Systems and methods for supporting solar panels
10367443 ยท 2019-07-30
Assignee
Inventors
- Sean Bailey (Emeryville, CA, US)
- Rodney Hans Holland (Novato, CA, US)
- Miguel M. L. Praca (Kentfield, CA, US)
Cpc classification
F24S25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S20/20
ELECTRICITY
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
F24S25/67
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Y02E10/47
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
H02S20/30
ELECTRICITY
F24S25/617
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
H02S20/20
ELECTRICITY
H02S20/30
ELECTRICITY
F24S25/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/67
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S25/12
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
Systems and methods are provided for supporting (racking) solar (e.g., photovoltaic) panels. At least one concrete track can be formed, first, second, and third racking structures can be assembled, each including two legs, landings at tops the legs, and feet that respectively can be secured to the at least one concrete track. A first solar panel can be placed on the landings of the first and second racking structures. A first edge of the first solar panel can be secured to each the landings of the first racking structure. A second solar panel can be placed on the landings of the second racking structure and on the landings of the third racking structure. A second edge of the first solar panel and a first edge of the second solar panel can be secured to each the landings of the second racking structure.
Claims
1. A method of supporting solar panels, the method comprising: forming first and second concrete tracks; assembling first, second, and third racking structures, each comprising: front and rear legs; first landings at tops of the front legs; second landings at tops of the rear legs, wherein the second landings are not directly coupled to the first landings by a structural member; front feet at bottoms of the front legs; and rear feet at bottoms of the rear legs; securing the front feet of the assembled first, second, and third racking structures to the first concrete track; securing the rear feet of the first, second, and third racking structures to the second concrete track; placing a first solar panel on the first and second landings of the first and second racking structures; securing a first edge of the first solar panel to each of the first and second landings of the first racking structure; placing a second solar panel on the first and second landings of the second racking structure and on the first and second landings of the third racking structure; and securing a second edge of the first solar panel and a first edge of the second solar panel to the first and second landings of the second racking structure wherein the first concrete track and the second concrete track are positioned in a direction that is transverse to the first edge of the first solar panel, the first edge of the second solar panel, and the second edge of the first solar panel.
2. The method of claim 1, wherein forming the at least one concrete track comprises slip forming first and second discrete concrete tracks.
3. The method of claim 1, wherein each of the first, second, and third racking structures further comprises a cross brace coupling the legs of that racking structure to one another, the cross brace extending in a direction substantially transverse to the at least one concrete track.
4. The method of claim 1, wherein each of the first, second, and third racking structures further comprises a strut extending in a direction substantially parallel to the at least one concrete track, the strut of the first racking structure coupling one of the legs of the first racking structure to one of the legs of the second racking structure, the strut of the second racking structure coupling one of the legs of the second racking structure to one of the legs of the third racking structure.
5. The method of claim 1, wherein securing the feet to the concrete track comprises inserting the feet into grooves of the concrete track and applying adhesive within the grooves.
6. The method of claim 1, wherein securing the feet to the concrete track comprises setting the feet into the concrete track while the concrete is wet.
7. The method of claim 1, wherein securing the second edge of the first solar panel and the first edge of the second solar panel to each of the first and second landings of the second racking structure comprises fastening a structure to each of the first and second landings, wherein the structure presses the solar panel onto a corresponding landing.
8. The method of claim 7, wherein the first and second solar panels each comprise a frame and wherein each of the first and second landings comprises a hook flange under which the frame of one of the first and second solar panels fits to pull the solar panel onto the corresponding landing.
9. The method of claim 7, wherein the structure comprises a retainer comprising first and second overhangs that respectively contact the upper surfaces of the first and second solar panels.
10. The method of claim 7, wherein the first and second solar panels each are frameless, wherein each of the first and second landings comprises a gasket, and wherein the structure comprises a clamp that contacts the upper surfaces of the first and second solar panels.
11. The method of claim 1, wherein the first solar panel is secured to the first and second landings of the first and second racking structures after the first and second racking structures are secured to the at least one concrete track.
12. The method of claim 1, wherein the first solar panel is secured to the first and second landings of the first and second racking structures before the first and second racking structures are placed on and secured to the at least one concrete track.
