BOLTLESS MODULE SUPPORT STRUCTURES AND BOLTLESS MODULE ATTACHMENT METHOD

Abstract

The present invention provides a boltless module mounting system and a method of installing a boltless module. The system includes at least one module frame containing a module laminate, at least one support structure having support rails, and multiple boltless mounting components. The mounting components attach the module frame to the support rails. The present invention also provides a boltless module mounting system including at least one module having posts and at least one support structure with support rails. The support rails have receiving slots with a receiving hole and two or more slide slots. The posts interlock with the receiving slots. The method includes aligning multiple boltless connectors, lowering a boltless module frame onto a support structure, and sliding the frame to interlock the boltless connectors.

Claims

1. A boltless module mounting system, comprising: a. at least one module frame having a module laminate therein; b. at least one support structure having support rails; and c. a plurality of boltless mounting components operative to attach the at least one module frame to the support rails.

2. The boltless module mounting system of claim 1, wherein said boltless mounting components selected from the group consisting of: interlocking posts and receiving slots, interlocking rail tabs, and combinations thereof.

3. The boltless module mounting system of claim 2, wherein the at least one module frame comprises a plurality of posts and the support rails comprise a plurality of receiving slots.

4. The boltless module mounting system of claim 2, wherein the at least one module frame comprises a plurality of receiving slots and the support rails comprise a plurality of posts.

5. The boltless module mounting system of claim 2, wherein the at least one module frame comprises module tabs and the support rails comprise rail tabs and wherein the module tabs are operative to interlock with the rail tabs.

6. The boltless module mounting system of claim 1, wherein the boltless mounting components comprise interlocking posts and receiving slots, said receiving slots having a modified keyhole conformation with two slide slots extending in perpendicular directions from a receiving hole.

7. The boltless module mounting system of claim 1, wherein the boltless mounting components comprise interlocking posts and receiving slots, said receiving slots having a modified keyhole conformation with two slide slots extending in opposite directions from a receiving hole.

8. The boltless module mounting system of claim 1, wherein at least two of the module frames are operative to mount together on one of the support rails.

9. The boltless module mounting system of claim 1, further comprising at least one grounding connector.

10. The boltless module mounting system of claim 1, wherein the support structure further comprises at least one rail having a plurality of receiving slots and at least one rail having a plurality of posts, wherein each post is operative to interlock with one of the plurality of receiving slots.

11. A boltless module mounting system, comprising: a. at least one module comprising posts; and b. at least one support structure comprising support rails with receiving slots having a receiving hole and two or more slide slots; wherein said posts are operative to interlock with said receiving slots.

12. A method of installing a boltless module, comprising: a. providing a boltless module frame with a module therein, said boltless module frame further comprising a plurality of boltless connectors, b. providing a support structure with a plurality of boltless connectors, c. aligning the plurality of boltless connectors, d. lowering said boltless module frame onto said support structure, and e. sliding said boltless module frame such that the plurality of boltless connectors interlock.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a detail perspective view of a boltless module and frame according to an embodiment of the invention;

[0015] FIG. 2 is a detail perspective view thereof, with the glass and solar cell laminate of the module hidden for clarity;

[0016] FIGS. 3, 4, and 5 are perspective views illustrating installation thereof;

[0017] FIG. 6 is a sectional view thereof, taken along line 6-6 in FIG. 2;

[0018] FIG. 7 is a detail perspective view of a boltless module mounting system according to another embodiment of the invention;

[0019] FIG. 8 is a detail exploded view thereof;

[0020] FIG. 9 is a sectional view thereof, taken along line 9-9 in FIG. 7;

[0021] FIG. 10 is a detail perspective view of a boltless module mounting system according to another embodiment of the invention;

[0022] FIG. 11 is a detail exploded view thereof;

[0023] FIG. 12 is a sectional view thereof, taken along line 12-12 in FIG. 10;

[0024] FIG. 13 is a perspective view of a boltless module mounting system according to yet another embodiment of the invention;

[0025] FIG. 14 is an exploded view thereof; and

[0026] FIG. 15 is a sectional view thereof, taken along line 15-15 in FIG. 13.

DETAILED DESCRIPTION OF THE INVENTION

[0027] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

[0028] As used herein, a solar panel is generally referred to as a module, a collection of modules is referred to as a panel, a collection of panels is referred to as a table, and a collection of tables is referred to as an array.

[0029] Broadly, one embodiment of the present invention is a boltless module mounting system, comprising interlocking stud and slot components on the module and support structure or interlocking flanges on the module and support structure.

[0030] In some embodiments, the inventive solar frame comprises a receiving slot and the inventive support structure comprises a stud corresponding to the frame slot. The stud may be provided on a C or Z rail or a C or Z channel, for example. Alternatively, the frame may be provided with a stud and the support structure may be provided with a receiving slot. In some cases, the stud may be provided directly on the module. In any case, the frame may be held in place by gravitational force, obviating the need for torquing. The receiving slot may be further provided with a notch to further secure the alignment of the frame and support structure and held in place by a cap on the post or rivet. In this method, modules are held in place by gravity during installation and further secured by the post cap/slot alignment when the panels are subject to uplift from prevailing winds

[0031] The studs may be fabricated in or on the panel frame or support structure by a manufacturing step selected from the group consisting of stamp, crimp, rivet, swage, and combinations thereof. The studs may be manufactured with a cap, head or hat that mechanically prevents the panel frame from separating from the support structure once in position. The receiving slot may be stamped or punched into the frame or the support structure. Preferably, a locking screw, pin or rivet may be provided to prevent the stud from sliding out of the slot due to updrafts from strong winds.

