Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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GROUND MOUNTED SOLAR MODULE INTEGRATION SYSTEM
CROSS REFERENCE TO RELATED APPLICATIONS
The current application claims the benefit under of U.S. Provisional Patent
Application Ser. No. 61/229,622 filed July 29, 2009, and is a continuation in
part of
U.S. Patent Application Ser. No. 12/056,791 filed March 27, 2008, the entire
contents of each of which are incorporated herein by reference.
BACKGROUND
Embodiments disclosed herein are directed to systems, devices for use with
systems, and methods of mounting and retaining solar panels.
Solar (e.g., photovoltaic) panels are often manufactured in the form of flat
rigid structures. To facilitate the performance of the function of generating
electricity, solar panels may be mounted in an area exposed to the sun or
other
source of light. Often, it is desirable to mount solar panels outdoors at an
angle from
the horizontal so that they will more directly face the sun during peak
daylight hours
as opposed to panels mounted flat on the ground. In some applications, it may
be
desirable to mount a number of solar panels together in an array in order to
combine
the power generation capabilities of the individual panels. In many instances,
it may
be desirable that mounting systems for solar panel arrays retain the solar
panels in
place. This may be accomplished by attaching the solar panels to one another
in a
mounting system and/or by mounting the panels to the mounting system.
For example, U.S. Patent Application Publication No. 2007/0133474 to
Mascolo et al. describes a supported solar panel assembly including a solar
panel
module comprising a solar panel and solar panel module supports including
module
supports having support surfaces supporting the module, a module registration
member engaging the solar panel module to position the solar panel module on
the
module support, and a mounting element. U.S. Patent No. 6,534,703 to Dinwoodie
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describes a solar panel assembly for use on a support surface comprising a
base, a
solar panel module, a multi-position module support assembly, and a deflector.
SUMMARY
Devices, systems, and techniques are disclosed for mounting and retaining
solar panels. In some embodiments, solar panels are mounted in arrays on the
ground, e.g. in an open field. In some embodiments, the ground includes local
surface undulations, and the array of solar panels may be constructed to
compensate
for these undulations.
In one aspect, a method is disclosed for installing a solar panel array, the
method including acts of: providing a support mechanism including a support
post
pivotably attached to a support base; selecting an angular orientation of the
support
post with respect to the support base; setting the selecting an angular
orientation of
the support post; providing a solar panel; selecting a height on the support
mechanism for attaching the panel; and attaching the panel at the selected
height.
In another aspect, an apparatus for mounting solar panels is disclosed
including:
a support mechanism including a support post pivotably attached to a support
base
and an attachment module for attaching the solar panel to the support
mechanism.
In one aspect, a method is disclosed of installing a solar panel array, the
method including the steps of: obtaining a first support mechanism including a
support post pivotably attached to a support base; selecting an angular
orientation of
the support post with respect to the support base; setting the selected an
angular
orientation of the support post; obtaining a first solar panel; selecting a
height on the
first support mechanism for attaching the first panel; and attaching the first
panel to
the first support mechanism at the selected height.
In some embodiments, the angular orientation of the support post is selected
to compensate for a local undulation in a surface on which the first support
mechanism is located.
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In some embodiments, the height on the first support mechanism for
attaching the panel is selected to compensate for the local undulation in the
surface
on which the first support mechanism is located.
In some embodiments, attaching the first panel to the first support
mechanism includes coupling an attachment module to the first solar panel; and
after
coupling the attachment module to the first solar panel, coupling the
attachment
module to the first support mechanism.
In some embodiments, the first support mechanism includes a support frame
coupled to the support post. The support frame includes: a first elongated
member
coupled to the support post and extending from a front end to a rear end along
a
direction substantially perpendicular to the support post; a second elongated
member
extending at an angle to the first elongated member between a front end
coupled to
the front end of the first elongated member and a rear end, the second
elongated
member include at least one facility adapted to receive the attachment module
to
couple the solar panel to the support frame; and a facility for adjusting the
height of
the first elongated member relative to the support base to a selected one of a
plurality of heights. The method further including the steps of. selecting a
height of
the first elongated member relative to the support base; setting the height of
the first
elongated member relative to the support base to the selected height; and
coupling
the attachment module to the second elongated member.
In some embodiments, the support frame includes a facility for adjusting the
angle of the second elongated member to the first elongated member to a
selected
one of a plurality of angles. In some embodiments, the method includes:
selecting a
mounting angle of the solar panel; setting the angle of the second elongated
member
to the first elongated member to correspond to the mounting angle of the solar
panel;
Some embodiments include: obtaining a second solar panel; attaching the
second solar panel to the first support mechanism by coupling an attachment
module
to the second solar panel; and, after coupling the attachment module to the
second
solar panel, coupling the attachment module to the first support mechanism.
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Some embodiments include: obtaining a second support mechanism, the
second support mechanism including: a support post pivotably attached to a
support
base; and a support frame coupled to the support post. The support frame
includes a
first elongated member coupled the support post and extending from a front end
to a
rear end along a direction substantially perpendicular to the support post;
and a
second elongated member extending at an angle to the first elongated member
between a front end coupled to the front end of the first elongated member and
a rear
end, the second elongated member include at least one facility adapted to
receive a
second attachment module to couple the solar panel to the support frame. In
some
embodiments, the method includes, for the second support mechanism: selecting
an
angular orientation of the support post with respect to the support base and
selecting
a height on the first support mechanism for attaching the first panel, where
at least
one of the angular orientation of the support post and the height on the first
support
mechanism for attaching the first panel is selected to compensate for a local
undulation in a surface on which the second support mechanism is located;
setting
the selected angular orientation of the support post; and attaching the first
panel to
the second support mechanism at the selected height.
