Portable solar photovoltaic array

Abstract

A portable PV module array, the modules being connected along adjacent end edges and being foldable relative to each other about the connected end edges between a closed condition and an open condition, whereby: in the closed condition, the PV modules are stacked together in a generally parallel and close facing relationship with the edges of the PV modules in general alignment, and in the open condition, the PV modules are disposed at an angle to each other so that the PV module array defines triangular configuration, and foldable movement of the PV modules from the closed condition to the open condition being restricted against movement beyond the open condition by a flexible connector that connects with a connection point associated with each of the PV modules of the PV module array and that is tensioned in the open condition and that is slack in the closed condition.

Claims

1. A portable photo-voltaic (PV) module array comprising: at least two planar PV modules which are of generally square or rectangular configuration so that each PV module defines a generally square or rectangular edge of substantially the same dimensions and comprising a pair of substantially parallel end edges and a pair of substantially parallel side edges, the PV modules being connected and being foldable relative to each other between a closed condition and an open condition, whereby: in the closed condition, the PV modules are stacked together in a generally parallel and close facing relationship with the edges of the PV modules in general alignment, in the open condition, the PV modules are disposed at an angle to each other so that the PV module array defines triangular configuration, and foldable movement of the PV modules from the closed condition to the open condition being prohibited against movement beyond the open condition by a flexible connector that connects with a connection point associated with each of the PV modules of the PV module array, the flexible connector being slack in the closed condition and remaining slack as the PV modules move to the open condition and the flexible connector being tensioned once the PV modules reach the open condition to prohibit movement of the PV modules beyond the open condition.

2. A portable PV module array according to claim 1, the flexible connector being fixed in length between the connection points associated with the PV modules of the PV module array.

3. A portable PV module array according to claim 1, the flexible connector being adjustable.

4. A portable PV module array according to claim 1, the flexible connector being flexible but substantially inextensible.

5. A portable PV module array according to claim 1, the flexible connector being supported in the closed condition so that it is retained relative to the PV modules in a supported condition.

6. A portable PV module array according to claim 5, the flexible connector being supported in the closed condition by a spring arrangement in which a spring is connected to the flexible connector and whereby as the PV modules move to the open condition, the spring extends as the flexible connector is tensioned and as the PV modules are shifted from the open condition to the closed condition, the spring retracts, lifting the flexible connector upwardly and supporting the flexible connector in the closed condition.

7. A portable PV module array according to claim 1, the connection of the PV modules being by a flexible plastic, rubber or fabric hinge.

8. A portable PV module array according to claim 1, the connection of the PV modules being by rope, cable or chain.

9. A portable PV module array according to claim 1, the connection of the PV modules being by a metal hinge which comprises two parts that are separately connected to facing end edges of adjacent PV modules and a pin that extends between the parts and allows them to pivot relative to one another in a hinging manner.

10. A portable PV module array according to claim 1, the PV array comprising at least four PV modules whereby the PV modules form a series of alternative peaks and troughs.

11. A portable PV module array according to claim 1, the connection points being spaced from the peak of the triangular configuration of the PV modules of the PV array.

12. A portable PV module array according to claim 1, the PV array including at least four PV modules connected in a series of alternating peaks and troughs, and the connection points being made at the troughs of the PV array.

13. A portable PV module array according to claim 1, the connection points being formed on side edges of the PV modules.

14. A portable PV module array according to claim 1, the connection points being formed inboard of side edges of the PV modules.

15. A portable PV module array according to claim 1, the PV array comprising at least two adjacent rows of PV modules formed in a triangular configuration whereby the triangular configuration of the adjacent rows are aligned.

16. A portable PV module array according to claim 15, the flexible connector being operable to prohibit foldable movement of all of the rows of PV modules against movement beyond the open condition.

17. A portable PV module array according to claim 1, the flexible connector being electrically conductive and the PV modules being electrically connected to the flexible connector to earth the PV modules.

18. A method of installing a portable PV module array, the PV module array comprising at least two planar PV modules which are of generally square or rectangular configuration so that each PV module defines a generally square or rectangular edge of substantially the same dimensions and comprising a pair of substantially parallel end edges and a pair of substantially parallel side edges, the PV modules being connected and being foldable relative to each other between a closed condition and an open condition, whereby: in the closed condition, the PV modules are stacked together in a generally parallel and close facing relationship with the edges of the PV modules in general alignment, in the open condition, the PV modules are disposed at an angle to each other so that the PV module array defines triangular configuration, and foldable movement of the PV modules from the closed condition to the open condition being prohibited against movement beyond the open condition by a flexible connector that connects with a connection point associated with each of the PV modules of the PV module array, the flexible connector being slack in the closed condition and remaining slack as the PV modules move to the open condition and the flexible connector being tensioned once the PV modules reach the open condition to prohibit movement of the PV modules beyond the open condition, the method comprising the steps of: transporting the PV module array to an installation site in the closed condition such that the flexible connector is slack; and moving the PV modules relative to each other, so that the flexible connector moves from slack to tensioned when the PV modules reach the open condition, wherein tensioning of the flexible connector indicates that the PV module array has reached the open condition.