13. The method of claim 12, wherein the third racking structure is placed on and secured to the at least one concrete track after the first solar panel is secured to the first and second landings of the first and second racking structures.
14. A system for supporting a solar panel, the system comprising: first and second concrete tracks; first, second, and third racking structures each comprising: front and rear legs; first landings at tops of the front legs; second landings at tops of the rear legs, wherein the second landings are not directly coupled to the first landings by a structural member; front feet at bottoms of the front legs; and rear feet at bottoms of the rear legs; rear feet at bottoms of the rear legs; the front feet of the first, second, and third racking structures being secured to the first concrete track; the rear feet of the first, second, and third racking structures being secured to the second concrete track; wherein a first solar panel is disposed on the first and second landings of the first and second racking structures, wherein a first edge of the first solar panel secured to the first and second landings of the first racking structure; and wherein a second edge of the first solar panel and a first edge of a second solar panel are secured to the first and second landings of the second racking structure wherein the first concrete track and the second concrete track are positioned in a direction that is transverse to the first edge of the first solar panel, the first edge of the second solar panel, and the second edge of the first solar panel.
15. The system of claim 14, wherein forming the at least one concrete track comprises slipformed first and second discrete concrete tracks.
16. The system of claim 14, wherein each of the first, second, and third racking structures further comprises a cross brace coupling the legs of that racking structure to one another, the cross brace extending in a direction substantially transverse to the at least one concrete track.
17. The system of claim 14, wherein each of the first, second, and third racking structures further comprises a strut extending in a direction substantially parallel to the at least one concrete track, the strut of the first racking structure coupling one of the legs of the first racking structure to one of the legs of the second racking structure, the strut of the second racking structure coupling one of the legs of the second racking structure to one of the legs of the third racking structure.
18. The system of claim 14, wherein the feet are disposed in grooves of the concrete track and locked within the grooves with adhesive.
19. The system of claim 14, wherein the feet are set into the concrete track.
20. The system of claim 14, wherein the second edge of the first solar panel and the first edge of the second solar panel are secured to each of the first and second landings of the second racking structure by a structure fastened to each of the first and second landings, wherein the structure presses the solar panel onto a corresponding landing.
21. The system of claim 20, wherein the first and second solar panels each comprise a frame and wherein each of the first and second landings comprises a hook flange under which the frame of one of the first and second solar panels fits to pull the solar panel onto the corresponding landing.
22. The system of claim 20, wherein the structure comprises a retainer comprising first and second overhangs that respectively contact the upper surfaces of the first and second solar panels.
23. The system of claim 20, wherein the first and second solar panels each are frameless, wherein each of the first and second landings comprises a gasket, and wherein the structure comprises a clamp that contacts the upper surfaces of the first and second solar panels.
Description
BRIEF DESCRIPTION OF DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
DETAILED DESCRIPTION
(15) Systems and methods are provided for racking solar panels, such as photovoltaic panels.
(16)
(17)
(18) In the exemplary configuration illustrated in
(19)
(20)
(21)
(22) After fully or partially assembling the racking system at operations 502-506, the solar panels 102 are installed on the racking system. For example, in method 500, a solar panel can be placed on four landings on the racking row (operation 508), e.g., on the respective landings 210 of first and second front legs 202 that are adjacent to one another, and on the respective landings 210 of first and second rear legs 204 that are adjacent to one another. In method 500, the retainers on at least one edge of the solar panel can be fastened to those landings, e.g., so as to press the solar panel against any suitable number of the landings, e.g., against two of the four landings (operation 510); in configurations where the solar panel placed in operation 508 is the first solar panel in the row, the fasteners are fastened on the edge of the row. In method 500, another solar panel is placed adjacent to the previous one (operation 512), e.g., is placed on four landings on the racking row, where two of the four landings are coupled to the solar panel placed during operation 508. In method 500, the retainers are fastened on the edge between the solar panel and the previous one (operation 514). Operations 512 through 514 can be repeated until solar panels are placed on the entire racking system (operation 516). The retainers can be fastened on the last solar panel on the edge at the end of the racking row (operation 518).