Some embodiments include: obtaining a second support mechanism, the
second support mechanism including: a support post pivotably attached to a
support
base; and a support frame coupled to the support post, the support frame
including: a
first elongated member coupled to the support post and extending from a front
end
to a rear end along a direction substantially perpendicular to the support
post; and a
second elongated member extending at an angle to the first elongated member
between a front end coupled to the front end of the first elongated member and
a rear
end, the second elongated member include at least one facility adapted to
receive a
second attachment module to couple the solar panel to the support frame. In
some
embodiments, the method includes attaching the front end of the first
elongated
member of the first support mechanism to the rear end of the first elongated
member
of the second support mechanism.
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In some embodiments, the front end of the first elongated member of the first
support mechanism and the rear end of the first elongated member of the second
support mechanism are attached using a facility which allows for the relative
position and angular orientation of the elongated members to be adjusted. Some
embodiments include selecting and setting the relative position and angular
orientation of the attached elongated members.
In some embodiments, the relative position or angular orientation of the
attached elongated members is adjusted to compensate for a variation in change
in a
slope of the surface underlying the first and second support mechanisms.
In another aspect, a method is disclosed of installing a solar panel array,
the
method including the steps of. obtaining a first plurality of solar panels;
placing a
first plurality of support mechanisms, each including a support post pivotably
attached to a support base, on a first region of a surface, the first region
having a
generally flat portion and localized undulations. In some embodiments, the
method
includes, for each respective support mechanism in the first plurality:
Selecting an
angular orientation of the support post with respect to the support base;
setting the
selected an angular orientation of the support post; selecting an attachment
height on
the first support mechanism for attaching the first panel; and attaching at
least one
respective solar panel to the respective support mechanism at the selected
height. In
some embodiments, the selected angular orientations and the attachment heights
are
selected to compensate for the local undulations in the first region such that
each of
the first plurality of panels are positioned with substantially the same
orientation
relative to the generally flat portion of the surface in the first region.
In some embodiments, the orientation relative to the generally flat portion of
the surface in the first region includes a height of the respective panel
relative to the
generally flat portion of the surface in the first region.
In some embodiments, the panels in the first plurality of panels are each
attached to a respective support mechanism while the support mechanism is
unattached to any other support mechanisms.
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Some embodiments include attaching each support mechanism in the first
plurality of support mechanisms to at least one other support mechanism in the
first
plurality of support mechanisms.
Some embodiments include attaching cross bracing between at least two
adjacent support mechanisms in the first plurality of support mechanisms.
In some embodiments, the support mechanisms in the first plurality are
substantially identical.
Some embodiments include: obtaining a second plurality of solar panels;
placing a second plurality of support mechanisms, each including a support
post
pivotably attached to a support base, on a second region of the surface, the
first
region having a generally flat portion and localized undulations, the second
region
being adjacent to the first region and having a general slope which differs
from a
general slope of the first region. Some embodiments include, for each
respective
support mechanism in the second plurality: selecting an angular orientation of
the
support post with respect to the support base; setting the selecting an
angular
orientation of the support post; selecting an attachment height on the first
support
mechanism for attaching the first panel; and attaching at least one respective
solar
panel from the second plurality of solar panels to the respective support
mechanism
at the selected height, where the angular orientations and the attachment
heights are
selected to compensate for the local undulations in the second region such
that each
of the second plurality of panels a are positioned with substantially the same
orientation relative to the generally flat portion of the surface in the
second region.
Some embodiments include attaching at least one of the support mechanisms
of the first plurality with at least one support mechanisms in the second
plurality.
In some embodiments, for each support mechanisms of the first plurality
which is attached to a support mechanism in the second plurality: the support
mechanism includes an attachment facility allows for the relative angular
orientation
of the support members to be adjusted to one of a plurality of orientations.
In some
embodiments, the method includes attaching the support mechanism includes
using
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the facility to set the relative angular orientation to compensate for the
difference in
the slopes of the first and second regions.
In some embodiments, the support mechanisms of the first and second
pluralities of support mechanisms are substantially identical.
In some embodiments, substantially no portion of each of the support
mechanisms in the first plurality is located below the surface.
Some embodiments include driving one or more nails through the at least
one of the support mechanisms and the surface to secure the support mechanism
to
the surface.
In another aspect, a solar panel module mounting system component is
disclosed including: support base; a support post; a pivot pivotably coupling
the
support post to the support base; and a support frame coupled to the support
post and
including a facility for attaching a solar panel module.
Some embodiments include one or more attachment modules adapted to
couple to the solar panel module and to couple to the solar panel module at a
selected height and orientation relative to the support base.
In some embodiments, the support frame includes: a first elongated member
coupled at a substantially right angle to the support post and extending from
a front
end to a rear end; a second elongated member extending at an angle to the
first
elongated member from a front end coupled to the front end of the horizontal
member and a rear end, and including the facility for attaching a solar panel
module;
and a facility for adjusting the height of the first elongated member relative
to the
support base to a selected one of a plurality of heights.
Some embodiments include a facility for adjusting the angle of the second
elongated member to the first elongated member to a selected one of a
plurality of
angles.
In some embodiments, the pivot is configured to allow the support post to
pivot about at least two transverse axes. In some embodiments, the pivot is
configured to allow the support post to pivot over at range angles from about
0 to at
least about 5 degrees from normal to the support base. In some embodiments,
the
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pivot is configured to allow the support post to pivot over at range angles
from 0 to
at least 10 degrees from normal to the support base. In some embodiments, the
pivot
is configured to allow the support post to pivot over at range angles from 0
to at least
30 degrees from normal to the support base.
