Integrated photovoltaic module mounting system for use with tufted geosynthetics
11031902 · 2021-06-08
Assignee
Inventors
- Michael R. Ayers (Johns Creek, GA, US)
- S. Kyle Ehman (Milton, GA, US)
- Neta Reef (Beit Elazari, IL)
- Sharone Zehavi (Cupertino, CA, US)
Cpc classification
F24S25/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2025/6003
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L31/0475
ELECTRICITY
F24S25/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/50
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
H02S40/425
ELECTRICITY
F24S25/634
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/33
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/632
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S20/20
ELECTRICITY
F24S2025/6005
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/52
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
Y02B10/10
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
International classification
F24S25/13
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/632
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/61
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/636
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/33
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L31/0475
ELECTRICITY
F24S25/634
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A mounting system 10 for a solar panel 11 includes a base plate 14 having a mounting channel 16 defined by an elongated base member 17, two oppositely disposed elongated channel walls 18 having clamping tangs 19, and a support wall 20. The mounting system also includes an I-beam 24 having a lower member 25, an upper member 26 and a spanning member 27. A C-shaped bracket 30 is slidably coupled to the upper member and has a mounting post with a staggered clamp 36 having a contact ledge 37. A nut 38 is threadably coupled to the mounting post 32 to force the contact ledge downwardly against the peripheral margin of the solar panel, thus locking the position of the solar panel. The mounting system includes a weld harness or weld harness strip 39 and anti-creep strips 44 which are coupled to the base member.
Claims
1. An integrated photovoltaic module mounting system for use with a tufted-geosynthetic cover, comprising: an elongated base plate; at least one elongated rail coupled to said base plate; a plurality of brackets for movably coupling to said rail for releasable, slideable movement along a longitudinal length of said rail, each said bracket comprises: a C-shaped bracket member; a threaded post coupled to said C-shaped bracket member; a clamp having a post hole therethrough; and a threaded nut for threadably coupling to said threaded post extending through the post hole to bear against said clamp for coupling to a photovoltaic module; and a harness strip having one end coupled to said base plate and an opposite end for coupling to a tufted geosynthetic cover.
2. The integrated photovoltaic module mounting system of claim 1 wherein said base plate includes a pair of oppositely disposed channel walls, and wherein said rail has a portion positioned between said oppositely disposed channel walls.
3. The integrated photovoltaic module mounting system of claim 2 wherein said base plate further includes a central support wall positioned between said oppositely disposed channel walls, and wherein said rail rests upon said central support wall.
4. The integrated photovoltaic module mounting system of claim 3 wherein each said oppositely disposed channel wall includes an inwardly extending tang configured to engage said rail.
5. The integrated photovoltaic module mounting system of claim 1 further comprising an anti-creep strip coupled to a bottom surface of said base plate.
6. The integrated photovoltaic module mounting system of claim 1 wherein said rail is in the form of an I-beam.
7. The integrated photovoltaic module mounting system of claim 1 wherein said harness strip is formed of a material for heat welding the opposite end to said tufted geosynthetic cover.
8. The integrated photovoltaic module mounting system of claim 1 wherein said elongated rail extends integrally from said elongated base plate.
9. The integrated photovoltaic module mounting system of claim 1 wherein said rail captures each said bracket within a bracket channel.
10. An integrated photovoltaic module mounting system for use with a tufted-geosynthetic cover, comprising: an elongated base plate; at least one elongated rail coupled to said base plate; a bracket movably coupled to said rail for releasable, slideable movement along a longitudinal length of said rail, said bracket for coupling to a photovoltaic module, said bracket comprising: a C-shaped bracket member; a threaded post coupled to said C-shaped bracket member; a clamp having a post hole therethrough; and a threaded nut for threadably coupling to said threaded post extending through the post hole to bear against said clamp for coupling to a photovoltaic module; and an anti-creep strip coupled to a bottom surface of said base plate.
11. The integrated photovoltaic module mounting system of claim 10 wherein said base plate includes a pair of oppositely disposed channel walls, and wherein said rail has a portion positioned between said oppositely disposed channel walls.
12. The integrated photovoltaic module mounting system of claim 11 wherein said base plate further includes a central support wall positioned between said oppositely disposed channel walls, and wherein said rail rests upon said central support wall.
13. The integrated photovoltaic module mounting system of claim 12 wherein each said oppositely disposed channel wall includes an inwardly extending tang configured to engage said rail.