[0032] In another embodiment, interlocking flanges may secure the panel frame to the support structure and preserve its alignment. The flanges or tabs may be formed in or on the panel frames and support structure rails by a method selected from the group consisting of stamp, weld, swage, screw, glue, and combinations thereof. The flange may also be described as a frame lip, a frame edge, or rail.

[0033] Module support structures are generally manufactured from metal, although the material of manufacture is not particularly limited. In some embodiments, module support structures may feature rivets or slot and stud combinations and structures such as shelving may be assembled using slot and stud components. A stud may also be described as a post, boss, rod, pin, rivet, protuberance, or swage fitting. The studs may be manufactured with a head or hat that mechanically prevents the panel frame from separating from the support structure once in position.

[0034] The slot of the present invention may be a type selected from the group consisting of a keyhole slot, a modified keyhole slot with a second slide slot 90 around a receiving hole from a first slide slot, and 180 around the receiving hole from the first slide slot. The dual slide keyhole slot may be particularly useful for structures which may have a slide slot aligned at an angle from the vertical position or for structures that may have a portrait orientation and a landscape orientation. The slot may also be described as a notch, opening, or groove.

[0035] In some aspects of the invention, the module frame and/or support structure may be provided with a pin, screw, and/or rivet to provide electrical grounding. A pin, screw, rivet, or rivet pin may additionally provide anti-theft security. Use of pins, screws, and/or rivets assures proper module to support structure grounding without need for additional torquing.

[0036] In some aspects of the invention, one or more studs may be hollow and may be provided with a rivet passing therethrough. The rivet may preferably ground the frame and/or module to the support structure.

[0037] In some cases, each module frame may interlock with an adjacent frame, thereby reducing the number of underlying support structure rails required in the system.

[0038] Furthermore, the boltless concept may be extended to the entirety of the support structure, thereby reducing the number of required bolts for the assembly.

[0039] None of the embodiments of the invention preclude the use of bolts in addition to the slot and stud or interlocking flange connections.

[0040] Referring to FIGS. 1-15, FIGS. 1-6 illustrate a module 36 according to an embodiment of the invention with a module frame comprising rails 10 with rail bottom plates 14 and panel slots 22 to hold the module's glass/solar cell laminate 36. The rail bottom plates 14 may have a plurality of modified keyhole slots, each having an insertion hole 16 and two locking slots 18 perpendicular to each other. The rail bottom plates 14 may also have a plurality of ground pin holes 20. The frame may be installed onto a support structure as shown in FIGS. 3-5. The module frame may be lowered onto the support rail 24 with insertion holes 16 aligned over studs or posts 28 and slid into position so that posts 28 rest in locking slots 18. The frame may be further secured using rivets 32 through the posts 28, such that a rivet compression portion 34 remains beneath the post retainer 30. With the support rail 24 ground pin holes 26 aligned with the bottom plate 14 ground pin holes 20, a locking pin, screw or self-tapping screw may be used to lock the frames into position, maintaining alignment, and to provide an electrical ground connection between the metal parts.

[0041] FIGS. 7-9 illustrate an alternate embodiment in which the locking slots 40 extend in opposite directions from the insertion hole 38. The module frame may be slid into position such that the post 42 rests in a locking slot 40.

[0042] FIGS. 10-12 illustrate another embodiment in which the bottom plate 14 has a rail slot 44 with a rail flange or rail tab 46 extending beneath and parallel to the rail slot 44 and the support rail 24 has a support slot 48 with a support flange or support tab 50 extending above and parallel to the support slot 48. The bottom plate 14 may be installed onto the support rail 24 by lowering the bottom plate 14 onto the support rail 24 with the rail slot 44 and the support slot 48 aligned such that the rail tab 46 extends into the support slot 48 and the support tab 50 extends into the rail slot 44 and sliding the module frame into position such that the rail tab 46 couples with the support tab 50.

[0043] In some embodiments, a frame rail 10 and a reverse frame rail 52 may be installed together on the same support rail 24, as shown in FIGS. 13-15, reducing the support structure necessary and providing further savings. The reverse rail insertion hole 56 in the reverse rail bottom plate 54 may be aligned with the insertion hole 38 in the bottom plate 14 so that the grounding pin holes 20, 60 are aligned, the rails 10, 52 are back to back, and the panel slots 22, 62 extend in opposite directions. The paired rails 10, 52 may be lowered onto a support rail with the insertion holes 38, 56 aligned with an extended support rail post 64 and the module frame may be slid into position so that the post 64 rests within locking slots 40, 58.

[0044] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.