In some embodiments, the support base includes a base pan for receiving and
bearing the weight of a ballast, the base pan configured and arranged to
receive the
ballast in a position such that the ballast does not interfere with a pivoting
motion of
the support post.
In some embodiments, the front end of the first elongated member includes a
facility for attachment to an adjacent solar panel module mounting system
component.
In some embodiments, the facility for attachment of the first elongated
member to an adjacent second solar panel module mounting system component is
configured to allow adjustment of at least one of the attachment angle and the
spacing between the component and the adjacent second solar panel module
mounting system component.
Some embodiments consist or consist essentially of the support base; the
support post; the pivot; the support frame, the one or more attachment
modules, and
attachment hardware.
Some embodiments consist or consist essentially of the support base; the
support post; the pivot; the support frame, the one or more attachment
modules, one
or more cross bracing members adapted to extend from the component to an
adjacent support component, and attachment hardware. In some embodiments, the
attachment hardware consists essentially of nuts, bolts, and screws.
In some embodiments, the support base, pivot, and support post includes a
first integral unit; the support frame includes a second integral unit; and
the
attachment module includes a third integral unit.
In some embodiments, the support base, pivot, and support post and the
support frame include a first integral unit; and the attachment module
includes a
third integral unit.
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In some embodiments, when the component deployed on a surface (e.g., the
ground), substantially no portion of the component extends through the
surface.
In another aspect, a solar panel module mounting system is disclosed
including: a first plurality of support mechanisms configured to receive a
first
plurality of solar panel modules, positioned on a first region of a surface
(e.g., the
ground), the first region having a generally flat portion and localized
undulations,
and each support mechanism including: a support base; a support post; a pivot
pivotably coupling the support post to the support base allowing the support
post to
pivot to selected one of a plurality of angular orientations relative to the
support
base; and a support frame coupled to the support post at a selected one of a
plurality
of attachment heights relative to the support base, and including a facility
for
attaching a solar panel module. In some embodiments, for each of the plurality
of
support mechanisms, the respective selected angular orientation and attachment
height compensates for the localized undulations such that each of the first
plurality
of solar panel modules is positioned with a substantially uniform height above
the
generally flat portion of the first region.
In some embodiments, each support mechanism is directly coupled to at least
one other support mechanism.
In some embodiments, each solar panel module extends between and is
supported by a pair of support mechanisms.
In some embodiments, the support mechanisms are substantially identical.
In some embodiments, each support mechanism includes a fixture configured
to allow coupling between the support mechanism and another support mechanism
and adapted to allow coupling at a selected one of a plurality of relative
positions of
the coupled mechanisms.
Some embodiments include a second plurality of support mechanisms
configured to receive a second plurality of solar panel modules, positioned on
a
second region of a surface, the second region having a generally flat portion
with a
slope differing from a slope of the generally flat portion of the first region
and
localized undulations. In some embodiments, each support mechanism of the
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second plurality includes: a support base; a support post; a pivot pivotably
coupling
the support post to the support base allowing the support post to pivot to
selected
one of a plurality of angular orientations relative to the support base; and a
support
frame coupled to the support post at a selected one of a plurality of
attachment
heights relative to the support base, and including a facility for attaching a
solar
panel module. In some embodiments, for each of the second plurality of support
mechanisms, the respective selected angular orientation and height compensates
for
the localized undulations such that each of the second plurality of solar
panel
modules is positioned with a substantially uniform height above the generally
flat
1o portion of the second region.
In some embodiments, for each support mechanisms of the first plurality
which is attached to a support mechanism in the second plurality: the support
mechanism includes an attachment facility allowing for the relative angular
orientation of the support members to be adjusted to one of a plurality of
orientations. In some embodiments, the method includes attaching the support
mechanisms includes using the facility to set the relative angular orientation
to
compensate for the difference in the slopes of the first and second regions.
In some embodiments, the support mechanisms of the first and second
pluralities of support mechanisms are substantially identical.
In some embodiments, substantially no portion of each support mechanisms
of the first and second pluralities is located below the surface.
Some embodiments include one or more nails extending through the at least
one of the support mechanisms and the surface to secure the support mechanism
to
the surface.
Various embodiments may feature any of the steps, features, and elements
described above, alone, or in any suitable combination.
BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings are not intended to be drawn to scale. In the
drawings, each identical or nearly identical component that is illustrated in
various
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figures is represented by a like numeral. For purposes of clarity, not every
component may be labeled in every drawing. In the drawings:
FIG. I is an array of solar panel modules;
FIG. 2A is a perspective view of a support base;
FIG. 2B is a perspective view of a support base with ballast;
FIG. 3 is a perspective view of a support frame;
FIG. 4A is perspective view of a support frame mounted on a support base;
FIG. 4B is a side view of the support frame mounted on a support base of
FIG.4A;
FIG. 5 is an attachment module of a solar module mounting system;
FIG. 6A is a perspective view of the top side of a solar panel module
illustrating attachment modules mounted on the solar panel module;
FIG. 6B is a view from the rear underside of a solar panel module illustrating
attachment modules mounted on the solar panel module;
FIG. 6C is a view from underneath a solar panel module illustrating
attachment modules mounted on the solar panel module according to an aspect of
the present inventions;
FIG. 7 is a perspective view of a solar panel module mounted to a support
frame and support base;
FIG. 8 is a rear perspective view of an array of solar panel modules featuring
cross bracing;
FIG. 8A is a rear perspective view of an array of solar panel modules
featuring cross bracing;
FIG. 9 is a rear perspective view of an array of solar panel modules deployed
on undulating ground;
FIG. 9A is a side perspective view of an array of solar panel modules
deployed on undulating ground having regions with differing slope;
FIGs. IOA-IOD are perspective views of attachment modules of a solar panel
module mounting system;
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FIG. 11 is a flowchart of a method of forming an array of solar panel
modules;
FIG 12A is a perspective view of an attachment module of a solar module
mounting system;
FIG 12B is a perspective view of an attachment module of a solar module
mounting system attached to a solar panel module.
