WIND TUNNEL OPTIMIZED SOLAR PANEL SYSTEM

• US 20130112248A1
• Filed: 10/01/2012
• Published: 05/09/2013
• Est. Priority Date: 09/30/2011
• Status: Active Grant

• Current Assignee: Sunrun Inc.
• Original Assignee: Mainstream Energy Corporation
• Inventors: McPheeters, Greg
• Granted Patent: US 10,302,333 B2
• Time in Patent Office: Days
• US Class Current: 136/251
• 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;

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;

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

a ballast weight supported by the windscreen; and

a top wind grate disposed between a top edge of the solar panel module and a top edge of the windscreen, wherein the top wind grate is configured to allow air to escape from the top of the wind optimized solar panel system for reducing lift on the solar panel system.

2. The wind optimized solar panel system of claim 1, comprising a plurality of feet coupled to the first rail and the second rail, wherein each foot of the plurality of feet comprises a flat portion configured to rest on an installation surface and a vertical portion configured to couple to a rail.

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

4. The wind optimized solar panel system of claim 1, wherein the first support leg and the second support leg each comprise a top section, a rail section, and a base section, and 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 support leg extends obliquely from a corresponding rail of the first rail and the second rail at a predetermined angle.

7. The wind optimized solar panel system of claim 6, wherein a length of the support leg and the predetermined angle are configured to 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 ballast support tray extending from the windscreen to form a ledge for supporting the ballast weight.

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

11. The wind optimized solar panel system of claim 10, wherein the ballast support tray, the top wind grate, and the windscreen are each one section of a ZEE-shaped roll-form part.

12. The wind optimized solar panel system of claim 9, wherein the ballast support tray is separate from and coupled to the windscreen.

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

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

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

14. The wind optimized solar panel system of claim 13, 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 trim piece comprises a slot configured to receive and securely retain an edge of a side windscreen of the first side windscreen and the second side windscreen.

15. The wind optimized solar panel system of claim 1, further comprising at least one horizontal ballast support tray disposed beneath at least one of the solar panel module and the windscreen and coupled to the first rail and the second rail.

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 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 installation surface; and

a standoff section coupled to the standoff attachment.

18. A wind optimized solar panel system, comprising:

a plurality of rails running parallel with respect to each other;

a plurality of support legs, each support leg comprising a top section, a rail section, and a base section, the base section of each support leg coupled to each rail of the plurality of rails, and wherein the support legs form a plurality of rows perpendicular to the plurality of rails;

a plurality of rectangular solar panel modules, wherein each solar panel module is coupled to at least two adjacent rails and to the top section of at least two adjacent support legs; and

a plurality of windscreens, wherein each windscreen is parallel to and coupled to at least two adjacent support legs, and wherein each windscreen comprises a ballast support tray for supporting a ballast weight.

19. The wind optimized solar panel system of claim 18, wherein the plurality solar panel modules form an array of solar panel modules comprising a plurality of rows perpendicular to the plurality of rails and a plurality of columns parallel to the plurality of rails.

20. The wind optimized solar panel system of claim 19, further comprising a plurality of side windscreens, wherein each side windscreen is coupled to a side of a solar panel module that is not adjacent to any other solar panel module.

21. The wind optimized solar panel system of claim 19, further comprising:

a plurality of self-adjusting end clamps that couple a side of a solar panel module that is not adjacent to any other solar panel module to a top section of a support leg;

a plurality of mid clamps that couple a side of a solar panel module that is adjacent to another solar panel module to a top section of a support leg, wherein each mid clamp is shared by two adjacent solar panel modules.

22. The wind optimized solar panel system of claim 19, further comprising support feet coupled to the rails, wherein the each support foot comprises a flat section that rests on an installation surface.

23. The wind optimized solar panel system of claim 19, wherein each windscreen comprises a ZEE-shaped roll-formed steel member.

24. The wind optimized solar panel system of claim 23, wherein:

a top section of the windscreen is vented to allow for passive cooling of the module and pressure equalization to mitigate wind loading;

a main section of the windscreen directs wind around the wind optimized solar panel system; and

a bottom section forms a ledge for supporting ballast weight

25. The wind optimized solar panel system of claim 24, wherein the adjacent windscreens overlap to increase structural integrity of the wind optimized solar panel system.