14. The integrated photovoltaic module mounting system of claim 10 further comprising a harness strip having one end coupled to said base plate and an opposite end for coupling to a tufted geosynthetic cover.
15. The integrated photovoltaic module mounting system of claim 10 wherein said rail is in the form of an I-beam.
16. The integrated photovoltaic module mounting system of claim 10 wherein said harness strip is formed of a material for heat welding the opposite end to said tufted geosynthetic cover.
17. The integrated photovoltaic module mounting system of claim 10 wherein said elongated rail extends integrally from said elongated base plate.
18. The integrated photovoltaic module mounting system of claim 10 wherein said rail captures each said bracket within a bracket channel.
19. A method of mounting a photovoltaic module for use with a tufted geosynthetic cover, comprising the steps of: (a) coupling an anti-creep strip to a bottom surface of a base plate; (b) positioning the anti-creep strip onto a portion of a tufted geosynthetic cover covering a surface; (c) coupling a rail to the base plate; (d) slidably positioning a bracket movably coupled to said rail for releasable, slidable movement along a longitudinal length of said rail, to a photovoltaic module, said bracket comprising a C-shaped bracket member having a threaded post for extending through a post hole of a clamp and a nut; and (e) coupling the photovoltaic module to the elongated rail with the bracket upon threading the nut on to the threaded post, whereby the photovoltaic module generates electricity and the anti-creep strip inter-engaged with the tufts of the tufted geosynthetic cover resists wind uplift.
20. The method as recited in claim 19, further comprising the step of attaching a harness strip coupled at one end to said base plate and an opposite end to the tufted geosynthetic cover, whereby the harness strip further resists wind uplift.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(21) The present invention provides an integrated photovoltaic module mounting system for use with a tufted geosynthetic system on a surface without a racking structure and without ballast for support.
(22) The essential components of this invention are a tufted geosynthetic system and one or more integrated photovoltaic module mounting systems.
(23) Cover System
(24) Examples of tufted geosynthetic systems useful in the integrated photovoltaic module mounting system of this invention are the covers marketed by Watershed Geosynthetics LLC under the registered trademarks ClosureTurf and VersaCap. These covers 11 comprise a composite of at least one geotextile 213 which is tufted with a plurality of spaced-apart tufts 215 with one or more synthetic yarns (i.e., a tufted geosynthetic) to simulate grass blades in a synthetic grass, and an impermeable geomembrane 217 comprised of a polymeric material.
(25) The synthetic grass blades of the system may contain an infill material and/or a material for protection of the synthetic grass blades against ultraviolet rays.
(26) Solar Module
(27) One or more mono- or multi-crystalline solar modules can be used in the integrated photovoltaic module mounting system of this invention, such as commercially available polycrystalline silicon solar modules. Examples of effective solar modules are available from BYD (China) under the designation BYD 260P6C-30-DG and from Trina (China) under the designation Solar Duomax TSM-PEG14, Tallmax PE14A, and BYD P6C-36. An alternate embodiment discussed below gainfully uses a bifacial solar module.
(28) Referring now to the drawings, in which like numerals represent like elements,
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(30) Instead of a tab 1 for the weld harness,
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(39) Friction
(40) This invention also provides a method for a non-ballasted module mounting system utilizing one or more anti-creep strips 5 integrated on the photovoltaic module when mounted over tufted geosynthetics, by increasing the coefficient of friction between the anti-creep strips and the tufted geosynthetic. The anti-creep strips 5 include a plurality of spaced-apart feet 46 depending from a bottom surface. The feet 46 inter-engage with the tufts 215 to provide frictional connection of the photovoltaic solar module 3 to the tufted geosynthetic cover 11. In the illustrated embodiment, the anti-creep strips 5 connect to the mounting plate 2 using a threaded fastener to engage the threaded passageway 23 in the baseplate 2. In embodiments that uses both the anti-creep strips 5 and the weld harness 1 (or elongated attaching strip 4), the fastener extends through the anti-creep strip and the weld harness and threadably engages the passage 23. Alternatively, separate, or additional baseplates 2 may be used.
(41) The anti-creep strips footing is generally a structured geomembrane or tufted geosynthetic cover 11.
(42) The anti-creep strips, when used in this invention, comprise a polymeric material such as polyethylene, polypropylene, ethylene propylene diene monomer, rubber, metal, textured metal, polyvinyl chloride, polyurethane, etc.
