or floor of the truck or other object when moving modules in transit from the factory

preassembly site and during installation at roof site and for guiding bracket to bracket coupling or facilitating alignment or easing precision coupling precision requirements during bracket to bracket coupling. [0066] There may be corner protection bumpers overlapping both edges at corners of solar panel modules in accordance with certain embodiments. These bumpers may overlap the flat top and underside surfaces of the solar panels for facilitating of stacking modules without damaging solar panel surfaces. There may be middle alignment bumpers for alignment during coupling of adjacent panels.

[0067] There may be a middle protection bumper for protection between male or protrusion connector tabs of one of the pair of complementary bracket connector components. There may also be a pair of surrounding protection bumpers for protecting female or recess connector tabs of the other bracket to bracket connector component of the complementary pair. As understood, the male or protrusion components could be switched with female or recess components inside-outside for a complementary pair and/or bracket to adjacent bracket.

[0068] At least one installed preassembled solar panel may have two mounting brackets coupled to two respective mounting feet and two mounting brackets coupled to two respective mounting brackets of an adjacent solar panel.

[0069] At least one installed preassembled solar panel may have one mounting bracket that is coupled to a mounting foot and three mounting brackets coupled each to one or two mounting brackets of one or two respectively adjacent solar panels.

[0070] A frameless and modular solar power system is also provided. At least six spaced- apart mounting feet are configured for coupling at six locations to a surface that receives effective amounts of sunlight. Two or more preassembled solar panels may each include four mounting brackets that are each configured for coupling to one of the mounting feet or to one or two other mounting brackets of one or two respectively adjacent preassembled solar panels, or combinations thereof. Upon installation, the system includes at least one installed preassembled solar panel that has all four of its mounting brackets coupled each to one of four respective mounting feet that are installed on the sunlight receiving surface before of after coupling to the solar panels. At least one installed preassembled solar panel may have two of its mounting brackets coupled each to one of two spaced-apart mounting feet and two mounting brackets coupled each to one of two mounting brackets of an adjacent solar panel.

[0071] One or more installed preassembled solar panel may have two of its mounting brackets coupled each to a respective mounting foot and the other two mounting brackets may be coupled each to a respective mounting bracket of an adjacent solar panel. [0072] One or more installed preassembled solar panel may have one mounting bracket that is coupled to a mounting foot and its other three mounting brackets coupled each to one or two mounting brackets of one or two respectively adjacent solar panels.

[0073] A frameless module array is provided that may be mounted to a sunlight receiving structure includes integrated module-mounted brackets that attach to other frameless modules with integrated module-mounted brackets by using interlocking bracket-io-brackei connections. The module mounted brackets also attach to mounting feet specifically configured for coupling to the sunlight receiving surface, interlocking mating connections between brackets of adjacent solar panel modules are spring-loaded with pins or shaped for passive alignment or have mating pairs of complementary protrusions and recesses.

[0074] A frameless module may be installed directly onto the pitched roof with flashing and screw anchors to complete the rooftop installation. A frameless module may include an integrated assembly of frameless solar panel, brackets, mounting connectors or feet, supports, wire clips, wire conductors, and optionally a module-mounted inverter that allows the installation of a system of integrated frameless modules directly onto a pitched roof with flashing and screw anchors to complete the installation.

[0075] A frameless module system of frameless modules is provided that are interlocked through integrated module-mounted brackets that enable a first module to be installed to the roof with four mounting connectors or feet securing the first module to the pitched roof and then the array may be expanded by interlocking additional modules up slope from the anchor module, down slope from the anchor module, toward the left side of the anchor module and or toward the right side of the anchor module without any separate hardware or connectors necessary to be installed on the roof before the expansion in any direction. Each expanded frameless module would only have one (1) or two (2) mounting connectors or feel to secure to the pitched roof.

[ΘΘ76] A frameless module system may be made up of integrated frameless modules interlocked through integrated module-mounted brackets with integral mounting connectors or feet that connects to a pitched roof without separate connectors being first a chored or attached to the pitched roof structure.

