WO2016204941A1 - Système de montage de modules photovoltaïques à verrouillage automatique - Google Patents

Système de montage de modules photovoltaïques à verrouillage automatique Download PDF

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Publication number
WO2016204941A1
WO2016204941A1 PCT/US2016/033843 US2016033843W WO2016204941A1 WO 2016204941 A1 WO2016204941 A1 WO 2016204941A1 US 2016033843 W US2016033843 W US 2016033843W WO 2016204941 A1 WO2016204941 A1 WO 2016204941A1
Authority
WO
WIPO (PCT)
Prior art keywords
lobe
base portion
orientation
photovoltaic module
assembly according
Prior art date
Application number
PCT/US2016/033843
Other languages
English (en)
Inventor
Brian Atchley
Tyrus Hudson
David Molina
Jack Raymond WEST
Original Assignee
Solarcity Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US14/739,942 external-priority patent/US9397607B2/en
Application filed by Solarcity Corporation filed Critical Solarcity Corporation
Publication of WO2016204941A1 publication Critical patent/WO2016204941A1/fr

Links

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
    • 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
    • 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
    • F24S25/65—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules for coupling adjacent supporting elements, e.g. for connecting profiles together
    • 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
    • F24S2025/01—Special support components; Methods of use
    • F24S2025/023—Means for preventing theft; Locking means
    • 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
    • F24S2025/6007—Fixation means, e.g. fasteners, specially adapted for supporting solar heat collector modules by using form-fitting connection means, e.g. tongue and groove
    • 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
    • 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
    • Y02B10/20—Solar thermal
    • 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

