Mounting System for Photovoltaic Arrays

Abstract

Photovoltaic (PV) systems are disclosed, to include mounting brackets and mounting systems. In one embodiment, a PV array mounting system with brackets comprising pairs of panel connectors and panel connector receivers is disclosed.

Claims

1. A system for mounting of a PV array, the system comprising: a mounting bracket comprising elastomeric materials or polymeric materials configured to be installed between a PV array and a rail, said mounting bracket having a panel connector and a panel connector receiver; wherein the panel connector comprises a plurality of arms, each protruding from the panel connector, wherein the panel connector is configured to attach to a PV array, wherein the panel connector receiver comprises a plurality of arm apertures configured to receive a cable or wire that protrudes from the panel connector receiver; wherein the plurality of arms are each configured to be received in the respective plurality of arm apertures of the panel connector receiver; and wherein the plurality of arms of the panel connector are configured, when engaged with the respective plurality of arm apertures of the panel connector receiver, to form one of: an interference fit, a connection means comprising a pin having an upper threaded portion and a lower angled or bullet portion; and a bolt and nut combination.

2. The system of claim 1, wherein the mounting bracket is configured to interconnect to a longitudinal axis of a structural rack.

3. The system of claim 2, wherein the mounting bracket is configured to interconnect parallel to the longitudinal axis of a structural rack.

4. The system as set forth in claim 1, wherein said bracket has a shelf which comprises a connector and a mount.

5. The system as set forth in claim 1, wherein said rail is adapted to be interconnected to a rack.

6. The system as set forth in claim 1, wherein the plurality of arm apertures have a shape selected from the group consisting of a square, a rectangular, and a non-round shape.

7. The system as set forth in claim 1, wherein the rail has predetermined holes.

8. The system as set forth in claim 1, wherein the mounting bracket is configured to be snap inserted into the rail from underneath the rail.

9. The system as set forth in claim 1, wherein the rail is pre-wired.

10. The system as set forth in claim 1, wherein the mounting bracket is installed directly into the rail in a parallel relationship to the rail.

11. The system as set forth in claim 1, wherein the mounting bracket is installed perpendicular to a pair of PV arrays.

12. A system for mounting of a PV array, the system comprising: a mounting bracket comprising elastomeric materials or polymeric materials configured to be installed between a PV array and a rail, said mounting bracket having a panel connector and a panel connector receiver; wherein the panel connector comprises a plurality of arms, each protruding from the panel connector, wherein the panel connector is configured to attach to a PV array, wherein the panel connector receiver comprises a plurality of arm apertures configured to receive a cable or wire that protrudes from the panel connector receiver; wherein the plurality of arms are each configured to be received in the respective plurality of arm apertures of the panel connector receiver; and wherein the plurality of arms of the panel connector are configured, when engaged with the respective plurality of arm apertures of the panel connector receiver, to form an interference fit.

13. The system of claim 12, wherein the mounting bracket is configured to interconnect to a longitudinal axis of a structural rack.

14. The system of claim 12, wherein the mounting bracket is configured to interconnect parallel to the longitudinal axis of a structural rack.

15. The system as set forth in claim 12, wherein said bracket has a shelf which comprises a connector and a mount.

16. The system as set forth in claim 12, wherein said rail is adapted to be interconnected to a rack.

17. A system for mounting of a PV array, the system comprising: a mounting bracket comprising elastomeric materials or polymeric materials configured to be installed between a PV array and a rail, said mounting bracket having a panel connector and a panel connector receiver; wherein the panel connector comprises a plurality of arms, each protruding from the panel connector, wherein the panel connector is configured to attach to a PV array, wherein the panel connector receiver comprises a plurality of arm apertures configured to receive a cable or wire that protrudes from the panel connector receiver; wherein the plurality of arms are each configured to be received in the respective plurality of arm apertures of the panel connector receiver; and wherein the plurality of arms of the panel connector are configured, when engaged with the respective plurality of arm apertures of the panel connector receiver, to form a connection means comprising a pin having an upper threaded portion and a lower angled or bullet portion.