10077] Each preassembled solar panel may include four integrated mounting brackets that are each configured to couple to a mounting foot or to at least one mounting bracket of an adjacent preassembled solar panel or both, and wherein upon installation, fewer mounting feel are installed directly to the roof structure than the number of mounting brackets that, are each coupled to a mounting foot or to at least one mounting bracket of an adjacent preassembled solar panels or both.

[ΘΘ78] A frameless module system made up of frameless modules interlocked through integrated module-mounted brackets that couple to a fixed structure, ground area, roof system or temporary stmcture through a specific set of mounting connectors or feet that have sensors which electronically measure the compressive pressure exerted by the mounting connector or foot on to the fixed stmcture or exerted by the anchor head agamst the mounting connector or foot. Sensors may be coupled with an active or passive transmitter that can be read by wireless radio signal -enabled mobi le devices,

[0Θ79] A frameless module with integrated module-mounted brackets that attaches to other frameless modules with integrated module-mounted brackets by using interlocking bracket- to-bracket connections made at any angle between zero and a maximum angle that is as high as 90 degrees in certain embodiments and may be 45 degrees in still advantageous embodiments for ease of installation and removal.

[0080] Figure 1 schematically illustrates an embodiment including eight installed solar panels coupled together in 4x2 arrangement. Two rows of four solar modules are shown in the example of Figure 1. Modules 1-4 are higher on the roof than modules 5-8. Various numbers of modules can be installed, including a single module or any number of multiple modules that may each be stand alone or coupled together in groups of two or more. Each preassembled solar module in accordance with certain embodiments can be coupled to another preassembled solar module at either or both long sides and/or at either or both short sides. Thus, for example, a 3x3 arrangement may be installed, where a center module is coupled to an adjacent solar module at each of its four sides.

[0081] In the example of Figure 1, module 1 is installed to the roof by coupling each of its four preassembled mounting brackets to one or four mounting feet. The mounting feet may be coupled to the mounting brackets in preassembly or at the site prior to coupling the solar module to the roof. In another embodiment, one or more mounting feet may be coupled to the roof prior to coupling with a mounting bracket of a solar module that is being installed.

[0082] An electrical box 1102 is included with the solar module 1. The electrical box 1102 has cables 1104 and 1106 coupled electrically thereto and extending each toward an adjacent solar module. In Figure 1, cable 1104 is turned so that it can connect to cable 1108 of module 5, while cable 1106 is a straight cable that connects to cable 1110 of module 2. Cable 1108 is also turned to connect with cable 1104, as modules 1 and 5 are end modules in the example arrangement of Figure 1. The cables of modules 2-4 and 6-8 are each straight like cable 1106 of module 1.

[0083] The electrical box 1102 of module 1 is coupled to one of the two short stiffeners (among the four stiffeners that are arranged to form a smaller rectangular shape than the solar panels themselves: two of the four stiffeners are long and the other two stiffeners are short, the two rectangular shapes being approximately in proportion in Figure 1). Similar electrical boxes are similarly disposed in each of modules 2-4, i.e., coupled to the short stiffeners that is lower on the roof than its counterpart. Similar electrical boxes are also disposed in each of modules 5-8, except these are coupled to the short stiffener that is higher on the roof than its counterpart. In this way, the four electrical boxes of modules 1-4 are disposed each closer to adjacent electrical boxes of modules 5-8 than they would be if the electrical boxes included with modules 5-8 were coupled to the other short stiffener that is lower on the roof than its counterpart.

[0084] Each solar module illustrated in the example of Figure 1 has four corners labeled as A, B, C and D, wherein the electrical boxes are disposed closer to corners A and B than to corners C and D. The preassembled bracket at each of corners A, B, C and D of module 1 is coupled to a mounting foot. Only the preassembled brackets at corners A and C of modules 2-4 are coupled to mounting feet, and only the preassembled brackets at corners C and D of module 5, and only the preassembled brackets at corners D of modules 6-8 are coupled to mounting feet in preassembly either at the factory or at the site prior to being affixed, mounted, attached or otherwise connected mechanically to the roof. The mounting brackets that are not coupled to mounting feet, as just identified for the example of Figure 1, are coupled directly to a mounting bracket of an adjacent solar module.