(43) Further, an alternate embodiment may charge the geosynthetic cover 11 with ballast infill 221, to provide a mass that increases the frictional resistance to movement with the plurality of particles of the infill that fill interstices and spaces above the geotextile 213 and among the tufts 215. When used in this invention, suitable materials for infill are sand, concrete and materials available from Watershed Geosynthetics LLC (Alpharetta, Ga.) under the trademarks HydroBinder and ArmorFill. Infill can be of various colors, sizes and textures.
(44) When used in this invention, examples of suitable materials for anti-creep strips are calendared, textured and structural membranes made by Agru America, Inc. under the trademark SureGripnet.
(45) Wind Uplift Resistance
(46) The present invention comprises a wind-resistant non-ballasted integrated photovoltaic module mounting system for use on a tufted geosynthetic, which preferably includes both anti-creep strips and an attachment layer. The system does not rely on weight to resist wind forces, but instead relies on wind-breaking turf blades (i.e., the synthetic grass) and an attachment to the turf blades (synthetic grass). The cover of the present invention can be deployed over a large area with very minor ballasting. Wind-breaking elements 219 may also be utilized to break up the airflow over the integrated photovoltaic module to provide wind uplift resistance. As illustrated in
(47) With this invention, the wind velocity on the impermeable surface (geomembrane) becomes turbulent near the surface of the cover, thus greatly reducing the actual wind velocity at the liner surface and decreasing associated uplift. The reaction of the synthetic grass of the tufted geosynthetic to the wind forces can also create a downward force on the geomembrane. This reaction is caused by the filaments of the synthetic grass applying an opposing force against the wind which is transferred as a downward force on the geomembrane.
(48) The integrated photovoltaic module of this invention can be used with an optional tilting device to raise or lower the module for better results depending on the location.
(49) Further, the mounting baseplate 2 spaces the photovoltaic solar module 3 from the tufted geosynthetic ground cover 11. The spacing thereby creates a gap between the tufted geosynthetic ground cover and the photovoltaic solar module 3, which gap facilitates air flow therealong for heat dissipation in that heating of the photovoltaic solar module 3 which occurs reduces the solar generation efficiency of the solar module. In an alternate embodiment, the mounting base plate 2 is sized to provide at least an 18 inch to 24 inch gap under the photovoltaic solar module 3. To further enhance solar generation energy capacity, the photovoltaic solar module 3 is bifacial and the tufted geosynthetic ground cover 11 includes light reflective features, such reflectants added into the polymeric used the extrusion of the yarn from which the tufts 215 are formed during tufting. As shown in
(50) With reference next to
(51) A C-shaped bracket 30 is slidably coupled to the upper member 26 for selective longitudinal movement along the upper member 26. The C-shaped bracket 30 includes a threaded mounting post or bolt 32 extending upwardly and through a mounting hole 34 within a staggered clamp 36. The staggered clamp 36 includes a contact ledge 37. A nut 38 is threadably coupled to the mounting post 32 to force the contact ledge 37 of the staggered clamp 36 downwardly against the peripheral margin of the solar panel 11, thus locking the position of the solar panel 11. The tightening of the nut 38 upon the post 32 also causes the staggered clamp 36 to be forced downward into abutment with the upper member 26 of the I-beam, thereby locking the position of the C-shaped bracket 30 and staggered clamp 36 relative to the I-beam 24. The base plate 14, I-beam 24, bracket 30, and clamp 36 may all be made of a polymer or metal material, such as aluminum.
(52) Lastly, the mounting system 10 includes a weld harness or weld harness strip 39 and anti-creep strips 44 which are coupled to the base member 17 through bolts 40. As with all embodiments herein, the anti-creep strips 44 include a generally planar support 45 and an array or arrangement of downwardly extending feet or projections 46. The anti-creep strip 44 may be made of a polymer material or the like. The weld harness strip 39 has a first portion 39′ which is coupled to the base plate 14, and a second portion 39″ which is meltable to the underlying tufted geosynthetic 41.
(53) In use, the weld harness strip 39 overlays a portion of the tufted geosynthetics 41 wherein heat, or other form of welding, is applied to the weld harness strip 39 so that the weld harness strip 39 partially melts or becomes molten and thereby bonds or coupled with the strands or yarns 42 of the geosynthetic material when cooled. The bonding of the weld harness strip 39 to the yarns is depicted by welding reference W.