DETAILED DESCRIPTION
The embodiments described herein are not limited to the details of
construction and the arrangement of components set forth in the following
description or illustrated in the drawings. The embodiments are capable of
other
embodiments and of being practiced or of being carried out in various ways.
Also,
the phraseology and terminology used herein is for the purpose of description
and
should not be regarded as limiting. The use of "including," "comprising," or
"having," "containing," "involving," and variations thereof herein, is meant
to
encompass the items listed thereafter and equivalents thereof as well as
additional
items. The description of one aspect of the embodiments disclosed herein is
not
intended to be limiting with respect to other aspects of the present
embodiments.
FIG. 1 illustrates an example of a section of an array of solar panel modules
100 that may be deployed on a mounting surface, for example, an area of open
ground such as a field. Aspects of the present embodiments may be applied to
other
mounting surfaces, such as roof structures.
The array 100 in this example includes a plurality of solar panel modules
110. In some embodiments, solar panel module 110 is a packaged interconnected
assembly of solar cells, e.g., photovoltaic cells. In some embodiments, the
solar
panel module may be used as a component in a larger photovoltaic system to
offer
electricity for commercial and residential applications.
The solar panel modules 110 are illustrated in FIG. 1 as being mounted at an
angle from the horizontal, but in some embodiments, the solar panel modules
may
be mounted at angles other than that illustrated in FIG. 1 or even
horizontally. The
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solar panel modules 110 may in some embodiments be mounted at different angles
throughout the array 100 and uniformly in others such as the one shown in FIG.
1.
The solar panel modules. 110 are shown in FIG. 1 facing away from what will be
described herein as the Top side of array 100. What is described as the Top
side
may correspond to geographical North position of the array. As shown here, the
Top side may be positioned approximately to the North so that the tilted faces
of the
panel modules are directed generally toward the South, e.g., tilted to more
squarely
face the direction of the sun for an installation north of the equator. In
some
embodiments, deflector elements (not shown) may be mounted facing the lateral
sides (i.e., the sides perpendicular to the Top side) at the edges of the
array, or in
other positions on the array to deflect wind currents.
Solar panel modules 110 in this example are mounted on support frames 120
which are in turn mounted on support bases 130 (sometimes referred to,
collectively,
as a support mechanism). A support frame is a support structure that may be
used to
support at least a portion of a solar panel; in this example, each support
frame 120 is
used to support a side of a solar panel module 110. A support base is a
support
structure which contacts the ground and supports one or more support frames
120.
Examples of support frame 120 and support base 130 are described more fully
below.
Note that although a 2x2 array is shown, arrays featuring any other number
of solar panel modules 100 arranged in any number of rows and columns may be
used. In some embodiments the array is formed with many panels over a large
area
e.g. and acre, several acres, or more.
Note also that while support frame 120 and support base 130 are shown as
separate components, but, in some embodiments, they may be integrated in a
single
unit.
FIG. 2A is a perspective view of a support base 130. The support base
includes a support post 131 connected to a base pan 132. As shown, support
post
131 is connected to base pan 132 with a pivot 133. The pivot 133 allows the
angle
of the support post 131 relative to base pan 132 to be adjusted. Pivot 133
includes
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two pivot bolts 134a and 134b, allowing post 131 to pivot in two transverse
directions. Accordingly, support post 131 may be positioned at a variety of
angles.
For example, in some embodiments, support post 131 may be positioned at any
selected angle in a range less than 30 degrees from normal to base pan 132.
Other
embodiments may have greater or lesser angular ranges, e.g. angles less than
20
degrees from normal, less than 10 degrees from normal, less than 5 degrees
from
normal, etc. In various embodiments, any other suitable type of pivot known in
the
art may be used, including, e.g., a ball and socket joint, a saddle joint, a
ball bearing,
etc.
The angle of support post 131 may be selected to compensate for local
undulations in the ground on which base pan 132 sits. For example, if the
ground
under base pan 132 had a local tilt of 20 degrees along a given direction, the
angle of
support post 131 could be adjusted to 20 degrees in the opposite direction,
thereby
compensating for the local tilt. Once the angle of support post 131 is chosen,
pivot
bolts 134a and 134b may be tightened to prevent further pivoting thereby
setting the
angle in place.
Support post 131 includes an attachment mechanism (sometimes referred to
as a facility), which in this example is support host bolt hole 135, which
maybe
used to attach post 131 to support frame 120. As described in greater detail
below,
support post 131 may be attached to support frame 120 at a variety of heights,
providing further flexibility to compensate for local undulations in the
ground on
which base pan 132 sits.
As shown in FIG. 2B, ballast 136 may be placed on support pan 132 to
provide support base 130 with mass that may assist in keeping array 100
securely in
place. In some embodiments, ballast 136 may comprise standard size concrete
blocks, such as, for example, blocks with dimensions of 8 inches wide x 8
inches tall
x 16 inches long, which may be available at numerous home improvement and/or
building supply stores. In some embodiments, blocks may be used with a nominal
size 8"x8"x16". This is a nominal size, typically the true dimensions are
smaller in
each direction by 1/8-1/4". In various embodiments, other size blocks may be
used.
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Where the base pans 132 are designed to permit use with standard sized,
commercially available blocks, the need to ship heavy ballast elements along
with
other elements of the system may be reduced (although one could ship the
ballast
elements or design ballast element specifically for use with base pans 132). A
purchaser/installer of the system could purchase or construct the ballast
blocks
locally.