19. A method according to claim 18, the PV module array including at least four PV modules.

20. A method according to claim 19, the method including lifting the PV array in the closed condition onto a surface on which the PV module array is to be installed and shifting the PV modules from closed condition to the open condition, whereby the modules are shifted from one end of the PV module array and move to the open condition progressively from the closed condition.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) In order that the invention may be more fully understood, some embodiments will now be described with reference to the figures in which:

(2) FIG. 1 is a perspective view of a portable PV array in an open condition.

(3) FIG. 2 is a view of the portable PV array of FIG. 1, but in the closed position.

(4) FIG. 3 is a further view of a portable PV array in the closed condition.

(5) FIG. 4 is an underneath perspective view of the PV array shown in FIG. 2.

(6) FIG. 5 is a view of the bottom section of the PV array shown in FIGS. 2 and 4.

(7) FIGS. 6 to 8 are perspective views from different angles of a further portable PV array shown in a partially installed condition.

(8) FIG. 9 is a detailed view of an arrangement for earthing a PV module.

(9) FIG. 10 is a view of the trough between a pair of PV modules and showing a hinge arrangement that supports a flexible connector.

(10) FIG. 11 is a perspective view of a portable PV array in an open condition and showing a flexible connector in a tensioned condition.

DETAILED DESCRIPTION

(11) FIG. 1 is a perspective view of a portable PV array 10 according to one embodiment of the invention and is shown in an open or operational condition in which modules of the array are disposed in a triangular configuration to form an EW array of the kind described above.

(12) The array 10 includes a first planar PV module 11 and a second planar PV module 12. All of the modules described herein will have the same construction which is rectangular and planar. The first and second modules 11 and 12 form part of a greater or larger PV array 10, but discussion will firstly focus on the modules 11 and 12 only.

(13) Each of the modules 11 and 12 are of rectangular configuration, so that each defines a generally rectangular edge, the dimensions of which are about the same for each module 11 and 12. The edges comprise a pair of substantially parallel end edges 13 and 14 of the module 11 and end edges 15 and 16 of the module 12, and side edges 17 and 18. It can be seen, in particular with respect to the module 11, that the modules comprise a grid or matrix of PV cells 19.

(14) The modules 11 and 12 are connected along facing or adjacent end edges 14 and 15. In the arrangement of FIG. 1, the edges 14 and 15 are connected via a hinge arrangement, which is better seen in FIG. 2. FIG. 2 is a view of the PV array 10 but shown in a closed or stacked condition as would be adopted for storage or transport of the array 10. In FIG. 2, hinges 20 can be seen connecting the end edges 14 and 15 of the modules 11 and 12 together.

(15) FIGS. 1 and 2 thus show the array 10 in both the open (FIG. 1) and the closed (FIG. 2) conditions. As will be evident from FIG. 2, in the closed condition, the modules 11 and 12 are stacked together in a generally parallel and close facing relationship, with the end and side edges of the modules 11 and 12 in general alignment.

(16) In relation to FIG. 1, the modules 11 and 12 are disposed relative to one another at an angle β, which in FIG. 1 is in the region of about 160°. The angle could of course be different to this and can be altered by the length of connector 22 extending between the bars 23 and 24. It is evident from FIG. 1, that in the opened condition, the modules 11 and 12 define a triangular configuration. This thus forms the modules 11 and 12 in an East-West configuration which has advantages compared to planar PV arrays as discussed above.

(17) The transition of the modules 11 and 12 from the closed condition of FIG. 2 to the open condition of FIG. 1 is via folded or hinged movement about the end edges 14 and 15 of the modules 11 and 12, facilitated by the hinges 20. That folding movement could continue until the modules 11 and 12 arrived at a flat or planar condition relative to each other, except that the array 10 includes a flexible connector that connects with connection points associated with each of the modules 11 and 12 and that is tensioned in the opened condition as shown. It is the flexible connector that prevents the modules 11 and 12 from unfolding all the way to a flat or planar condition and which thus maintains the modules in the triangular configuration shown in FIG. 1.

