Wind tunnel optimized solar panel system

• US 10,302,333 B2
• Filed: 10/01/2012
• Issued: 05/28/2019
• Est. Priority Date: 09/30/2011
• Status: Active Grant

• Current Assignee: Sunrun Inc.
• Original Assignee: Sunrun Inc.
• Inventors: McPheeters, Greg
• Primary Examiner(s): Baumann, Liesl C
• Application Number:
  US13/633,051
• Publication Number:
  US 20130112248A1
• Time in Patent Office: 2,430 Days
• Field of Search: 136243-265
• CPC Class Codes: F16B 2/12 using sliding jaws
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 2025/6003 by clamping
• CPC Class Codes: F24S 25/30 using elongate rigid mounting elements extending substantially along the supporting surface, e.g. for covering buildings with solar heat collectors extending in directions away from the supporting surface F24S25/10; peripheral frames for modules F24S25/20
• CPC Class Codes: F24S 40/85 Arrangements for protecting solar collectors against adverse weather conditions F24S40/10 takes precedence
• CPC Class Codes: H02S 20/00 Supporting structures for PV modules
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: H02S 20/30 Supporting structures being movable or adjustable, e.g. for angle adjustment
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y10T 24/44974 Threaded cylindrical rod and mating cavity

Abstract

The invention is a new stabilized racking system for solar cell panels on a surface through a novel use of ballast weights and a wind optimized design. The system is further optimized to fit a range of sizes and thicknesses of modules through a combination of self adjusting end clamps, adjustable tilt legs, and unique wind screen design. The system can include an array of individual solar panel systems that are reinforced in both lateral directions to reduce the amount of ballast weight required.

Claims

1. A wind optimized solar panel system, comprising:

a first rail and a second rail, the first rail and the second rail each having an inner surface, where the inner surface of the first rail faces the inner surface of the second rail, and the inner surface of the first rail is separated by a distance in a first direction from the inner surface of the second rail;

a first support leg coupled to the first rail and a second support leg coupled to the second rail, wherein the first support leg and the second support leg each comprise a top section, a rail section, and a base section;

a solar panel module coupled to the first rail with a first clamp, the second rail with a second clamp, the first support leg with a third clamp, and the second support leg with a fourth clamp;

a windscreen directly coupled to the rail sections of the first support leg and the second support leg; and

a ballast support tray, wherein

the windscreen and the ballast support tray are one contiguous part that form a ledge for supporting at least one ballast weight,

the windscreen has a first width in the first direction and the ballast support tray has a second width in the first direction, where the second width is less than the first width,

the ballast support tray is situated in a position between the inner surface of the first rail and the inner surface of the second rail such that the second width of the ballast support tray extends between the inner surface of the first rail and the inner surface of the second rail, and

the ballast support tray extends perpendicularly from the windscreen and in an outwardly direction away from the windscreen, the first and second support legs, and the solar panel module.

2. The wind optimized solar panel system of claim 1, comprising:

a first plurality of feet coupled to the first rail; and

a second plurality of feet coupled to the second rail, wherein each foot of the first and second pluralities of feet comprises a flat portion configured to rest on an installation surface and a vertical portion configured to couple to one rail of the first rail and the second rail.

3. The wind optimized solar panel system of claim 2, wherein the first rail and the second rail each comprise flanges configured to snap into notches in the vertical portion of at least one foot of the first and second pluralities of feet.

4. The wind optimized solar panel system of claim 1, wherein the base section of the first support leg is coupled to the first rail and the base section of the second support leg is coupled to the second rail.

5. The wind optimized solar panel system of claim 4, wherein the solar panel module is coupled to the top section of the first support leg with the third clamp and the top section of the second support leg with the fourth clamp.

6. The wind optimized solar panel system of claim 4, wherein the rail section of each of the first and second support legs extends at an oblique angle from a corresponding rail of the first rail and the second rail.

7. The wind optimized solar panel system of claim 6, wherein a length of each of the first and second support legs and the corresponding oblique angles optimize an angle for coupling the solar panel module to the wind optimized solar panel system.

8. The wind optimized solar panel system of claim 7, wherein the angle for coupling the solar panel module is optimized based on at least one of a latitude and wind conditions at an installation site.

9. The wind optimized solar panel system of claim 1, further comprising:

a top wind grate coupled to a top edge of the solar panel module and a top edge of the windscreen, wherein

the top wind grate is comprised of a single contiguous portion of material with a plurality of openings formed therein, thereby permitting airflow through the plurality of openings.