[0085] In the example of Figure 1, each single mounting bracket that is not coupled to another mounting bracket is preassembled with a mounting foot. Thus, the mounting brackets at corner D of module 1, corner C of module 5, corner D of module 8 and at corner C of module 4 are coupled to mounting feet in preassembly are not coupled with any other mounting bracket in the example of Figure 1. In addition, each of the mounting brackets at corners A and C of modules 2-4 are preassembled with mounting feet, while each of the mounting brackets B and D of modules 2-4 does not have a mounting feet coupled thereto in preassembly.

[0086] In installation, mounting brackets B and D of modules 2-4 are coupled to mounting brackets A and C of an adjacent module rather than directly to the roof via a mounting foot and flashing. Similarly, mounting brackets A and B of modules 5-8 do not have mounting feet coupled thereto in preassembly, and each couples to mounting brackets B and A, respectively, of adjacent modules 1-4. With regard to modules 5-8, module 5 has mounting brackets C and D coupled to mounting feet, while brackets A and B are instead coupled to adjacent brackets, and modules 6-8 are preassembled with mounting feet coupled only to the mounting brackets at corner D for directly coupling to the roof, while the mounting brackets at corners A-C of modules 6-8 are instead coupled to brackets of adjacent modules. In short, wherever two or four adjacent solar module corners couple together in the example of Figure 1 , one mounting bracket (of the two or four) is directly coupled to the roof via a preassembled mounting foot while the other one or three are instead coupled to adjacent mounting brackets. Among the three instances where four corners of four different solar modules meet in the example of Figure 1, three mounting brackets at the corners A of modules 6-8 are not coupled either (i) to the roof directly via a mounting foot or (ii) to an adjacent mounting bracket that is itself coupled to the roof directly via a mounting foot.

[0087] Figure 2 schematically illustrates a preassembled solar panel including mounting brackets in accordance with certain embodiments.

[0088] Figure 3 schematically illustrates a mounting foot in accordance with certain embodiments.

[0089] Figure 4 schematically illustrates an anchor including a snap toggle and machine screw in accordance with certain embodiments.

[0090] Figure 5 schematically illustrates a flashing in accordance with certain embodiments.

[0091] Figure 6 schematically illustrates a junction box in accordance with certain

embodiments.

[0092] Figure 7 schematically illustrates a pair of end caps in accordance with certain embodiments.

[0093] A example method of installing a set of four preassembled solar modules of a solar electric system that includes snap together modules that may be attached directly to a composite shingle roof, for example, without any prerequisite mounting structure. Steps A to D below are general steps involved in an example process in accordance with certain embodiments.

[0094] A. LAYOUT ROOF (for flashing at each foot)

[0095] Use the INSTALLATION SCHEMATIC (e.g., Figure 1) to guide the layout of flashing. Flashing is placed under each mounting foot. Mounting feet may be shared by up to four modules as described with reference to Figure 1.

[0096] B. PLACE FLASHING [0097] Place flashing at each bracket centerline location, tucking the flashing under the next roofing course up.

[0098] C. PREP MODULES

[0099] In this step, feet may be installed if they have not been coupled to mounting brackets in preassembly at the factory. Cables also should be dressed if not already preassembled.

Before laying the modules on the roof, each should be prepared in accordance with the general principles described with reference to Figure 1.

[0100] D. INSTALL MODULES

[0101] Lift the modules to the roof and install.

[0102] Further examples and alternative embodiments are described below with reference to

Figures 8-27, which schematically illustrate a method of installing a set of four preassembled solar modules on a roof surface in accordance with certain embodiments.