For example, ballast 136 may include concrete blocks made at or near the
site where array 100 is to be positioned. Ballast 136 in some embodiments may
be
made from any concrete mix that is intended to withstand the elements for an
appropriate period of time, such as cement intended for outdoor applications
and
having an intended life span of 30+ years. Ballast 136 may in some embodiments
be
made using a Portland Type III concrete with air entrainment of about 5%. This
concrete is a high early strength, normal weight concrete with a fully cured
strength
of 5,000 psi, and is available from Precast Specialties Inc. of Abington, MA.
Alternatively, ballast 136 may be formed from materials such as, for example,
rocks,
metal, natural or recycled rubber, or Quazite , a polymer concrete available
from
Hubbell Lenoir City, Inc. of Lenoir City, TN, or other materials.
Although two similarly size ballast elements 136 are illustrated in FIG. 2B,
it
is to be understood that alternate embodiments may include, for example, left
and
right and/or front and back ballast elements having different configurations,
multiple
ballast elements positioned in any suitable configuration, or a single ballast
element.
If more than two ballast elements are utilized (e.g. as shown in FIG. 8A),
these
ballast elements may comprise, for example, standard sized building materials,
including, for example, standard sized bricks with dimensions of 3 5/8 inches
wide x
21/4 inches high x 8 inches long. If more than two ballast elements are used,
they
may be mounted on base pan 132 in a stacked or a side-by-side configuration,
or
both.
As shown, ballast 136 is placed on base pan 132. In some embodiments
ballast 136 may be attached or affixed to base pan 132 using any suitable
means
including fasteners, adhesives, hook and loop materials, etc. Base pan 132 may
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include a textured surface or retaining features to help maintain the
placement of
ballast 136.
Additionally, or as an alternative to ballast 136, one or more nails (e.g., 12
inch long nails) may be driven through base pan 132 into the ground below to
secure
the support base 136. In some embodiments, base pan 132 may include one or
more
holes, slots, etc. (not shown) to receive the nails and allow the nails to
pass through
the base pan 132 into the ground.
In some embodiments, support base 130 or any component thereof may also
contain one or more wire chases (not shown) that can be used for running
electrical
wire through the support base 130. Such wire chases may provide integrated
wire
management (e.g., allowing the electrical interconnection of two or more solar
panel
modules 110) and integrated grounding capabilities (e.g., accommodating one or
more ground wires).
Referring to FIG. 3, support frame 120 includes a horizontal member 125.
The front end of horizontal member 125 includes a front support frame
attachment
facility 126. The rear end of horizontal member 125 includes a rear support
frame
attachment facility 127. As shown in FIG. 1, the front support frame
attachment
facility 126 of one support frame 120 attaches to rear support frame
attachment
facility 127 of another support frame 120 to form columns of support frames
120 in
array 100.
Rear support frame attachment facility 127 receives the front support frame
attachment facility 126 of an adjacent support frame 120. This allows the
horizontal
members 125 of adjacent support frames to be attached, e.g., in this example,
bolted
together. The attachment facilities 126 and/or 127 may include multiple
horizontally spaced bolt holes, allowing the spacing between support frames
(and
hence modules 110) to be adjusted as desired. For example, as shown, the rear
attachment facility 126 includes six horizontally spaced bolt holes, while the
front
attachment facility 127 includes two horizontally spaced bolt holes, allowing
for
twelve possible spacings. Further, support frames 120 may be a pivotably
connected, allowing for adjustment of the angle at which horizontal members
meet.
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This allows for construction of an array 100 where the angular orientation of
modules 110 may vary row to row. Accordingly, support frames 120 allow for a
great deal of flexibility in the positioning of modules 110 in array 100.
Referring again to FIG. 3, support frame 120 includes angled member 128
which includes a facility to permit attachment of panels to the frame. In this
example, rear mounting hole 150 is provided on the rear portion of angled
member
128 and provides locations for the attachment of attachment modules 140,
described
in detail below. In some embodiments, (e.g. as shown in Fig. 7) an attachment
module 140 mounted to angled member 128 through rear mounting holes 150 may
be attached to a solar panel module 110 proximate a Top edge 210 of the solar
panel
module 110 that is vertically higher than a Bottom edge 220 of the solar panel
module when the solar panel module 110 is mounted on some embodiments of
certain aspects of the present embodiments. Some embodiments include a
facility
which allows for the adjustment of the angular orientation of angled member
128
relative to horizontal member 125. In other embodiments, support frame 120 is
constructed as an integral unit, with a fixed orientation of horizontal member
125
and angled member 128.
The Bottom edge 220 of solar panel module 110 may be attached with
another attachment module 140 to forward mounting slots 160 on angled member
128. Multiple forward mounting slots 160 are provided to allow flexibility in
mounting panel modules 110 of various sizes. For example, FIGS 4A and 4B show
a pair of attachment modules 140, a first one attached to mounting holes 150
and
second one attached to mounting slots 160 of angled member 128. The distance
between the pair of modules 140 may be coarsely adjusted by choosing which
mounting slot 160 the second attachment module 140 is mounted to, and more
finely
adjusted by slidably adjusting the position at which the module is mounted
within
the slot.
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In some embodiments, edges of two solar panel modules 110 may be
attached to respective sides of angled member 128 using attachment modules
140.
As shown in Fig. 1, this allows solar panel modules 110 to be attached to form
the
rows of the array 100.