  • the invention relates generally to mounting systems for photovoltaic modules, and more specifically to roof-top mounting systems for use in residential and commercial applications.
  • FIG. 1 is a plan view of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 2 is another plan view of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 3 is an end view of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG 4 is a side view of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 5 is a top view of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 6 is a partially exploded perspective view of the components of a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 7 is another perspective view of a photovoltaic mounting system in the unlocked position according to various embodiments of the invention.
  • FIG. 8 is another perspective view of a photovoltaic mounting system in the partially locked position according to various embodiments of the invention.
  • FIG. 9 is close-up perspective view of a photovoltaic mounting system in the locked position according to various embodiments of the invention.
  • FIG. 10 is another perspective view of a photovoltaic mounting system including a flashing according to various embodiments of the invention.
  • FIG. 11 is another perspective view of a flashing for a photovoltaic mounting system according to various embodiments of the invention.
  • FIG. 12 is a side view of another perspective view of a photovoltaic mounting system including a flashing according to various embodiments of the invention.
  • FIG. 13 is a perspective view of a flashing according to various embodiments of the invention.
  • Various embodiments of the invention accomplish this with a self-locking mounting system for photovoltaic panels that reduces and ideally minimizes tool usage when installing PV.
  • Various embodiments may utilize a photovoltaic module lever-lock that couples together two photovoltaic modules with manually applied torque.
  • the lever-lock may be joined to a planar base portion having a pair of parallel channels that enable the lever-lock to be installed with adjustability in the east-west (left side to right side) and north-south (roof eave to roof ridge) directions.
  • the lever-lock may incorporate a torque lever for torqueing the coupling device into one of the channels formed in the base portion.
  • the, lever-lock may incorporate a photovoltaic module coupling that couples together two or more photovoltaic modules.
  • Various embodiments may also include a partial flashing portion that covers the up-roof end of the base portion as well as a lag-bolt screw opening formed therein. Other embodiments may include a bottom flashing.
  • FIGs 1-9 illustrate various views of a first exemplary embodiment of a photovoltaic mounting system according to this invention.
  • the system 100 according to the exemplary embodiment illustrated in these figures comprises base portion 110, which in this example is an substantially planar extrusion having top sky-facing surface 1 11, bottom roof- facing surface 118, and channels 112A, 112B that run between down-roof end 114 and up- roof end 115.
  • Each channel 112A, 112B has an opening that leads to a corresponding larger diameter, asymmetrical recess running the length of extrusion (e.g., see recesses 119A and 119B depicted in FIG. 1).
  • the outside of each such recess is framed by respective sides 1 17 and 116 of base portion 110 and by the middle of base portion 110.
  • System 100 also comprises manually actuated lever lock 130.
  • lever lock 130 comprises torque lever 131, lobe 132, threaded opening 133 and threaded stud 134, which terminates at pedestal 135.
  • lobe 132 may be dimensioned so that when it is aligned lengthwise with (i.e., parallel with) either channel 112A or 122B, it will fit within the channel opening.
  • lobe 132 fits within the asymmetric recess in each channel, thereby locking it into place so that the main axis of lobe 132 is approximately oriented perpendicular to channel 112A.
  • torque may be applied either clockwise or counterclockwise, however, as shown, the recesses in channels 112A and 112B, as well as lobe 132 all have an orientation that results in torque lever 131 pointing outward, perpendicular to the outer surface of either side 117 or 1 16. It should be appreciated that in various embodiments, the orientation of either recess, lobe 132, or both, may be oriented differently so that when locked into place, torque lever 131 points in towards the center of base portion 110. Such modifications are within the scope of the invention.
  • each end of lobe 132 is tapered to match the tapering formed in the wall of each recess. This geometry may provide better fitment and tolerances than a squared edge, however, other geometries may also be used.
  • base portion 1 10 also includes concentric openings 113A, 113B that allow lag bolt 120 to be installed through top surface 111 into a support surface such as a roof deck.
  • top opening 113A is larger than bottom opening 113B so that lag bolt head 121 and a socket, drill and/or other tool can pass through opening 113A but be stopped by opening 113B when bolt 120 is tightened down to the roof.
  • two or more pairs of concentric openings may be used to provide additional support (e.g., two or more lag bolts). Such modifications are within the spirit and scope of the invention.
  • base portion 110 may include pad 150 of rubber, butyl, sealant or other resilient, water-resistant material spanning the entire roof-facing side 118, or simply a portion of the bottom of base portion 110.
  • This pad 150 may help prevent the ingress of water around the lag bolt opening as well as helping to adjust for variations in the roof surface, such as, for example, when the base portion spans two courses of shingles.
  • an installer may simply apply some sealant on underside 118 of base portion 110 and/or around the lag boh hole in the roof surface prior to torqueing down the lag bolt.
  • FIGs 6, 7, and 9, these Figures illustrate various close-up perspective views of exemplary torque lever 130 combined with base portion 110.
  • torque lever 130 may include a catch 136 that prevents lever 131 and lobe 132 from coming unlocked after they have been torqued into the channel recess.
  • catch 136 is attached to one side of lever 131, protruding down slightly further than the bottom of lever 131, like a spring, so that once lever 131 has been rotated far enough to allow catch 136 to clear the top surface 111 of base portion 110 (see e.g., FIG. 9), catch 136 will tend to prevent the rotation in the reverse direction resulting in an unintentional release of lever lock 130.
  • an operator will have to slightly lift up on torque lever 131 while rotating the catch towards the base portion (either clockwise or counterclockwise depending on which channel it is engaged with) so that the catch clears top surface 111 of base portion 110.
  • a metal flashing is typically installed first, directly over the shingles, or in some cases after removing one or shingles or portions of one or more shingles.
  • Known advantages of such flashings include additional protection against leaks and coverage of errant lag bolt pilot holes that missed the roof rafter.