18. The system as set forth in claim 17, wherein said bracket has a shelf which comprises a connector and a mount.

19. The system as set forth in claim 17, wherein said rail is adapted to be interconnected to a rack.

20. The system as set forth in claim 17, wherein the mounting bracket is configured to be snap inserted into the rail.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the invention given above, and the detailed description of the drawings given below, serve to explain the principals of this invention.

[0044] FIG. 1 is an illustration of two prior art landfill cover systems;

[0045] FIG. 2 is an image of a prior art exposed geomembrane cover system having flexible laminate solar panels adhered directly to the surface of the membrane;

[0046] FIG. 3 is a perspective view of a standoff mount constructed in accordance with the teachings of the present invention;

[0047] FIG. 4 is a top view thereof;

[0048] FIG. 5 is a cross-sectional view thereof taken along line 5-5 of FIG. 4;

[0049] FIG. 6 is a cross-sectional end view of a female mounting rail and male attachment rail constructed in accordance with the teachings of the present invention;

[0050] FIG. 7 is a cross-sectional view of the complete mounting system attached to a geomembrane;

[0051] FIG. 8 is a cross-sectional end view of a female mounting rail and a wind shield;

[0052] FIG. 9 is a cross-sectional view of the mounting system including the wind shield attached to a geomembrane;

[0053] FIG. 10 is a is a cross-sectional view of the mounting system including the wire management rail and a wind shield attached to a geomembrane;

[0054] FIG. 11A is a perspective view of a plurality of standoff mounts attached to a carrier tape;

[0055] FIG. 11B is a perspective view of a plurality of standoff mounts attached to a carrier strapping;

[0056] FIG. 11C is a perspective view of an attachment system including plurality of standoff mounts and a bonding tape including a plurality of spaced openings;

[0057] FIG. 12 is a top view of an annular bonding ring in accordance with the invention;

[0058] FIG. 13A is a top view of a mounting bracket, according to another embodiment of the invention (this figure is to scale);

[0059] FIG. 13B is a lower perspective view of the mounting bracket of FIG. 13A (this figure is to scale);

[0060] FIG. 13C is a top perspective view of the mounting bracket of FIG. 13A (this figure is to scale);

[0061] FIG. 13D is a cross-sectional left side elevation view of the mounting bracket of FIG. 13A (this figure is to scale);

[0062] FIG. 13E is a cross-sectional view of Section A-A of FIG. 13D (this figure is to scale 1:2);

[0063] FIG. 13F is a cross-sectional view of Section B-B of FIG. 13E (this figure is to scale 1:2);

[0064] FIG. 13G is a bottom view of the mounting bracket of FIG. 13A (this figure is to scale);

[0065] FIG. 13H is a cross-sectional view of Section C-C of FIG. 13G (this figure is to scale 1:2);

[0066] FIG. 14 is an upper perspective view of the mounting system of FIG. 13 as engaged with a PV array;

[0067] FIG. 15 is a lower perspective view of the mounting system of FIG. 13 as engaged with PV arrays and racks;

[0068] FIG. 16A is an exploded lower perspective view of a mounting system according to another embodiment of the invention; and

[0069] FIG. 16B is an exploded perspective view of details of the mounting system of FIG. 16A.

[0070] It should be understood that the drawings are not necessarily to scale (those that are to scale are so noted.) In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION

[0071] FIGS. 1-16 depict several views of embodiments of the invention. The present invention provides a unique and novel, low-cost PV array mount system which will allow for ease of installation, flexibility of movement, and the ability to remove and redeploy the system as needed.

[0072] Before proceeding with the description, it is to be understood that the mount system herein is capable of being used with all types of photovoltaic (PV) panels 100, including flexible PV panels, as well as rigid PV panels, regardless of the length or width of the panels. The system has the flexibility to be deployed in virtually any configuration. It is also noted that the electrical systems that accompany the PV panels 100 are generally well known in the art, and will not be described in detail herein, albeit there will be mention of the mount system accommodating the required wiring of the panels.

