ARRAY INCLUDING FRAMELESS SOLAR MODULES

• US 20200132339A1
• Filed: 03/25/2017
• Published: 04/30/2020
• Est. Priority Date: 03/25/2016
• Status: Active Grant

• Current Assignee: Tecsi Solar Incorporated
• Original Assignee: Tecsi Solar Incorporated
• Inventors: Truthseeker, Samuel Marcus-Flack
• Granted Patent: US 11,047,599 B2
• Time in Patent Office: Days
• CPC Class Codes: F24S 2025/014 Methods for installing support elements
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 25/33 forming substantially planar assemblies, e.g. of coplanar or stacked profiles
• CPC Class Codes: F24S 25/617 Elements driven into the ground, e.g. anchor-piles; Foundations for supporting elements; Connectors for connecting supporting structures to the ground or to flat horizontal surfaces
• CPC Class Codes: F24S 25/634 Clamps; Clips
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02E 10/47 Mountings or tracking
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy

Abstract

A solar array is mounted on a surface of a structure, the surface being generally planar. The solar array comprises a solar module and a support that supports the solar module a distance above the surface. The support defines a channel to receive the solar module. A locking mechanism engages the support to secure the solar module to the support, wherein the solar module extends between the support and the locking mechanism and into the channel such that the solar module is allowed to move relative to the support in a first plane generally parallel to the surface when the solar module is secured to the support. The locking mechanism and the support inhibit movement of the solar module in a second plane generally perpendicular to the surface when the solar module is secured to the support.

Claims

1. A solar array mounted on a surface of a structure, the surface being generally planar, the solar array comprising:

a solar module;

a support that supports the solar module a distance above the surface, wherein the support defines a channel to receive the solar module;

a locking mechanism engaging the support to secure the solar module to the support, wherein the solar module extends between the support and the locking mechanism and into the channel such that the solar module is allowed to move relative to the support in a first plane generally parallel to the surface when the solar module is secured to the support, wherein the locking mechanism and the support inhibit movement of the solar module in a second plane generally perpendicular to the surface when the solar module is secured to the support.

2. The solar array of claim 1, wherein the support is free to move a fixed distance in the first plane.

3. The solar array of claim 2, wherein the solar module is allowed to move a fixed distance in the first plane.

4. The solar array of claim 1, wherein the support includes a keyway, and wherein the locking mechanism includes a key that extends into the keyway and engages the support to secure the solar module to the support.

5. The solar array of claim 3, wherein the key is configured to be operated manually without the use of a tool.

6. The solar array of claim 1 further comprising ballasts removably located in channels in the supports, and wherein the ballasts are substantially perpendicular to the structure surface when the ballasts are in the channels.

7. The solar array of claim 1, wherein the support and the locking mechanism are electrically insulative.

8. The solar array of claim 1 further comprising a second support and a wind deflector that attaches to and extends between the supports, wherein the wind deflector is supported a distance above the surface by the supports, and wherein the wind deflector is allowed to move in the first plane a fixed distance when the wind deflector is attached to the first support and the second support.

9. The solar array of claim 1 further comprising at least three of the supports to provide at least three points of support for the solar module on the structure surface.

10. The solar array of claim 9 further comprising four of the supports, wherein each support is located at a corner of the solar module.

11. The solar array of claim 10 further comprising at least two mid-span supports located along edges of the solar module.

12. The solar array of claim 1, wherein the locking mechanism includes a key including a visual top extending over the solar module to indicate when the locking mechanism is in an unlocked position.

13. The solar array of claim 1 further comprising a plurality of the modules, wherein the modules are secured to the support such that the modules are allowed to move in the first plane relative to each other.

14. The solar array of claim 13, wherein the support has a spacer to keep modules at a minimum distance from each other to allow for pressure equalization.

15. The solar array of claim 1, wherein the module allows water flow along edges of the module and inhibits water collecting along the edges.

16. A method of assembling frameless solar modules, the method comprising:

attaching a first set of clips to a first laminate;

securing the first set of clips on the first laminate in a position;

attaching a second set of clips on the second laminate; and

stacking the second laminate on the first laminate such that the first set of clips engage the second set of clips, wherein the first set of clips and the second set of clips align when the second laminate is stacked on the first laminate.