(23) In some configurations of the present systems and methods, the solar modules do not include frames, and such modules can be referred to as frameless solar modules or solar panels. Such panels can include two pieces of glass with photovoltaic cells sandwiched therebetween, and an encapsulant surrounding and protecting the photovoltaic cells. In the present systems and methods, frameless modules can be supported using a different attachment system than framed modules. For example,
(24)
(25) After fully or partially assembling the racking system at operations 902-906, the solar panels 102 are installed on the racking system. For example, in method 900, a solar panel can be placed on four landings on the racking row (operation 908), e.g., on the respective landings 210 of first and second front legs 202 that are adjacent to one another, and on the respective landings 210 of first and second rear legs 204 that are adjacent to one another. In method 900, the edge hooks are secured to the bottom edge of the solar panel on both bottom corners, e.g., so as to secure the solar panel against any suitable number of the landings, e.g., against two of the four landings, such as the two landings 606 associated with the front legs 202 (operation 910). In method 900, the clamps and gaskets on the edge of the solar panel are fastened (operation 912); for example, in configurations where the solar panel placed in operation 908 is the first solar panel in the row, operation 908 fasteners are fastened on the edge of the row. In method 900, another solar panel is placed adjacent to the previous one (operation 914), e.g., is placed on four landings on the racking row, where two of the four landings are coupled to the solar panel placed during operation 908. In method 900, edge hooks are secured to the bottom edge of the solar panel on both bottom corners (operation 916), e.g., similarly as in step 910. In method 900, the clamps and gaskets on the edge of the solar panel are fastened on the edge between the solar panel and the previous one (operation 918). Operations 914 through 918 can be repeated until solar panels are placed on the entire racking system (operation 920). The clamps and gaskets can be fastened on the last solar panel on the edge at the end of the racking row (operation 922).
(26)
(27)
(28) In one exemplary configuration, a method of supporting solar panels is provided that includes forming at least one concrete track; and assembling first, second, and third racking structures each including two legs, landings at tops of respective ones of the legs, and feet at bottoms of respective ones of the legs. The feet of the assembled first racking structure can be secured to the at least one concrete track; the feet of the assembled second racking structure can be secured to the at least one concrete track; and the feet of the assembled third racking structure can be secured to the at least one concrete track. A first solar panel can be placed on the landings of the first and second racking structures. A first edge of the first solar panel can be secured to each the landings of the first racking structure. A second solar panel can be placed on the landings of the second racking structure and on the landings of the third racking structure. A second edge of the first solar panel and a first edge of the second solar panel can be secured to each the landings of the second racking structure. Non-limiting examples of such a method are provided herein, e.g., with reference to
(29) Optionally, forming the at least one concrete track includes slip forming first and second discrete concrete tracks, e.g., such as provided herein with reference to
(30) Additionally, or alternatively, each of the first, second, and third racking structures optionally further includes a cross brace coupling the legs of that racking structure to one another, the cross brace extending in a direction substantially transverse to the at least one concrete track. Examples of such racking structures are provided herein with reference to
(31) Additionally, or alternatively, each of the first, second, and third racking structures optionally further includes a strut extending in a direction substantially parallel to the at least one concrete track, the strut of the first racking structure coupling one of the legs of the first racking structure to one of the legs of the second racking structure, the strut of the second racking structure coupling one of the legs of the second racking structure to one of the legs of the third racking structure. Examples of such racking structures are provided herein with reference to
(32) Additionally, or alternatively, securing the feet to the concrete track optionally includes inserting the feet into grooves of the concrete track and applying adhesive within the grooves, e.g., such as provided herein with reference to
(33) Additionally, or alternatively, securing the feet to the concrete track optionally includes setting the feet into the concrete track while the concrete is wet, e.g., such as provided herein with reference to
(34) Additionally, or alternatively, securing the second edge of the first solar panel and the first edge of the second solar panel to each the landings of the second racking structure optionally includes fastening a structure to that landing, wherein the structure presses the solar panel onto that landing. Examples of such structures are provided herein, such as retainer 406 described with reference to
(35) As a further option, the first and second solar panels optionally each can include a frame, and each of the landings can include a hook flange under which the frame of one of the first and second solar panels fits to pull the solar panel onto that landing. Examples of such a hook flange are provided herein, such as hook flange 404 described with reference to