(18) In FIG. 1, the connection points associated with each of the modules 11 and 12 are tubes, bars or posts 23 and 24, that extend parallel to the end edges 13 and 16 of the respective modules 11 and 12. The bars 23 and 24 are connected to the end edges 13 and 16 via a pair of sleeves 25 and 26 at each of the end edges 13 and 16 and as can be seen in FIG. 1. The sleeves 25 and 26 are also seen in FIGS. 4 and 5 and those figures also show that the sleeves connect to the end edge of the modules via brackets 27. The brackets can be fixed to the end edges by screws for example. The bars 23 and 24 extend beyond the side edges 17 of each of the modules 11 and 12 for connection of the flexible connector 22. FIG. 4 is an underneath perspective view of the PV array shown in FIG. 2 which shows that extension while FIG. 5 also shows the extension.

(19) It will be appreciated that as the modules 11 and 12 are folded and expanded from the closed condition of FIG. 2 to the open condition of FIG. 1, that the flexible connector 22 will remain slack until the modules 11 and 12 reach the angled positioned shown in FIG. 1. At that point, the flexible connector will be tensioned and taut and will prevent further unfolding movement between the modules 11 and 12. The modules 11 and 12 are thus fixed in the open or operational position shown in FIG. 1 against further unfolding movement.

(20) The discussion above in relation to FIGS. 1 and 2 has been made in relation to modules 11 and 12 only. Accordingly, it is within the scope of the present invention to provide a portable PV array which comprises just two modules, equivalent to modules 11 and 12, with a single flexible connector being provided to limit or restrict movement of the modules 11 and 12 just to the open position and not beyond that position. However, it will be clearly evident from FIGS. 1 and 2 that PV arrays which include greater number of PV modules are within the scope of the present invention. For example, further PV modules 30 to 33 can be provided to extend the PV array to form an elongate row of PV modules so that the PV array defines a series of alternating peaks and troughs. In FIG. 1, the modules 11, 30 and 32 could be east-facing modules, while the modules 12, 31 and 33 could be west-facing modules.

(21) In FIG. 1, the modules 30 to 33 repeat the connection arrangement of the modules 11 and 12, so that the end edge 16 of the module 12 and the end edge of 34 of the module 30 connect via the bar 24. Moreover, the facing end edges of the modules 30 and 31 which are located at the peak 35 are connected by hinges 36 (see FIG. 2) which are the same as the hinges 20.

(22) Likewise, the end edges of the modules 31 and 32 which are in facing relationship at the trough 37 are hingedly connected by the bar 38 and this form of connection at the respective peaks and troughs is repeated throughout the length of the PV array. While the array 10 is shown to have six modules, 11, 12 and 30 to 33, any number of modules could be connected in the manner shown and described, so that arrays of eight, ten or greater numbers of modules, connected end to end or in rows, can be provided.

(23) It is to be noted that the hinges 20 and 36 which are described in relation to FIGS. 1 and 2 could be employed rather than the bars 23, 24 and 38, or alternatively, that the hinges 20 and 36 could be replaced by bars which are of the same configuration and connection as the bars 23, 24 and 38. The provision of the bars 23, 24 and 38 is to provide connection for the flexible connector 22, and as shown in FIG. 1, that connector extends from the bar 23, in connection with the bars 24 and 38, and finally to the bar 39.

(24) Moreover, the bars 23, 24, 38 and 39 also assist the provision of a second and additional PV module to be placed or connected laterally side by side the modules 11, 12 and 30 to 33 as described above. Again, with reference to FIGS. 1 and 2, further modules 40 to 45 can be included in the PV array 10 to increase the surface area of the array 10 and common connections to the earlier modules described above can be made via the bars 23, 24, 38 and 39. The bars 23, 24, 38 and 39 can extend fully from one side of the PV modules comprising modules 11, 12 and 30 to 33, to the other side of the modules 40 to 45, or separate bars could extend through the respective rows of PV modules and be connected at free ends at the junction between facing side edges of the PV modules.

(25) The modules 40 to 45 are not required to be connected to the modules 11, 12 and 30 to 33, although connections can be made if desired. For example, facing side edges of the modules 11 and 40 can be connected, while the hinges 20 formed at the facing end edges 14 and 15 of the modules 11 and 12 can be modified for connection with the facing end edges of the modules 40 and 41. FIG. 3 illustrates this form of arrangement, whereby a stack of modules 46 is connected via fixed connectors 47 to an adjacent stack of modules 48. However, as shown in FIG. 2, the modules need not be connected to the modules 11, 12 and 31 to 33, other than through the bars 23, 24, 38 and 39. Moreover, the modules 40 to 45 can simply be placed next to the modules 11, 12 and 31 to 33 and have no connection at all between them. The benefit of connecting the modules in the PV array shown in FIGS. 1 and 2 is that movement between the open and closed conditions is quicker that two separate rows of modules.