17. The method of claim 16 further comprising applying adhesive to the first set and second set of clips.

18. The method of claim 16, wherein positioning a first set of clips on a first laminate comprises positioning corner clips on corners of the laminate and mid-span clips on edges of the laminate.

19. The method of claim 16 further comprising locking each clip of the second set of clips to a respective clip of the first set of clips.

20. The method of claim 16, wherein location features of the first set of clips and the second set of clips cause the second set of clips to align with the first set of clips in three directions.

21. A solar array for mounting on a surface of a structure, the array comprising:

solar modules;

supports to support the solar modules above the surface, wherein each support includes a keyway; and

keys to secure the solar modules to the supports, wherein each key extends into the keyway and engages the respective support, and wherein each key has an unlocked position in which the key is inserted into the keyway and a locked position in which the key extends into the keyway and secure the solar modules to the respective support.

22. The solar array of claim 21, wherein the key is rotatable between the unlocked position and the locked position.

23. The solar array of claim 22, wherein each key comprises a lock pin, the lock pin aligning with the keyway when the key is in the first position and being offset from the keyway when the key is in the locked position.

24. The solar array of claim 23, wherein the rotation of the key causes the lock pin to rotate along a ramp path until it overcomes the leading edge of a capture feature to which it then settles to a lower stress state.

25. The solar array of claim 21, wherein each of the locked position and unlocked position are visible after installation.

26. The solar array of claim 21, wherein the unlocked position covers the photovoltaic module.

27. The solar array of claim 21, where no tool is required to engage the key.

28. The solar array of claim 21, wherein the mechanism is engaged by rotating the key in the keyway of the support.

29. The solar array of claim 21, wherein the mechanism does not require preloading or tensioning to remain in the locked position.

30. The solar array of claim 21, wherein the key further comprises a visible top that extends over the solar module when the key is in the unlocked position.

31. The solar array of claim 22, further comprising an electronic controller configured to detect if a key is in the unlocked position based on the visible top shading the solar module and thereby enabling remote detection of the key in the unlocked position.

33. The solar array of claim 31, wherein the receiver includes horizontal slots and vertical slots, the vertical slots connecting the horizontal slots to allow insertion of the wire around the cleat.

34. The solar array of claim 31, wherein the wire receiver includes horizontal fingers to facilitate securing the wire around the cleat, the wire receiver being sized to receive multiple wires.

35. The solar array of claim 31, wherein the pylon includes a drain to allow for water flow through the pylon.

36. The solar array of claim 31 further comprising wind deflectors received in features in the pylons, wherein the wind deflectors are securable without the use of tools.

37. The solar array of claim 35, wherein the deflectors are movable in a plane generally parallel to the surface.

38. The solar array of claim 31, wherein each pylon is shaped to enable nesting of pylons with respect to one another for compact shipping of the pylons.

40. The solar array of claim 38, wherein the clips include side clips and corner clips.

42. The solar array of claim 38, wherein the clips, the support, and the locking mechanism are electrically insulative so that no electrical grounding of the solar array is required.

44. The assembly of claim 42 wherein the clips include corner clips and side clips.

45. The assembly of claim 42, wherein the first set of clips and the second set of clips engage to facilitate the solar modules being stacked for shipment.

46. The assembly of claim 42, wherein the first set of clips align with the second set of clips to align the the first and second solar modules.

47. The assembly of claim 42, wherein the clips are configured to mount the solar modules to a support when the solar modules are assembled to form an array.

32. A solar array positioned on a surface of a structure, the solar array comprising:

a solar module;

a pylon that supports the solar module a distance above the surface, wherein the support defines a wire receiver to secure wires to the support, the wire receiver including at least one slot and a cleat extending across the at least one slot.

39. A solar array mounted on a surface of a structure, the solar array comprising:

a solar module including a laminate and wherein the solar module is substantially frameless;

clips attached to the laminate;

a support for supporting the solar module a distance above the surface, wherein the support defines a channel configured to receive the clips;

a locking mechanism engageable with the support to secure the solar module to the support, wherein the clips extend between the support and the locking mechanism and into the channel.

41. The solar array of claim 39, wherein the support includes a saddle configured to receive the clip.

43. An assembly of solar modules, the assembly comprising:

a first solar module including a first set of clips;

a second solar module including a second set of clips, wherein the first set of clips engage the set of clips, the first set of clips and the second set of clips facilitating assembly, shipping and installation of the solar modules.