As shown in FIGS. 3, 4A, and 4B, support frame 120 includes a support post
attachment mechanism 121 which allows attachment of support frame 120 to
support post 131. As previously noted, this attachment mechanism allows the
height
of support frame 120 above support pan 132 to be adjusted. As shown, support
post
attachment mechanism 121 includes several bolt holes spaced apart vertically.
Mechanism 121 receives support post 131 and support post 131 is bolted to
mechanism 121 with bolt 122 at a desired height using support post bolt hole
135.
Alternatively, in some embodiments, support base 130 and support frame 120 may
be constructed as an integral unit.
In some embodiments, support frame 120 (or any component thereof) may
also contain one or more wire chases (not shown) that can be used for running
electrical wire through the support frame 120. Such wire chases may provide
integrated wire management and integrated grounding capabilities.
FIG. 4 is an enlarged view of attachment module 140. Attachment module
140 may in some embodiments include a threaded hole 142 and a non-threaded
hole
144. In this example, attachment module 140 may be attached to support frame
120
with an appropriate attachment mechanism. In this example a bolt is used to
attach
attachment module 140 to support frame 120. In other embodiments, a metal pin
or
a clip may be used, or other attachment devices or mechanisms as would be
apparent
to one of skill in the art based on the disclosure provided herein.
Attachment module 140 may in some embodiments be made from 6061 -T6
aluminum which can be anodized if desired. The attachment module 140 can also
be made from other metal or some other material of sufficient strength. Where
a
conductive material is selected, the attachment module may be used to assist
in
passing ground among panels. The attachment module may be formed by machine
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cutting, but can also be extruded, laser cut, or water jet cut or formed using
another
suitable manufacturing method.
FIG. 6A illustrates one embodiment of attachment module 140 according to
one aspect of the present embodiments, mounted proximate the corners of solar
panel module 110. In this example the attachment modules 140 may be made of a
metal such as aluminum. In some embodiments, the attachment modules 140 may
be made of a conductive material to assist in grounding of the panel modules
or may
include a grounding path.
Referring back to FIG. 4, attachment module 140 includes an attachment
mechanism which in this example is a threaded hole for a bolt which may be
used to
attach the attachment modules 140 to a solar panel module 110. The attachment
module 140 may also include second, non-threaded holes for bolts 145 that may
used to attach (or facilitate attaching) an attachment module 140 to support
frame
120 (e.g. at rear mounting hole 150 or front mounting slot 160 of angled
member
128). Other attachment mechanisms may be employed with attachment modules
140, including, for example, screws, adhesives, clips, or solder.
Since many commercially available solar panels include a similar edge, this
particular attachment module is compatible for use with solar panels provided
by
multiple suppliers. This particular attachment module is also compatible for
use
with solar panel mounting systems provided by multiple suppliers. Other
designs
for compatibility with multiple suppliers may be provided based on the
disclosure
provided herein and different attachment modules may be designed for use with
different solar panels but made compatible for use with a common support frame
configuration.
Other mechanisms may be employed in other embodiments to facilitate
attachment of panel to support frame and those embodiments may (or may not)
provide flexibility in ability to vary the height of attachment with respect
to the
frame by allowing multiple attachment points or by allowing slidable
adjustment, as
would be readily designed by one of skill in the art based on the disclosure
provided
herein.
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In one embodiment, attachment module 140 is configured to permit it to be
attached to a plurality of different panel modules and/or panel module
mounting
systems available in the market.
FIGS. 6A - 6C illustrate one example of how attachment modules 140 may
be utilized to attach solar panel modules 110 to support frame 120. FIGS. 6B
illustrates a solar panel module with three attachment modules 140 attached
and one
attachment module 140 unattached. As illustrated in FIGS. 6A-6C an attachment
module 140 may be attached to a solar panel module 110 by a threaded bolt 145
passing through a threaded hole in attachment module 140 to secure attachment
module 140 to an inner edge of solar panel module 110. This provides for
positioning and alignment of solar panel module 110 relative to support frame
128.
Attachment modules 140 may be attached through non-threaded holes or slots to
support frame 120 by bolts passing through one of rear mounting hole 150 and
forward mounting slots 160 for a rear and a forward attachment module 140
respectively. In this manner, solar panel modules 110 may be secured in place
relative to support frame 120 and relative to one another in a fashion
compatible
with a number of commercially available solar panels. Other configurations may
be
designed to permit compatibility with multiple panel types whether attaching
at this
portion of the solar panel or designed for integration with future solar
panels, based
on the disclosure provided herein.
FIG. 7 shows a solar panel module 110 with a first lateral edge 230 and a
second lateral edge 240 attached to first and second support frames 120A and
120B,
respectively. The assembly shown in FIG. 7 can be considered to be a basic
unit
which may be repeated as shown in FIG. 1 to form the array 100.
FIG. 8 shows a rear view of the array 100 of FIG. 1. Cross bracing 801
provides additional support for solar panel modules 110. As shown, the cross
bracing includes three bracing members which extend horizontally between
adjacent
columns of support frames 120. However, in various embodiments, any other
suitable cross bracing or mechanical support members may be used. For example
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the embodiment in FIG. 8A included only two cross bracing members extending
between adjacent pairs of support frames 120a and 120b.
FIG. 9 is a rear perspective view of the array 100 deployed on undulating
ground. As shown, the ground 900 is generally flat and level, but includes
local
portions 901 having deviating heights and portion 902 which has a deviating
height
and tilt angle.
Array 100 has been adjusted to compensate for the undulation in the ground,
such that the height and tilt angle of panels 110 of array 100 are fixed
relative to the
flat and level portion of ground 900 across the entire array.
Three support bases. 130a are a positioned on the flat level portion or the
ground. For these support bases 130a, support posts 131 a are oriented normal
to
their respective base pans 132a and are attached to their respective support
frame
120a at equal heights.