[0103] Referring to Figure 8, set the Anchor Point on first course. An INSTALLATION

SCHEMATIC may be provided that defines the dimension of the anchor point off of roof edge. Figure 1 illustrates an example where the anchor point is set at the installation point of corner D of module 1.

[0104] Referring to Figure 9, mark centerline of 1st flashing on first course, e.g., where the lower left bracket, e.g., at corner C of module 1 of Figure 1, is to be placed.

[0105] Referring to Figure 10, Measure 31 1/2" & mark centerline of 2nd flashing, e.g., where lower right bracket at corner B of module 1 of Figure 1, is to be placed.

[0106] Referring to Figure 11, Measure 41 1/4" & mark centerline of 3rd flashing, e.g., where lower left bracket at corner C of module 2 in Figure 1 , is to be placed.

[0107] Referring to Figure 12, Using Install Template, find & mark the open shingle course [up slope]. Use the course which aligns with 4 of the inch scale marks at the top of the template - this is the course where the next row of flashing will be placed and where the top of module 1 will be.

[0108] Referring to Figure 13, Mark the centerline of the 4th flashing, where the upper left corner A of module 1 will be placed.

[0109] Referring to Figure 14, Measure over 31 1/2" and 41 1/4" and mark centerline of 5th and 6th flashing locations.

[0110] Referring to Figure 15, Install flashing at all centerline marks.

[0111] Referring to Figure 16, Prep modules: Install Junction Box & End Caps.

[0112] Referring to Figure 17, Prep modules: Verify cable management (see

INSTALLATION SCHEMATIC, e.g., as described above and illustrated at Figure 1). [0113] Referring to Figure 18, Prep modules: Verify Feet locations, e.g., as described and illustrated with reference to Figure 1.

[0114] Referring to Figure 19, Install Module 1 (aka "anchor module"). Align with flashing and secure. Adjust up slope feet as required & tighten with alien wrench.

[0115] Referring to Figure 20, Drill ½" holes through feet (to Insert SNAPTOGGLE anchors into).

[0116] Referring to Figure 21, DRILL 2 X holes per foot. Insert SNAPTOGGLE into each ½" hole in foot. Insert toggle nut first (making sure that the toggle nut is positioned straight up and down.

[0117] Referring to Figure 22, SNAP off SNAPTOGGLE and insert 3/16" screw through SNAPTOGGLE.

[0118] Referring to Figure 23, Drive 3/16" screw in SNAPTOGGLE. It may facilitate this step if the top of SNAP is secured or held. TOGGLE to prevent spinning.

[0119] Referring to Figure 24, Install Module 2: lock to Anchor Module. Hold module vertical against edge of Anchor Module. Lower & snap into the snap connectors of the anchor module.

[0120] Referring to Figure 25, Install Module 2: connect electrical cables. Connect the electrical cables and secure cables in the clips.

[0121] Referring to Figure 26, Install Module 2: secure to roof. Rotate the panel down so that both feet are laying on roof. Adjust feet & tighten ¼ turn with wrench. Secure to the roof with two (2) SNAPTOGGLE Anchors in each foot and two (2) 3/16 screws in each anchor.

[0122] Referring to Figure 27, Repeat for Module 3 and Module 4.

What follows is an example of an interlocking module system installation process, wherein an initial step, or step 0, involves installing or exposing flashing areas for securing mounting feet. Certain installation work-flows are advantageously provided for solar panels in accordance with certain embodiments including "Process One" (PI).

The assembly of a solar module, an integral mounting bracket and attached mounting feet

(with or without a micro-inverter) may be referred to herein as an "interlocking module". At Step 0: install appropriate flashing at the attachment points for the interlocking modules using a provided guide with dimensioned flashing locations depending on the type of fixed structure and roofing type.

[0123] A next step follows in an Interlocking module system installation process - Step 1. [0124] Step 1 : Install first interlocking module in the first row. Be sure to install in a location which allows for future expansion. Once in the correct location, anchor each mounting foot with the provided anchors.

[0125] Step la includes installing an anchor through mounting foot A with the provided anchors.