  • Known disadvantages include extra cost, poor aesthetics, and creation of additional holes in the roof surface; shingle nails often need to be removed to allow the flashing to be tucked under the up-roof course of shingles, each of which creates a potential point of water ingress.
  • various embodiments of the invention may include a base flashing, such as flashing 180 illustrated in FIG. 13.
  • flashing 180 may comprise a substantially planar sheet of metal having a flat portion 181 typically shaped into a rectangle with rounded edges or, alternatively, shaped as a disk. Flashing 181 may also comprise raised portion 182 which defines the outline of base portion 110 and which also serves to divert water running down roof away from base portion 110.
  • flashing 180 may be installed as the first system component, at the location where a lag bolt pilot hole has been drilled, and be oriented so that raised portion 182 points up-roof (e.g., between lag bolt opening 163 and the roof peak) and so that opening 183 is located over the lag boh drill hole or pilot hole formed in the roof (not shown in the Figure).
  • Flashing 180 may also include a rubber gasket 184 having a bottom portion 185 and top portion 186 that is designed to be inserted into lab bolt hole 183, providing further protection against the ingress of water, in particular when compressed by base portion 100 under the force of the lag bolt.
  • lag bolt 120 is pushed through concentric holes 113A, 113B, of base portion 110 until threaded portion 122 penetrates the opening in top portion 186 of gasket 184, before being torqued down into the roof.
  • the base portion 110 and flashing 180 can be attached to the roof surface at the same time using a single lag bolt.
  • more than one lag bolt may be used and also, additional screws, nails, adhesive, or other fasteners maybe used to secure flashing 180 to the roof surface.
  • base portion 110 of system 100 may sit on top of flashing 180 so that it sits within the space defined by raised portion 182 and so that the concentric openings 113A, 113B are aligned directly over gasket 184 and opening 183 to permit a lag bolt to pass through all three structures (base portion 110, gasket 184, and flashing 180) before penetrating the roof surface.
  • top flashing 150 may include a flat, roof-contacting portion 151 designed to sit up-roof from base portion 110, at least partially under the next course of shingles on shingled roof surface 200. Tins will help divert water flowing down the roof away from the base portion and ideally prevent it from going under base portion 110.
  • Top flashing 150 may also include a raised portion 152 that is dimensioned to substantially accommodate and conceal the up-roof facing end 115 of base portion 110, sealing it off from the flow of water and extending down roof for a portion of the base portion 110 along either side 116, 117 and covering a portion of channels 112A, 112B.
  • Top flashing 150 may also include a protrusion 153 that although in the same plane as raised portion 151, extends further down roof either partially (as shown) or completely over base portion 110, thereby covering any lag bolt openings, such as concentric holes 113 A and 113B. This may also help to prevent potential leaks from both running and standing water, and may be sufficient to satisfy local code requiring the use of flashings.
  • FIGs 1-9 and 12 illustrate a pivot-lock coupling device, such as that described in commonly assigned U.S. Patent Application No. 14/615,320, Publication No. 2015/0155823-A1, the disclosure of which is herein incorporated by reference in its entirety.
  • coupling device 140 will support two adjacent photovoltaic modules that are in turn vertically supported above a roof surface by threaded stud 134, and base portion 110.
  • Coupling device 140 has a key side (short side) and tongue side (long side) each adapted to engage with a groove formed in the frame of a photovoltaic module. For example, in FIG. 4, the key side is shown on coupling device 140 pointing left, while the tongue side is shown pointing right.
  • Both the key side and tongue side may be considered male coupling portion.
  • the key side may be installed to point down-roof allowing a photovoltaic module, section of array skirt or other structure with a female coupling portion to be mated thereto.
  • Such a coupling device may be particularly advantageous because no tools are required to attach and detach a photovoltaic module to either the key side or the tongue side; they are simply pivot-locked into place.
  • coupling device 140 is free to rotate about threaded stud 140 and because it has an opening in the top that permits access to a geometric recess formed in the top of stud 140, vertical adjustment of the coupling device 140 is possible from above, even after two photovoltaic modules have been attached to coupling device 140, thereby enabling an installer to level that portion of the photovoltaic array during installation without having to first remove the modules.
  • lever lock 130 includes a clamping-style photovoltaic module connector 160 instead of rock-it coupling device 140.
  • Clamping-style connector 160 has the advantage that it works with virtually all photovoltaic module frames and does not require them to have a female receiving portion or groove formed in the outer surface of the module frame to mate with a reciprocal key portion or tongue portion of the connector.
  • clamping-style connector 160 includes a base 161 that provides a shelf for resting a photovoltaic module on. Base portion 161 may or may not include a pair of flanges at each distal end to serve as a catch to prevent the module from sliding out under the force of gravity before the clamping connector has been engaged.
  • Connector 160 also includes top clamping portion 162 that moves closer to base portion 161 via shaft 163 when screw 165 is rotated.
  • spring 164 may bias clamping portion 162 away from base 161 to make it easier to slide photovoltaic module frames 170 into either side of base portion 161.
  • base portion 161 and clamping portion 162 may be long enough to allow the corners of two adjacent photovoltaic modules to be attached on each side along the connector 160, thereby supporting a two-by-two sub-array of four adjacent photovoltaic modules at the internal intersecting of their respective corners.
  • lever lock 130 may be the same as in previous embodiments.
  • design and advantages of the lever lock according to various embodiments of the invention are not unique to any particular type of photovoltaic module mounting bracket, coupling or connector.
  • rock-it type connector, clamping-style connector or other module coupling device it may be desirable to incorporate integrated alternative path as way to electrically ground the photovoltaic modules connected to lever lock mounting assembly.
  • This function is accomplished in part by choice of materials (e.g., using aluminum or other electrically conductive allow) and also by including structure that is design to make an electrically conductive bond with the photovoltaic modules.
  • grounding is achieved through the use of a grounding clip that cuts into a portion of both PV module frames supported by the rock-it.
  • a grounding pin, prong, or other structure may be formed into either base portion 161 or clamping portion 162 to create an alternate ground path through lever lock 130 to the roof surface.