(26) In the arrangements discussed above, the flexible connector 22 can extend continuously between the bars 23 and 39, or separate connectors can extend between adjacent bars, such as between bars 23 and 24 and then separately between bars 24 and 38 and bars 38 and 39. FIG. 5 is a view just of the bars 23, 24, 38 and 39 of the array 10, shown in the closed condition of FIG. 2. In that position, loops 50 can be seen extending about each of the bars, and these include a crimp connection 51 by which opposite ends of discreet lengths of the flexible connector 22 can be connected. In FIG. 5, a portion of the connector 22 which extends between the bars 23 and 24 is shown, while the same reference number is used to show flexible connector sections extending between the bars 24 and 38 and 38 and 39.

(27) What is also shown in FIG. 5 is a short section of a further flexible connector, given the reference number 52 and this would extend from the bar 39 to a further bar which is not shown in the figures, if the array 10 included further PV modules extending from the last illustrated module 33.

(28) It is clear that other arrangements could be employed for securing the flexible connector to the respective bars of the array 10. In one arrangement which is not illustrated, the flexible connector 22 could extend through the respective bars of the array 10 and a grub screw could be screwed into engagement with the connector within the bars so as to locate the connector relative to the bars.

(29) Alternatively, the flexible connector 22 could cooperate with a hinge that is provided at the junction between adjacent PV modules at the trough between those modules, and FIG. 10 illustrates the PV modules 12 and 30, and 41 and 42 of the array 10 with an example alternative arrangement applied. In the illustrated arrangement two hinges 86 are illustrated. In the foreground hinge, the flexible connector 22 is shown extending up between the junction of the PV modules 12 and 30 and the through the bolt 87 that extends through the hinge 86. An opening is formed in the shank of the bolt 87 for passage of the flexible connector 22.

(30) While not visible in FIG. 10, the bolt 87 also includes a threaded bore or opening through the shank of the bolt laterally to the opening through which the flexible connector 22 extends and a grub screw can be is screwed into the threaded opening and into engagement with the portion of the flexible connector 22 within the opening. By this arrangement, the position of the flexible connector 22 can be secured.

(31) FIG. 11 shows a further example of a connection between modules 53 and 54, whereby the flexible connector 55 is a flat connector that is fixed by a bolt 58 to the side edges 56 and 57 of the respective modules 53 and 54. The bolt 58 is thus a connector attached along a free edge of the module 54.

(32) Moreover, as discussed above, the length of the flexible connector between the bars can be adjusted, such as by a screw adjuster, or by a cleat arrangement. However, it is preferred that the length of the flexible connector between the bars be set when the PV array is manufactured, as this removes one element or step of installation when the array is to be employed on site.

(33) The flexible connector shown in the drawings could be metal wire, rope, or a woven fabric. Plastic cord could alternatively be employed, as could other materials or products that meet the requirement for the invention, which is that they must be able to slacken for the PV modules to be folded to the closed condition, and to remain taut and tensioned in the opened condition.

(34) A major feature of the invention is the manner in which the PV modules can be folded into the closed position from the opened position, and then unfolded back to the opened condition. This allows the PV array to be portable and easily installed and removed. Accordingly, FIGS. 2, 3 and 4 show the PV array in the closed condition in which the array can be stored and transported. It will be evident that the compact nature of the array in the closed condition will allow much greater length of array to be stored and transported in a compact condition, and then installed at an installation site to provide significant area for capture of sunlight or electromagnetic radiation. As will be appreciated from the figures, the array 10 can be manufactured and preassembled completely in a manufacturing facility, and in a basic form of the invention, no additional structural material is required when the array is to be opened for use at an installation site. It is expected however, that ballast will be applied to the array 10 after installation, and in the illustrated figures, this can be fixed to the free ends of the bars and can be in the form of sand bags or concrete blocks, or the free ends of the bars can be pegged down.

(35) The PV array can be manufactured with all balance of system components in place, or they can be installed as part of the installation process. The flexible connector 22 maintains the modules in the triangular or east-west configuration that is required, and the preassembly of the flexible connector to the modules means that there is no requirement for the east-west orientation to be set by installation personnel. Rather, it sets automatically when the modules are shifted to the open position. It is to be noted that for installation purposes, wheels or skids such as structural feet, can be attached to the bars 23, 24, 38 and 39.

(36) FIGS. 6 to 8 illustrate the array 10 in a partially open condition. In FIGS. 6 to 8, the array 10 has been extended lengthwise, to include a greater number of modules than that shown in FIGS. 1 and 2. This illustrates the flexibility with which additional modules can be included in an array as the power requirements of an installation increase.