[0126] Step lb includes installing an anchor through mounting foot B with the provided anchors.

[0127] Step lc includes installing an anchor through a mounting foot D with the provided anchors.

[0128] Step Id includes installing an anchor through mounting foot C with the provided anchors.

[0129] Step 2a includes installing second interlocking module in the first row. Step 2a may involve inserting one edge of interlocking module two into mounting bracket connection point in interlocking module one and connecting the solar panel electrical conductors (not shown) from the first interlocking module and the second interlocking module.

[0130] Step 2b includes lowering the other edge of the second interlocking module for the mounting feet to rest on the flashing, and pivoting at the connection point [220] between the two pair of mounting brackets.

[0131] Step 2c illustrates anchoring two mounting feet on the opposite edge of the module 212 from the first interlocking module with the provided anchors, and Installing an anchor through mounting foot B and installing an anchor through mounting foot D as shown.

[0132] Step 3 of the example solar panel installation process includes repeating Step 2 N times, where N = the number of modules to install along the horizontal direction (e.g., the first row of modules or those adjacent modules spanning to the right of interlocking module 2).

[0133] Step 4a includes installing a first interlocking module [228] in the second row.

[0134] Step 4a may include inserting one edge of interlocking module three into the mounting bracket connection point in the first interlocking module.

[0135] Step 4b includes lowering the other edge of interlocking module three for the mounting feet to rest on the flashing and pivoting at the connection point between the two pair of mounting brackets.

[0136] Step 4c may include installing anchors through mounting foot C and anchoring through mounting foot D with the provided anchors. [0137] Step 5a includes installing the second interlocking module in the second row. Step 5a may include inserting one edge of interlocking module four in the mounting bracket connection point in the first interlocking module, then connecting the electrical conductors (not shown) from the first interlocking module and the second interlocking module in the second row.

[0138] Step 5b includes lowering the other edge of the interlocking module four for the mounting feet to rest on the flashing, including pivoting at the connection point between the two pair of mounting brackets.

[0139] Step 5d includes anchoring the bottom mounting foot D with the provided anchor.

[0140] Step 6a of the example process includes repeating Step 4 N times, where N = the number of modules to install along the second row of modules.

[0141] Figure 28 schematically illustrates a pair of uncoupled solar panel connectors in accordance with certain embodiments. A durable polymer may be used for the connectors, such that when coupling, certain components may bend and to permit a pair of male-female components, or protrusion-recess pairs, to couple together such as to snap into place at points of stable equilibrium where the protrusion just sets into the recess. When adjacent solar modules are brought together including adjacent mounting bracket connector pairs, the angular shapes of the four surfaces of the recess connector component allow imprecision that is compensated when complementary components of the protrusion connector component abut therewith to center to connectors in alignment for snapping together.

[0142] Figure 29 schematically illustrates a pair of coupled and unlocked solar panel connectors in accordance with certain embodiments. A sliding locking latch is coupled to the recess connector component including a pair of spacer protrusions that are aligned with open spaces on the insides of the protrusion connector components (the protrusions face outward or away from each other in the example of Figures 28-30, but these can be reversed).

[0143] Figure 30 schematically illustrates a pair of coupled and locked solar panel connectors in accordance with certain embodiments. After the protrusion and recess connector components are snapped into place, they are locked together securely when the sliding locking mechanism is actuated to bring the spacer protrusions in to fill the open spaces that are apparent in Figure 29 on the insides of the protrusion connector components after they are snapped into place and thereby coupled with the complementary recess connector

components. With the spaces being filled by the spacer protrusions, the protrusion connector components are unable to bend inwardly to uncoupled from the recess. In this way, the coupling of the adjacent mounting brackets is secured by actuating the locking mechanism. [0144] Figure 31 schematically illustrates a pair of adjacent preassembled solar panel module including two pairs of complementary bracket connectors 1202, 1204 that are not yet coupled together. Each side of a preassembled solar module includes two bracket connectors for coupling with two bracket connectors of an adjacent preassembled solar panel module. The two bracket connectors shown along each side of the two solar panel modules illustrated at Figure 31 include one of each complementary bracket connectors 1202 and 1204. In alternative embodiments, both can be the same on one side of one solar panel module as long as both connectors on the adjacent solar panel module are also the same and the bracket connectors that are to be coupled together, one from each adjacent solar panel module, comprise a pair of complementary bracket connectors 1202, 1204. Just to the outside of bracket connector 1204 is an alignment bumper 1206 upon which one of the outside segments of bracket connector 1202 can rest as coupling is being performed while preventing contact with the edge of the solar panel.