(54) It should be understood that the geosynthetic material may be used in combination with one or more layers of additional geosynthetic materials.
(55) With reference next to
(56) The side edge mounting bracket 50 may be coupled to mechanical means shown in
(57) With reference next to
(58) Here, the mounting attachment 62 includes a top portion 64 which captures the mounting flange 54 of the side edge mounting bracket 50 extendingly attached to the solar panel 11 and is affixed thereto and secured in position through a threaded mounting bolt 38. Optionally, the mounting attachment 62 may be made of a polymer material which allows it to flex, thereby allowing for the solar panel to be snap fitted into the top portion 64 without the need for the use of the mounting post and nut to secure the position of the solar panel 11 to the mounting attachment 62. The top portion 64 extends to and merges with a lower portion or cradle 66 which extends about the side and bottom of the mounting bracket 50. The lower portion 66 may be considered to be an elongated base plate or base portion and is integrally coupled with or extending from the mounting attachment 62. The lower portion 66 includes feet 68 to which the anti-creep strip 44 is coupled through conventional means, such as bolts, screws, or adhesive. The lower portion 66 also includes weld harness strips 39 which are welded W or otherwise coupled to the tufted geosynthetic material, and specifically the yarns of the tufted geosynthetic material, as previously discussed.
(59) The lowest part of lower portion 66 may be considered to be a base plate as it forms the base of the lower portion 66. Therefore, the highest part of lower portion 66, which forms the C-shaped channel about bracket 50, may be considered to be an elongated rail which is integrally formed with or extends from the portion considered to be the base plate.
(60) With this configuration, ballast B, such as elongated weight member, may be easily coupled to the mounting attachment 62 if desired, as shown in
(61) Multiple mounting attachments may be mounted end to end, as shown in
(62) With reference next to
(63) In use, the weld harness strip 72 is once again welded to the strands or yarns of the underlying tufted geosynthetic material, as previously discussed.
(64) With reference next to
(65) The top portion 92 is generally a half cylinder having ends 95 in the form of tangs that are releasably received within longitudinal grooves 96 along the upper ends of the bottom portion 93. The bottom portion 93 also being in the form of a half cylinder and includes longitudinal stand grooves 99.
(66) The stand 94 has a bottom portion 94′ is generally triangular in shape and includes an anti-creep strip 96 coupled to the bottom surface of the stand 94. The stand bottom portion 94′ also includes oppositely disposed weld harness strips 97. Lastly, the stand bottom portion 94′ includes a pair of oppositely disposed longitudinal catches 100 which are configured to be releasably received within the longitudinal grooves 99 of the conduit bottom portion 93.
(67) In use, the weld harness strips are welded or otherwise coupled to the yarn of the tufted geosynthetic material, as previously discussed. Again, the anti-creep strip 96 prevents relative movement of the wire tray system 90 relative to the tufted geosynthetic material.
(68) The conduit top portion 92 may be easily released from the conduit bottom portion 93 to provide easy access to the wiring within the conduit 91. Also, the entire conduit 91 may be easily removed from the stand 94 for replacement purposes.
(69) It should be understood that in these embodiments the weld harness strip is preferably made of a polyethylene material. Similarly, the yarns of the tufted geosynthetic material are also made of a polyethylene material. With this construction, the melting point of the weld harness strip is generally that of the yarns of the tufted geosynthetic material, thereby creating a superior bold or weld there between. However, it should be understood that other types of polymer materials may also be used for these components without departing from the scope of the invention.
(70) The distinct advantage to the invention described in the multiple embodiments herein is that the solar panels may be positioned or arranged in a manner that provides for a higher density of solar panels per area of land. This higher density allows for the generation of more electricity per land area. Another advantage is the easy of mounting solar panels without the need for a racking system or without the occurrence of panel movement over time.
(71) The wind breaking element, such as members 219, readily attach to the photovoltaic module 3, or alternatively, to the bracket 50 or 112, for wind uplift resistance, by creating turbulent flow near the surface of the cover, thus greatly reducing the actual wind velocity at the cover surface and decreasing associated uplift.
(72) In all embodiments wherein two base plates, spacers, or rails are shown, it should be understood that the invention may include at least one such component, however, such an arrangement is not preferred.
(73) This invention has been described with particular reference to certain embodiments, but variations and modifications can be made without departing from the spirit and scope of the invention.