[0073] Referring to FIGS. 3-12, the mount system in accordance with the teachings of the present invention generally comprises a plurality of standoff mounts 102 (FIGS. 3-5) which are secured to a substrate 10 (i.e. geomembrane) in a parallel grid system, elongated mounting rails 104 (FIG. 6) which are secured to the standoff mounts 102 in parallel, and attachment rails 106 secured to opposing side edges of the PV panels 100. The terms mounting rails and attachment rails are intended to define the relative placement of the rails in the system and it should be understood that these rails could be male or female depending on the application. While the exemplary embodiment illustrated herein is a female track and a male track insert, the disclosure should not be limited to only that arrangement. The shapes of the mounting rails and attachment rails can vary extensively and are determined by the requirements of the specific array. In the exemplary embodiment, the attachment rails (male track inserts) 106 are slidably received into mounting channels in opposing side edges of the parallel mounting rails (female tracks) 104 to suspend the solar panels 100 between the mounting rails 104 and above the substrate 10 (See FIG. 7).

[0074] For purposes of illustration and description, the preferred embodiments herein will be described in connection with mounting to an elastomeric membrane 10, such as a geomembrane, covering a brownfield or landfill. However, it should be appreciated that the mount system can also be deployed on other membrane covered substrates, such as the roofs of buildings or vehicles. In addition, other mounting options will be described for non-membrane covered substrates.

[0075] Referring back to FIGS. 3-5, the standoff mounts 102 include a base portion 108, a neck portion 110 extending upwardly from the base portion 108 and a fastener 112/114 received in the neck portion. In the exemplary embodiment as illustrated, a threaded cap nut 112 is inserted or molded into the top of the neck portion 110 for receiving a threaded fastener 114. Alternatively, the threaded fastener 114 could be inserted or molded into the top of the neck portion 110 and the cap nut 112 received onto the fastener. In addition, a variety of additional types of fasteners 112/114 are also possible within the scope of the disclosure. Even further still, it is contemplated that fastener elements may be directly incorporated into the mounting rails 104 for direct attachment of the mounting rails 104 to the standoff mounts 102.

[0076] The standoff mounts 102 can be manufactured in a variety of shapes as dictated by the attachment application and can be made from rigid or elastomeric materials, also as dictated by the attachment application. Where an elastomeric material is used for the standoff mounts 102 it allows the neck portions 110 thereof to flex under stress and provides a fair amount of flexibility of movement while maintaining a consistent grid array. The preferred shape as illustrated is a cone with a large bottom surface to provide structural stability and provide a securing platform.

[0077] Referring to FIGS. 7 and 12, the standoff mounts 102 can be secured to the membrane using a plurality of different attachment methods including, but not limited to adhesive bonding, ultrasonic welding, or annular bonding rings. In the exemplary embodiment as illustrated, the standoff mounts 102 are secured to the membrane 10 using an annular bonding ring 116 having a central opening 118. The bonding ring 116 has a diameter greater than the base portion 108 and is made of a material that is the same as or similar to the membrane material so that the bonding ring 116 can be bonded to the membrane 10. For example, the bonding ring material could comprise an engineered membrane of TPO, PP, PE, EPDM or other suitable materials that are capable of being bonded to the underlying membrane.

[0078] In use, the bonding ring 116 is received over the neck portion 110 of the standoff mount 102 and is bonded to the membrane 100 using conventional membrane bonding materials or methods, thereby trapping the base portion 108 and holding it in place (see FIG. 7).

[0079] Referring to FIG. 11A, the base portions 108 of the standoff mounts 102 can also be bonded to a tape carrier 120 with a predetermined spacing so that the standoff mounts 102 can be quickly and easily installed in parallel strips onto the membrane 10. The tape carrier 120 is preferably made from the same material or similar material to the membrane 10 so that the tape carrier 120 can be easily bonded to the membrane 10. Alternatively, a tape strip 122 can be provided with a plurality of holes formed at predetermined spacing (See FIG. 11C) wherein the standoff mounts 102 are inserted through the holes and the base portions 108 thereof held beneath the tape strip 122. The tape strip 122 is also preferably made from the same material or similar material to the membrane 10 so that the tape strip 122 can be easily bonded to the membrane 10.