[0145] Figure 32 schematically illustrates four solar panel corners installed as a 2x2 array or subarray that each include a corner bumper that overlaps in two dimensions. These bumper protect the solar panels from striking the ground along its edges and corners during transport and assembly. In another embodiment, the bumpers overlap the corners both above and below the solar panel, so that preassembled solar panels can be stacked without any components contacting the solar panel surface.

[0146] Various modifications and alterations of the invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention, which is defined by the accompanying claims. It should be noted that steps recited in any method claims below do not necessarily need to be performed in the order that they are recited.

Those of ordinary skill in the art will recognize variations in performing the steps from the order in which they are recited. In addition, the lack of mention or discussion of a feature, step, or component provides the basis for claims where the absent feature or component is excluded by way of a proviso or similar claim language.

[0147] While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not of limitation. The various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that may be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features may be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations may be implemented to implement the desired features of the present invention. Also, a multitude of different constituent module names other than those depicted herein may be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.

[0148] Although the invention is described above in terms of various exemplary

embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.

[0149] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term "including" should be read as meaning "including, without limitation" or the such as; the term "example" is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms "a" or "an" should be read as meaning "at least one," "one or more" or the such as; and adjectives such as "conventional," "traditional," "normal," "standard," "known" and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future.

Hence, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.

[0150] A group of items linked with the conjunction "and" should not be read as requiring that each and every one of those items be present in the grouping, but rather should be read as "and/or" unless expressly stated otherwise. Similarly, a group of items linked with the conjunction "or" should not be read as requiring mutual exclusivity among that group, but rather should also be read as "and/or" unless expressly stated otherwise. Furthermore, although items, elements or components of the invention may be described or claimed in the singular, the plural is contemplated to be within the scope thereof unless limitation to the singular is explicitly stated.

[0151] The presence of broadening words and phrases such as "one or more," "at least," "but not limited to" or other such as phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. The use of the term "module" does not imply that the components or functionality described or claimed as part of the module are all configured in a common package. Indeed, any or all of the various components of a module, whether control logic or other components, may be combined in a single package or separately maintained and may further be distributed across multiple locations.

[0152] Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives may be implemented without confinement to the illustrated examples. For example, block diagrams and their accompanying description should not be construed as mandating a particular architecture or configuration.

[0153] The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

[0154] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the such as represent conceptual views or processes illustrating systems and methods in accordance with particular embodiments. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named manufacturer.

INCORPORATION BY REFERENCE

[0155] What follows is a cite list of references which are, in addition to those references cited above and below herein, and including that which is described as background, the invention summary, brief description of the drawings, the drawings and the abstract, hereby

incorporated by reference into the detailed description of the preferred embodiments below, as disclosing alternative embodiments of elements or features of the preferred embodiments not otherwise set forth in detail below. A single one or a combination of two or more of these references may be consulted to obtain a variation of the preferred embodiments described in the detailed description below. Further patent, patent application and non-patent references are cited in the written description and are also incorporated by reference into the preferred embodiment with the same effect as just described with respect to the following references:

[0156] United States patent nos. 6161999, 6035595, 6750391, 7406800, 7435134, 7592537, 7762027, 7806377, 7819114, 7921607, 7977818, 7987641; and

[0157] United States published applications nos. 2003/0070368, 2006/0090789,

2007/0295393, 2009/0078299, 2009/0282755, 2010/0018571, 2010/0089389, 2010/0089390, 2010/0212244, 2010/0219304, 2011/0000526, 2011/0005983, 2011/0088740, 2011/0174365, 2011/0203637, 2011/0241426, 2012/0005983, 2012/0061337; and

[0158] PCT published application no. WO2014/059445A2; and

[0159] United States Design patent no. D600200S; and

[0160] Citation. PCT Notification of Transmittal of the International Search Report and the Written Opinion of the International Searching Authority, or the Declaration, for PCT Application No. PCT/US2013/065144, dated March 28, 2014, 9 pages.