(37) In FIGS. 6 to 8, a PV array 60 is shown comprising modules 61 to 67, and further modules 68 in a closed and generally parallel configuration. As with the array 10, the array 60 includes two sets of lengthwise extending rows of modules which are connected laterally or side by side along the bars 69 to 75. What is evident in FIGS. 6 to 8, is that the flexible connector 77 between the modules 61 and 62 is in tension and is therefore taut. However, the connectors 78 and 79 are slack, because the respective modules that those connectors extend between are not yet in the open condition. Again, this is evident from FIGS. 6 to 8, in which the interior angle between the modules 61 and 62 is greater than between the modules 63 and 64 and is greater again than between the modules 65 and 66. The modules 68 are yet to commence shifting to the open position and those modules remain in a generally parallel and close facing relationship.

(38) To install the array 60 (and the array 10, but comment will only be made in relation to the array 60), the array 60 can be lifted from the transport vehicle that has transported the array to the installation site, and the array 60 can thereafter be placed on the installation surface, which might be a roof, or an outdoor stage, or a park etc. Once the array 60 is on the installation surface, the bar 69 can be engaged either manually or with an installation device, and can be pulled away from the stack of PV modules so that the modules 61 and 62 are first shifted from the generally close facing and parallel relationship of the other modules. Importantly and advantageously, given that only two of the modules need to be shifted to commence the opening process, prototypes tested to date show that this can be a manual process. The process can be such that the modules 61 and 62 are taken to the open position before the modules 63 and 64 are moved from the closed condition. This means that the panels can be shifted to the open condition in a controlled manner and the weight that needs to be shifted is that of the modules 61 and 62. As the installation continues the weight that is moved does increase as further modules are released from the closed condition, but again, testing to date has again indicated that a module array of the size shown in FIG. 6 can be opened and closed manually. In this respect, the modules 61 to 68 shown in FIGS. 6 to 8 would have edge or external dimensions of 1 metre×2 metres per module so that with the array 60 fully extended in the open condition, the length of the array would be in the order of 24 metres. In contrast, when the array 60 is in the fully closed condition, the dimensions of the array are in the order of 0.9 metres long×2 metres high×2 metres wide and the weight of the array would be in the region of 800 kg.

(39) The flexible connectors 77, 78 and 79 shown in FIGS. 6 to 8 are shown in the fully extended condition (connector 77), in a still slightly slack condition (connector 78) and in a completely slack condition (connector 79). As an example of how the connectors can be installed, the connector 78 is attached by a spring 80 to the peak 81 between the modules 63 and 64 and that connection can be for example, to a hinge that is positioned at the peak 81. The spring thus extends as the modules 63 and 64 move towards the open condition, and it contracts and lifts the connector 78 as the modules 63 and 64 move to the closed condition. By this arrangement, the connector 78 is neatly stored in the closed condition, but fully able to assume a tensioned state in the opened condition.

(40) Alternative arrangements include clips provided on edges of the modules to which the flexible connector can be secured in the closed condition of the array, while a less permanent arrangement can involve using adhesive to attach the connectors to a surface of the modules when the array is initially assembled and the adhesive will break or shear when the modules are placed in the open condition. That arrangement obviously needs to be replenished each time the modules are returned to the closed condition, but it is a simple step and therefore potentially acceptable.

(41) It has been discussed above that lateral connection of further rows of arrays to side edges of an initial array can broaden the surface area of the array overall. Thus, the figures all show arrays in which a pair of modules are positioned side by side (for example see modules 11 and 40 in FIGS. 1 and 2). Further side additions to the arrays 10 and 60 can be made subject to the ability to transport the arrays. It will be appreciated that the dimensions of an array in the closed condition will increase as the number of modules is added end to end, as well as side to side.

(42) FIG. 9 is a view of one corner of the PV module 12 of FIG. 1, and therefore also shows one section of the bar 24. In addition to those features, FIG. 9 shows an earthing cable 85 that extends from the module 12 into connection with the flexible connector 22. In this embodiment, the flexible connector 22 is a conductive connector, such as steel or other metal wire or cable, and therefore the module 12 can be earthed by electrical connection to the connector 22.

(43) Throughout the description and claims of the specification, the word “comprise” and variations of the word, such as “comprising” and “comprises”, is not intended to exclude other additives, components, integers or steps.

(44) The invention described herein is susceptible to variations, modifications and/or additions other than those specifically described and it is to be understood that the invention includes all such variations, modifications and/or additions which fall within the spirit and scope of the present disclosure.