[0080] Still further, the standoff mounts 102 can also be bonded to a more rigid carrier strapping 124 (FIG. 11B) which can be used in other mounting configurations where the strapping 124 can be secured to any rigid underlying substrate, such as a building roof, concrete slab, or a vehicle roof with fasteners (not shown)

[0081] Referring now to FIGS. 6 and 7, the mounting rail 104 includes an elongated spine 126 having a plurality of holes 128 and/or elongated slots 130 paced longitudinally along the centerline. In use, the standoff mounts 102 are spaced to match the spacing of the holes/slots in the mounting rail 104. When installed, the holes/slots align with the standoff mounts 102 and fasteners 114 (FIG. 7) are inserted through the holes/slots into the cap nuts 112 in the tops of the neck portions 110. The elongated slots 130 provide for longitudinal sliding movement of the tracks 104 relative to the standoff mounts 102. In another alternative (not shown) it is contemplated that the insert of the standoff mount 102 may include a swivel arm (not shown) that would rotate relative to the neck portion 110 to provide further range of motion if needed. At least one side of the mounting rail 104 is provided with a mounting channel for receiving the attachment rail 106. In the exemplary embodiment, the opposing side edges of the mounting rail 104 are provided with symmetrically opposed mounting channels 132, 134 that receive the complementary attachment rails 106.

[0082] The attachment rail 106 generally comprises an elongated strip having an inner land portion 136 onto which the side edge portion of the PV panel 100 is seated. The PV panels 100 are secured to the land portions 136 of the attachment rails 106 with rivets 138 or other fasteners or bonded with an adhesive. Alternatively, the attachment rails 106 can be integrated into the construction of the PV panels, or can be integrated into a support carrier (not shown) for the PV panel 100. The attachment rails 106 further include an outer retaining tab portion 140 which is received into the mounting channel 132,134 in the mounting rail 104. Separating the land portion 136 from the tab portion 140 is a raised shoulder 142 which facilitates alignment of the attachment rail 106 with the panel 100 and the mounting rail 104. The attachment rail 106 and mounting channels 132, 134 include interfitting locking formations (hooks) 144A,144B to ensure that the attachment rail 106 remains captured within the mounting channels 132,134.

[0083] The mounting rail 104 and attachment rail 106 are made from polymeric materials, triglass, metal or both and include a low friction covering or additive allowing for free movement of the attachment rail 106 relative to the mounting rail 104. The depth of the channel 132,134 is variable depending on the desired ability of the attachment rail 106 to slide freely inward and outward from the centerline of the mounting rail 104. The attachment rail 106 is also able to slide longitudinally along the length of the channel 132,134. The height of the channel 132,134 is also variable and should be loose enough to allow for movement but also tight enough to ensure that the attachment rail 106 remains captured within the channel 132,134. The top wall of the channel 132,134 should be thin enough to allow the attachment rail 106 to be snapped into place (some degree of flex) but thick enough to prevent breaking during installation. It is also noted that the shape of the retaining “tooth” or “hook” 144 should not be limited by the attached illustrations. Other shapes and configurations of interfitting parts are also within the scope of the invention. Even further still, it is contemplated that the retaining “hook” 144 may be machined directly into the side edge of the PV panel eliminating the need for the attachment rail 106 altogether.