Claims

What is claimed is:

1. A preassembled solar power module system, comprising:

a plurality of at least four mounting feet coupled to a sunlight receiving surface that receives effective amounts of sunlight;

a plurality of solar panels each preassembled with a front surface configured to collect and convert solar radiation for use as a source of energy and a back surface including a preassembled mounting bracket at each corner that is configured for coupling with a mounting foot for coupling to said sunlight receiving surface, and with a preassembled mounting bracket of an adjacent solar panel,

wherein the preassembled mounting brackets of the adjacent solar panels comprise complementary flexible snap coupling components and a locking mechanism that prevents further flexing of the snap coupling components, and thereby prevents decoupling, when actuated into a locked position and permits flexing and coupling or decoupling when disposed in an unlocked position.

2. The system of claim 1, wherein each solar panel comprises an electrical box and cables to connect with electrical boxes of other solar panels.

3. The system of claim 1 , wherein mounting feet are configured to structurally attach to a roof surface at any location without first locating roof structural members such as rafters.

4. The system of claim 3, wherein upon installation, a first solar panel is anchored to the sunlight receiving surface with four mounting feet securing an anchor module to a pitched roof, and wherein the system is expanded by coupling additional solar panels together by snap-coupling adjacent mounting brackets and coupling mounting brackets having mounting feet coupled thereto directly to the sunlight receiving surface, such that solar panels other than the first solar panel include one or two mounting brackets that are each coupled to a mounting foot that is directly coupled to the roof and two or three mounting brackets, respectively, that are each coupled to a mounting bracket of an adjacent solar panel.

5. The system of claim 4, wherein solar panels other than the first solar panel couple with installed modules without first installing separate hardware or connectors on the roof before the expansion modules are installed in any direction.

6. The system of claim 4, wherein solar panels other than the first solar panel comprise no more than two (2) mounting brackets coupled directly to mounting feet anchored to the sunlight receiving surface.

7. The system of claim 6, wherein upon installation mounting brackets on expansion modules are interconnected with mounting brackets on adjacent modules at a maximum angle in the range of 45 degrees to 90 degrees to the plane of the adjacent solar panel.

8. The system of claim 3, wherein a mounting foot is configured to adjust in at least one dimension between itself and a mounting bracket, such as an adjustment in the upslope and downslope dimension or an adjustment that allows variability in the axis where the plane of the sunlight receiving surface and the plane of the exposed roofing course intersect, or combinations thereof.

9. The system of claim 3, wherein the mounting feet are configured with sensors which electronically measure compressive pressure exerted onto the fixed structure or exerted by the anchor head against the mounting foot.

10. The system of claim 1, wherein each solar panel comprises corner bumpers that overlap the solar panel in at least two dimensions.

11. The system of claim 10, wherein said corner bumpers overlap the solar panel in three dimensions.

12. The system of claim 1, wherein each solar panel comprises one or more alignment bumpers near at least one of the bracket connectors on each side that are configured for contacting a complementary bracket connector during coupling of adjacent solar panel modules.

13. A preassembled solar power module system, comprising:

wherein each solar panel comprises corner bumpers that overlap the solar panel in at least two dimensions.

14. The system of claim 13, wherein said corner bumpers overlap the solar panel in three dimensions.

15. The system of claim 13, wherein each solar panel comprises one or more alignment bumpers near at least one of the bracket connectors on each side that are configured for contacting a complementary bracket connector during coupling of adjacent solar panel modules.