(36) As an additional or other option, the structure optionally includes a retainer including first and second overhangs that respectively contact the upper surfaces of the first and second solar panels. Examples of such retainer are provided herein, such as retainer 406 described with reference to
(37) As another option, the first and second solar panels each can be frameless, each landing can include a gasket, and the structure can include a clamp that contacts the upper surfaces of the first and second solar panels. Examples of such gasket and clamp are provided herein, such as gasket 704 and clamp 702 described with reference to
(38) Additionally, or alternatively, the first solar panel optionally can be secured to the landings of the first and second racking structures after the first and second racking structures are secured to the at least one concrete track, e.g., such as described with reference to
(39) Additionally, or alternatively, the first solar panel optionally can be secured to the landings of the first and second racking structures before the first and second racking structures are placed on and secured to the at least one concrete track, e.g., such as described with reference to
(40) As a further option, the third racking structure can be placed on and secured to the at least one concrete track after the first solar panel is secured to the landings of the first and second racking structures, e.g., such as described with reference to
(41) Under another aspect, a system is provided for supporting a solar panel. The system can include at least one concrete track; and first, second, and third racking structures each including two legs, landings at tops of respective ones of the legs, and feet at bottoms of respective ones of the legs. The feet of the first, second, and third racking structures can be secured to the at least one concrete track. A first solar panel can be disposed on the landings of the first and second racking structures. A first edge of the first solar panel can be secured to each the landings of the first racking structure. A second edge of the first solar panel and a first edge of a second solar panel are secured to each the landings of the second racking structure. Non-limiting examples of such a system are provided herein, e.g., with reference to
(42) Optionally, the at least one concrete track includes slip-formed first and second discrete concrete tracks, e.g., such as described with reference to
(43) Additionally, or alternatively, each of the first, second, and third racking structures optionally further can include a cross brace coupling the legs of that racking structure to one another, the cross brace extending in a direction substantially transverse to the at least one concrete track. Examples of such racking structures are provided herein with reference to
(44) Additionally, or alternatively, each of the first, second, and third racking structures optionally further can include a strut extending in a direction substantially parallel to the at least one concrete track, the strut of the first racking structure coupling one of the legs of the first racking structure to one of the legs of the second racking structure, the strut of the second racking structure coupling one of the legs of the second racking structure to one of the legs of the third racking structure. Examples of such racking structures are provided herein with reference to
(45) Additionally, or alternatively, the feet optionally can be disposed in grooves of the concrete track and locked within the grooves with adhesive. As another option, the feet can be set into the concrete track. Such options are described, for example, with reference to
(46) Additionally, or alternatively, the second edge of the first solar panel and the first edge of the second solar panel optionally can be secured to each the landings of the second racking structure by a structure fastened to that landing, wherein the structure presses the solar panel onto that landing. Examples of such structures are provided herein, such as retainer 406 described with reference to
(47) As a further option, the first and second solar panels each can include a frame and each of the landings can include a hook flange under which the frame of one of the first and second solar panels fits to pull the solar panel onto that landing. Examples of such a hook flange are provided herein, such as hook flange 404 described with reference to
(48) As a still further option, the structure can include a retainer including first and second overhangs that respectively contact the upper surfaces of the first and second solar panels. Examples of such retainer are provided herein, such as retainer 406 described with reference to
(49) As another option, the first and second solar panels each can be frameless, each landing can include a gasket, and the structure can include a clamp that contacts the upper surfaces of the first and second solar panels. Examples of such gasket and clamp are provided herein, such as gasket 704 and clamp 702 described with reference to
(50) While various illustrative embodiments of the invention are described herein, it will be apparent to one skilled in the art that various changes and modifications may be made therein without departing from the invention. For example, the present systems and methods are not limited to use with photovoltaic modules, and instead can be applied to solar collectors including any type of solar module (e.g., a module such as used with a non-concentrating solar thermal collector or with a concentrated solar power system, such as a parabolic trough or heliostat), or to racking or supporting any other type of structure. All such changes and modifications that fall within the true spirit and scope of the invention are encompassed by the following claims.