[0084] Turning to FIG. 7, an end view of the system is shown as it may be typically deployed on a landfill geomembrane 10. The standoff mounts 102 are spaced as required and secured to the geomembrane 10 with bonding rings 116. Thereafter, the mounting rails 104 are secured to the standoff mounts 102 in parallel. The holes/slots in the mounting rails 104 are aligned with the standoff mounts 102 and the fasteners 114 are inserted through the holes/slots and secured to the standoff mounts 102. As seen in FIG. 7, the mounting rails 104 are elevated above the membrane 10. The attachment rails 106 are attached to the PV panels 100 in the factory or at a staging site. The PV panels 100 are then snapped into the mounting channels 132,134 of the parallel rails 104 to hold the PV panels 100 in position. Elevating the PV array above the membrane 10 separates movement of membrane 10, due to whatever reason, i.e. expansion, contraction shifting, from the array. The standoff mounts 102 buffer any resulting movement. Elevating the PV array also allows air to flow freely beneath the array serving to keep the panels 100 and the underlying membrane 10 cooler.

[0085] To reduce wind stresses on the system, an L-shaped wind shield 146 (See FIGS. 8 and 9) is provided and assembled with the outermost mounting rail 104 of the array. In the exemplary embodiment, the wind shields 146 having a retaining tab portion 148 which is received into the outer mounting channel 134 in the mounting rail 104 and a shield portion 150 which extends outwardly and downwardly to redirect air flow 152 up and over the array. The wind shield 146 could also be molded directly into an alternate design of the track (not shown) that would only be used as an outside edge.

[0086] Wiring (not shown) between adjacent panels 100 and wiring to a control system (not shown) can be fed beneath the elevated panels 100 or can be secured in conduits (now shown) that snap together with the mounting rails 104.

[0087] As illustrated in FIG. 10, the mount system may still further include a separate wire management rail 104A which includes the opposed mounting channels 132,134 and further includes a J-shaped wire management channel 154 extending downwardly from one side of the mounting rail 104. Wiring may be received within the hook portion of the J-shaped channel 154.

[0088] It is noted that the illustrated embodiments represent only two adjacent rows of panels 100 and tracks 104, but it is to be understood that the system can be expanded to implement an indefinite number of rows within the space of the membrane 10 or other substrate.

[0089] FIGS. 13-15 depict a mounting bracket according to another embodiment of the invention. Generally, FIGS. 13A-G provide a series of views of the mounting bracket 210, FIG. 14 depicts the mounting bracket 210 installed between a PV array/panel 100 and a rail 240, and FIG. 15 depicts the mounting bracket 210 installed between a PV array 100 and a rail 240 which is in turn connected to rack one 250 and rack two 252. Benefits of the mounting bracket 210 system of FIGS. 13-15 include rapid installation.

[0090] In one preferred embodiment, a standard-sized PV array 100, using a plurality of mounting brackets 210, may be installed in below one (1) minute; in a more preferred embodiment, in less than thirty (30) seconds, and in a most preferred embodiment, in less than twenty (20) seconds. Furthermore, the bracket 210 is configured such that when attached or engaged with a PV array 100, the PV array may be readily handled and/or moved so as to ease installation and/or decrease time of installation. Note that easier and/or quicker installation yields reduced costs, comprising labor costs and construction costs.

[0091] With reference to FIGS. 13A-H, bracket 210 comprises body 212 which comprises two fingered apertures 214 and one aperture 216. Each of fingered apertures 214 are configured to receive pin 218. Pin 218 comprises an upper threaded portion and a lower angled or bullet portion. The pin 218 press-fits or interference fits with fingers of fingered aperture 214 so as to initially spread the fingers before reaching a set position, which may be a locked position. Bracket 210 may comprise a shelf 220 which comprises connector 222 and mount 226. Connector 222 comprises ends 224. Connector may be an electrical connector and may comprise a metal alloy so as to provide electrical communication.

[0092] With respect to FIG. 14, bracket 210 interconnects with PV array by way of pin 218. That is, pin 218 is affixed or attached to PV array 100 through the afore-mentioned threaded (upper) portion of pin 218. Alternatively, pin 218 may interconnect to PV array 100 through any means known to one skilled in the art, to include by press or interference fit. The bracket 210 is interconnected to rail 240 as enabled by aperture 216. That is, a connecting means, such as a pin or screw or bolt/nut combination is inserted through aperture 216 to secure bracket 210 to rail 240. Note that bracket 210 interconnects perpendicular to a pair of PV arrays, wherein each of two fingered apertures 214 connects to a separate PV array 100.