10. The wind optimized solar panel system of claim 9, wherein the one contiguous part of the windscreen and the ballast support tray includes the top wind grate.

11. The wind optimized solar panel system of claim 10, wherein the one contiguous part is a ZEE-shaped roll-form part.

12. The wind optimized solar panel system of claim 9, wherein the top wind grate spans substantially the length of the top edge of the solar panel.

13. The wind optimized solar panel system of claim 9, wherein the material includes at least one of aluminum, steel, plastic, or composite.

14. The wind optimized solar panel system of claim 1, further comprising:

a first side windscreen coupled to the first rail, the first support leg, and a first side edge of the solar panel module; and

a second side windscreen coupled to the second rail, the second support leg, and a second side edge of the solar panel module.

15. The wind optimized solar panel system of claim 14, further comprising a first trim piece coupled to the first rail, a second trim piece coupled to the first support leg, a third trim piece coupled to the first edge side of the solar panel module, a fourth trim piece coupled to the second rail, a fifth trim piece coupled to the second support leg, a sixth trim piece coupled to the second edge side of the solar panel module, wherein each of the first, second, and third trim pieces comprises a slot configured to receive and securely retain an edge of the first side windscreen and each of the fourth, fifth, and sixth trim pieces comprises a slot configured to receive and securely retain an edge of the second side windscreen.

16. The wind optimized solar panel system of claim 1, further comprising:

an anchor rail extending perpendicularly between the first rail and the second rail;

a standoff attachment coupled to the anchor rail; and

a mechanical anchor coupled to the standoff attachment, wherein the mechanical anchor is configured to be coupled to an installation surface for the wind optimized solar panel system.

17. The wind optimized solar panel system of claim 16, further comprising a standoff bracket for coupling the standoff attachment to the anchor rail, wherein the standoff bracket comprises:

a riser section coupled to anchor rail;

a spacer section extending obliquely in a direction away from both the anchor rail and the installation surface; and

a standoff section coupled to the standoff attachment.

18. The wind optimized solar panel system of claim 1, further comprising:

the at least one ballast weight supported by the ledge.

19. The wind optimized solar panel system of claim 1, wherein at least one of the first clamp, the second clamp, the third clamp, and the fourth clamp is a self-adjusting end clamp.

20. A wind optimized solar panel system, comprising:

a first rail and a second rail, the first rail and the second rail each having an inner surface, where the inner surface of the first rail faces the inner surface of the second rail, and the inner surface of the first rail is separated by a distance in a first direction from the inner surface of the second rail;

a first support leg coupled to the first rail and a second support leg coupled to the second rail;

a solar panel module coupled to the first rail with a first clamp, the second rail with a second clamp, the first support leg with a third clamp, and the second support leg with a fourth clamp, each of the first and second rails extending from a point of coupling between that rail and a corresponding one of the first and second support legs to a point of coupling between that rail and the solar panel module;

a windscreen directly coupled to first and second ends of the first support leg and the second support leg; and

a ballast support tray, wherein

the windscreen and the ballast support tray are one contiguous part that form a ledge for supporting at least one ballast weight,

the windscreen has a first width in the first direction and the ballast support tray has a second width in the first direction, where the second width is less than the first width,

the ballast support tray is situated in a position between the inner surface of the first rail and the inner surface of the second rail such that the second width of the ballast support tray extends between the inner surface of the first rail and the inner surface of the second rail, and

the ballast support tray extends perpendicularly from the windscreen and in an outwardly direction away from the windscreen, the first and second support legs, and the solar panel module.

21. The wind optimized solar panel system of claim 20, further comprising:

the at least one ballast weight supported by the ledge.

22. The wind optimized solar panel system of claim 20, further comprising:

a top wind grate coupled to a top edge of the solar panel module and a top edge of a windscreen, wherein

the top wind grate is comprised of a single contiguous portion of material with a plurality of openings formed therein, thereby permitting airflow through the plurality of openings.

23. The wind optimized solar panel system of claim 22, wherein the material includes at least one of aluminum, steel, plastic, or composite.

24. The wind optimized solar panel system of claim 20, wherein:

the first support leg and the second support leg each comprise a top section, a rail section, and a base section;

the base section of the first support leg is coupled to the first rail and the base section of the second support leg is coupled to the second rail;

the first and second ends are located on the rail sections of each of the first support leg and the second support leg; and

the solar panel module is coupled to the top section of the first support leg with the third clamp and the top section of the second support leg with the fourth clamp.

25. The wind optimized solar panel system of claim 20, wherein at least one of the first clamp, the second clamp, the third clamp, and the fourth clamp is a self-adjusting end clamp.