Two support bases 130b are positioned on portions 901 of ground 900 which
are level, but have heights which deviate from the flat and level portion of
ground
900. For these support bases 130b, support posts 13 lb are also oriented
normal to
their respective base pans 132b. However, they are attached to their
respective
support frames 120b at heights which compensate for the local height
deviation.
One support base 130c is positioned on portion 902 of ground 900 which has
both a height and a tilt angle which deviates from the flat and level portion
of
ground 900. For the support base 130c, support post 131c is oriented at an
angle
from normal to its respective base pan 132b, to compensate for the tilt of
portion
902. Support post 131 c is also attached to its respective support frame 120b
at a
height which compensates for the local height deviation of portion 902.
Other adjustments to compensate for various configurations of undulating
ground may be provided based on the disclosure provided herein. For example,
ground 900 may be generally flat and inclined, with local undulations. In such
a
case, array 100 may be adjusted to compensate for the undulation in the
ground,
such that the height and tilt angle of panels 110 of array 100 are fixed
relative to the
flat and inclined portion of ground 900 across the entire array (or portions
thereof).
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In some cases, as shown in FIG. 9A, ground 900 may include a first region
910 and a second region 912 which are both generally flat with local
undulations,
but which are inclined at different slopes. As shown, because support frames
120a
and 120b may be pivotally connected (as discussed in detail above), the array
can
accommodate the regions of ground having varying slope. Note that although two
regions of varying slope are shown, and number may be accommodated.
Accordingly, array 100 may be easily installed over large areas of terrain
without the
need for specially constructed parts (i.e., support frames 120 in array 100
may be all
identical or substantially identical components.)
In general, the devices and techniques described herein allow ground
mounted solar panel module support arrays to be designed and constructed with
ease
and flexibility. Local undulations may be compensated for, and various
suitable row
and column spacings and angular orientations may be used.
Support frame 120, support base 130 can be made from metals (such as
stainless steel, mild steel, aluminum, etc), UV resistant plastic, fiberglass,
concrete,
or other materials.
In some embodiments, one or more of base pans 132 may include a pad or
sole on its underside. The sole may be made from any suitable material, e.g. a
textured material which improved the grip of base pans 132 on the supporting
surface. In cases where base pans 132 are not placed on the ground but, e.g.
on a
roof surface, material that can be considered an "inert pad" by the roofing
industry
may be used. In some embodiments, the sole may be made from recycled, non-
vulcanized crumb rubber, such as that available from Unity Creations Ltd. of
Hicksville, NY. In other embodiments the sole may be made from natural rubber,
EPDM (Ethylene Propylene Diene Monomer - a rubber roofing material), or
another
roofing material that may protect the roof or other surface upon which array
100
may be mounted from damage. The sole may be attached to the underside of base
pan 132 using any suitable attachment, e.g. adhesive, fasteners, etc.
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Figs. 1OA-1 OD show alternative embodiments of attachment module 140.
Referring to Fig. 10A, attachment module 140a includes upper member 301 and
lower member 302. An inner edge of panel 110 (not shown) can be attached
between the upper and lower members. The inner edge may include a hole (e.g. a
pre-formed hole provided by the panel manufacturer). Threaded bolt 303 can
pass
through a threaded bolt hole in the lower member, through the hole in the
inner
edge, and into a threaded bolt hole in upper member 301. Holes 304 in lower
member 302 maybe used to attach the attachment module 140a to support frame
120, e.g. using an attachment bolt.
Referring to Fig. I OB, attachment module 140b includes a c-shaped member
305 and a flat angled member 306. An inner edge of panel 110 (not shown) can
be
attached between the members 305 and 306. Threaded bolt 307 may pass through a
threaded bolt hole in the c-shaped member to clamp the inner edge between
members 305 and 306. Slot 308 in flat angled member 306 may be used to attach
the attachment module 140a to support frame 120, e.g. using an attachment
bolt.
Referring to Fig. I OC, attachment module 140c may be used for attachment
to a panel module 110 which lacks an inner edge along its lateral side, but
includes
an inner edge along its Top or Bottom side. Attachment module 140a allows for
the
panels of this type to be mounted to support frames 120 of the type shown in
Fig. 1
without additional modification.
Attachment module 104c includes a c-shaped member 309 and an extension
member 310. A Top or Bottom inner edge of panel 110 (not shown) can be
attached
between the c-shaped member 309, and portion 311 of attachment member 310.
Threaded bolt 307 may pass through a threaded bolt hole in the c-shaped member
to
clamp the inner edge between members 305 and 306.
Attachment module 140c may be attached to panel module 110 proximal to a
corner of the panel, such that portion 312 of extension member 310 extends out
past
the lateral side of the panel for mounting to support frame 120. Hole 313 in
attachment member 310 may be used to attach the attachment module 140c to
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support frame 120, e.g. using an attachment bolt. Note that although exemplary
dimensions are provided in the figure, any suitable dimensions may be used.
Referring to Fig. I OD, attachment module 140d includes upper member 301
and lower member 304. The members are connected by at pivot 316, thereby
forming "jaws" that can open and close. An inner edge of panel 110 (not shown)
can
be attached between the jaws formed by members 314 and 315. The pivoting of
the
jaws allows attachment module 140d to attach to inner edges having a variety
of
shapes and sizes, including irregular shapes. Thus, attachment module 140d may
be
compatible with multiple types of panels, and/or with panels of a single type
which
(e.g. due to manufacturing errors) have inner edges of varying shape or size.