[0093] In the event of failure of or damage to a panel 100, it is very simple to remove a single panel 100 from the system by simply snapping the insert 106 out of the track 104, disconnecting the wiring and then replacing the damaged panel 100 with another new panel.

[0094] With respect to FIG. 15, bracket 210 is depicted interconnected with two PV arrays by way of pins 218. That is, each pin 218 is affixed or attached to a PV array 100 through the afore-mentioned threaded (upper) portion of pin 218. Alternatively, pin 218 may interconnect to a PV array 100 through any means known to one skilled in the art, to include by press or interference fit. The bracket 210 is interconnected to rail 240 as enabled by aperture 216. That is, a connecting means, such as a pin or screw or bolt/nut combination is inserted through aperture 216 to secure bracket 210 to rail 240. Rail 240 is interconnected or attached to rack one 250 which in turn is interconnected or attached to rack two 252. In one embodiment, rack one 250 is a purlin structure and rack two is a rafter structure.

[0095] In alternate embodiments, the bracket 210 is installed to racks comprising a fixed rack, a tracking rack, and a rack without rails 240 (as may be found on a residential rooftop). In other embodiments, the electrical connection and/or inter-fitting mechanical connections, as depicted in FIG. 15, are provided in any manner known to those skilled in the art. For example, for the mechanical connection, the shape could be square, rectangular, etc., and not simply round. In one embodiment, the rail is punched and fitted with a snap or expanding metal clip. In another embodiment, the bracket 210 is snap inserted into the rail from underneath the rail, which transfers any upward force directly into the rail while the module bracket could be fashioned to allow the module weight to be transferred directly into the rail versus into the bracket.

[0096] In one embodiment, one or more rails 240 are pre-wired on site or at the place of manufacture to enable cheaper and/or faster installation.

[0097] With reference to FIGS. 16A-B, another embodiment of a mounting system 300 for PV panels/arrays is depicted. This embodiment allows the mounting bracket to be installed directly into to rail and thus parallel to the rail. Such a “parallel bracket” configuration may allow for elimination of cross member rails, and thereby save costs. An additional benefit to the parallel bracket configuration is the enablement of tighter tolerances in the parallel direction.

[0098] Mounting system 300 comprises panel connector 310, purlin 360, panel connector receiver 320, female wire assembly 340 and male jumper cable 350. Panel connector 310 comprises arm one 312, arm two 313 and center arm 314. Panel connector receiver 320 comprises arm one aperture 322, arm two aperture 323 and center arm aperture 324. Purlin 360 comprises purlin one aperture 362, purlin two aperture 363 and purlin center aperture 364. Panel connector 310 interconnects with panel connector receiver 320 with purlin 360 between panel connector 310 and panel connector receiver 320. That is, each of arm one 312, arm two 313 and center arm 314 fit through respective purlin one aperture 362, purlin two aperture 363 and purlin center aperture 364 to engage or fit or interconnect with respective arm one aperture 322, arm two aperture 323 and center arm aperture 324. Gasket 334 fits or interconnects with center arm 314. Nut 335 engages lower portion of panel connector receiver. Male jumper cable 350 fits within or interconnects with nut 335. Female wire assembly 340 engages with upper portion of panel connector 310.

[0099] In one embodiment, the PV arrays interconnect with the bracket (e.g. bracket 210) by way of a screw, an adhesive, magnetism or any means known to those skilled in the art.

[0100] Accordingly, it can be seen that the present invention provides a mounting system for a PV array that is inexpensive, that is easy to install, that will allow relative movement of the panels and the membrane thus reducing damage to both the PV panels and the membrane, and that will allow the PV panels to be easily reconfigured, removed or replaced when needed.

[0101] While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claim.