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  • Engineering & Computer Science (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)

Abstract

Ensemble de montage de module photovoltaïque comprenant un verrou à levier de module photovoltaïque et une partie de base pour la fixation des modules photovoltaïques sur une surface de toit. La partie base comprend un ou plusieurs canaux parallèles qui permettent d'accéder à un ou plusieurs évidements correspondants formés dans une surface supérieure de la partie base. Le verrou à levier comprend un lobe à une extrémité, un levier de couple à l'autre et supporte un connecteur de module photovoltaïque. Le lobe est dimensionné pour s'adapter dans le canal selon une première orientation, et lors d'une rotation d'approximativement 90 degrés, pour s'adapter dans l'évidement selon une seconde orientation. Le connecteur de module peut supporter deux, ou plus, modules photovoltaïques.
PCT/US2016/033843 2015-06-15 2016-05-23 Système de montage de modules photovoltaïques à verrouillage automatique WO2016204941A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/739,942 2015-06-15
US14/739,942 US9397607B2 (en) 2011-11-09 2015-06-15 Self-locking photovoltaic module mounting system

Publications (1)

Publication Number Publication Date
WO2016204941A1 true WO2016204941A1 (fr) 2016-12-22

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2016/033843 WO2016204941A1 (fr) 2015-06-15 2016-05-23 Système de montage de modules photovoltaïques à verrouillage automatique

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WO (1) WO2016204941A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107070388A (zh) * 2017-02-13 2017-08-18 马倩 安装光伏组件的钩锁装置

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008124158A1 (fr) * 2007-04-06 2008-10-16 West John R Procédé et appareil de formation et de montage d'un ensemble photovoltaïque
US20150107168A1 (en) * 2012-07-23 2015-04-23 Yanegijutsukenkyujo Co., Ltd. Securing structure for solar cell module
US20150155823A1 (en) 2011-12-13 2015-06-04 Solarcity Corporation Connecting components for photovoltaic arrays

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2008124158A1 (fr) * 2007-04-06 2008-10-16 West John R Procédé et appareil de formation et de montage d'un ensemble photovoltaïque
US20150155823A1 (en) 2011-12-13 2015-06-04 Solarcity Corporation Connecting components for photovoltaic arrays
US20150107168A1 (en) * 2012-07-23 2015-04-23 Yanegijutsukenkyujo Co., Ltd. Securing structure for solar cell module

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN107070388A (zh) * 2017-02-13 2017-08-18 马倩 安装光伏组件的钩锁装置

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