In cases where the inner edge includes a hole (e.g. a pre-formed hole
provided by the panel manufacturer), Threaded bolt 317 can pass through a
threaded bolt hole in the lower member, through the hole in the inner edge,
and into
a threaded bolt hole in upper member 301. In cases where the inner edge does
not
include a hole, threaded bolt 317 can be used to clamp the edge in place.
Holes 304
in lower member 302 maybe used to attach the attachment module 140a to support
frame 120, e.g. using an attachment bolt.
Referring to FIGs. 12A and 12B attachment module 140e includes two
facilities 601a and 601b (e.g., flanges or tabs including one or more bolt or
screw
holes) which can each attach to a support frame (e.g., each facility may be
attached
to adjacent support frames in an array). Elongated member 602 extends between
facilities 601a and 601b, and includes surfaces 604 adapted to be placed in
intimate
contact with flange 606 on solar panel module 110. One or more threaded or
unthreaded screw or bolt holes may be used to secure attachment module 140e to
flange 606. Attachment module 140e may include one or more apertures 608 (or
other slots, openings, etc.) to allow access to one or more features on module
110
such as a ground lug, wire connector, etc (see FIG. 12B, inset).
Note that when attachment module 140e is used to mount solar panel module
110 on one or more support frames 120, the elongated member 602 operates to
spread the force on the module 110 over a relatively large area (e.g. as
compared to
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the mounting configuration shown in Figs. 6A-6C, where attachment modules 140
couple to solar panel module 110 at four discrete positions), thereby reducing
potentially disadvantageous effect due to, e.g., bowing or bending of solar
panel
module 110.
Referring to FIG. 11, there is illustrated a flowchart 500 of a method of
forming a solar module array of the type described above.
In act 510, support bases 130 are positioned on the ground (or another
surface). In some embodiments, ballast may be added to secure the bases to the
ground. In some embodiments, one or more nails (e.g., 12" nails) or similar
devices
may be embedding in the ground through support base 130 (in addition to or as
an
alternative to ballast) to secure the support base to the ground. In some
embodiments support base 130 may include apertures, openings, slots, etc. to
accommodate the nails.
In act 520, the angles of support posts 131 relative to support pans 132 are
adjusted to compensate for local undulations in the ground, and set to a
desired
angle. For example, as described above, pivot 133 may be used to adjust the
angle,
and pivot bolts 134a and 134b may be tightened to prevent further pivoting
thereby
setting the angle in place.
In act 530, support frames 120 are attached to support posts 131 at heights
selected to compensate for local undulations in the ground. For example, as
described above, support post attachment mechanism 121 includes several bolt
holes
spaced apart vertically. Mechanism 121 receives support post 131 and support
post
131 is bolted to mechanism 121 with bolt 122 at a desired height using support
post
bolt hole 135.
In act 540, support frames 120 are attached to each other to form columns of
the array. As described in detail above, in some embodiments, the support
frames
may be attached in such a way that the spacing of the support frames 120 may
be
varied over the array (e.g., to provide varied row to row spacings). Further,
as
described in detail above, in some embodiments the some or all of the
attachment
points for support frames may be pivotable, to allow for adjustment of the
angle
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orientation of the attached support frames (e.g., to accommodate regions of
varying
slope in the surface on which the array is located). In some embodiments, the
cross
bracing is attached between support frames in adjacent columns in the array
(e.g. as
shown in FIGs. 8 and 8A). In some embodiments, cross bracing 801 may be
attached loosely, and tightened after the attachment of the solar panel
modules 110
to the support frames 120, e.g., as described in act 560 described below.
In act 550, attachment modules 140 are attached to solar panel modules 110.
In act 560, solar panel modules 110 are attached to support frames 120 using
the attachment modules 140. Note that, in some embodiments, solar panel
modules
110 may be attached to the support frames 120 only after all or substantially
all of
the support frames 120 are in place and attached. As described above, in some
embodiments, cross bracing 801 may be tightened after the attachment of the
solar
panel modules 110.
It is to be appreciated that acts 510 - 560 of flowchart 500 may in some
embodiments be performed in alternate orders. It is also to be appreciated
that not
all acts need be performed in all embodiments, and that in some embodiments
additional or alternate acts may be performed.
Some embodiments of the installation method described above may include
further acts, including: e.g., running wires through one or more wire chases
in the
array to connect solar panel modules 110, or to provide grounding. Some
embodiments may include the act of forming ballast at or near the site on
which
array is located (e.g., using cement, concrete, etc.).
Solar panel module installation systems of the type described herein provide
a number of features and advantages. In some embodiments, the installation may
be
completed without the use of heavy tools and machinery. For example, as
described
above, in some embodiments, none or substantially none, of the components of
the
system are embedded in the ground. Accordingly, the need for excavation tools
(e.g., post hole diggers, etc.) is avoided.
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In some embodiments, the entire system may be composed of only a few
different component types. For example, in some embodiments, the system
includes
only sets of support bases 130, support frames 120, attachment modules 140
and,
optionally, cross bracing 801 and various hardware (e.g., limited to screws,
nuts, and
bolts). In some embodiments, an entire array may be constructed using only
these
sets of identical components. However, as described in detail above, the
installation
remains highly customizable, with the ability to adjust for surface
undulations,
variations in surface slope, variation in array element spacing, etc. Note
also that the
use of only a few components simplifies manufacturing and shipping.
In various embodiments, the various devices, systems, components, features,
techniques, etc. described herein may be used in any suitable combination.
Having thus described several aspects of at least one embodiment of this
technology, it is to be appreciated various alterations, modifications, and
improvements will readily occur to those skilled in the art. Such alterations,
modifications, and improvements are intended to be part of this disclosure,
and are
intended to be within the spirit and scope of the embodiments. Accordingly,
the
foregoing description and drawings are by way of example only.
