Mounting system for solar module array

• US 8,683,761 B2
• Filed: 06/25/2012
• Issued: 04/01/2014
• Est. Priority Date: 06/25/2012
• Status: Active Grant

• Current Assignee: Sunpower Corporation (Totalenergies Se)
• Original Assignee: Sunpower Corporation (Totalenergies Se)
• Inventors: Danning, Matthew G.
• Primary Examiner(s): Cajilig, Christine T
• Application Number:
  US13/532,731
• Publication Number:
  US 20130340810A1
• Time in Patent Office: 645 Days
• Field of Search: 521/733, 136/244, 136/251, 126/621, 126/623
• US Class Current: 52/173.3
• CPC Class Codes: F24S 2025/6008 by using toothed elements
• CPC Class Codes: F24S 25/20 Peripheral frames for modules
• CPC Class Codes: F24S 25/35 by means of profiles with a cross-section defining separate supporting portions for adjacent modules
• CPC Class Codes: F24S 25/61 for fixing to the ground or to building structures
• CPC Class Codes: F24S 25/636 clamping by screw-threaded elements
• CPC Class Codes: F24S 25/67 for coupling adjacent modules or their peripheral frames for fixing modules or their peripheral frames to supporting elements F24S25/63
• CPC Class Codes: F24S 25/70 with means for adjusting the final position or orientation of supporting elements in relation to each other or to a mounting surface; with means for compensating mounting tolerances
• CPC Class Codes: H02S 20/23 specially adapted for roof structures
• 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 29/49355 Solar energy device making

Abstract

A mounting system for a solar array can include a plurality of couplers that are designed to engage and disengage all modules without the use of rails that are greater than the maximum dimension of a solar module. The couplers can be configured to cooperate with height adjuster mechanisms. Additionally, the couplers can be configured to accommodate the engagement and disengagement of solar modules without the need to loosen or remove fasteners, for example, through a hook and tilt movement.

Claims

1. A solar array, the array comprising:

a plurality of solar modules, each solar module comprising at least four sides, a frame extending around the four sides of each solar module, the frame comprising an upwardly projecting ridge and a downwardly projecting ridge;

a plurality of braces, each brace supporting at least one side of one of the frames, each brace being shorter than twice a length of one of the sides of one of the frames, wherein each brace comprises a first lip extending from a top portion, the first lip comprising a hook sized and shaped to receive the upwardly projecting ridge of the frame; and

a plurality of roof anchors configured to be mounted to a roof, each roof anchor coupled to one of the plurality of braces.

2. The solar array of claim 1, wherein the solar array does not include rails that are longer than twice a length of one of the sides of the frames and that extend parallel to and engage a plurality of the frames.

3. The solar array of claim 1, further comprising a first brace supporting a first frame and slidably coupled to a first roof anchor.

4. The solar array of claim 3, further comprising a second brace supporting a second frame and a third frame adjacent the second frame.

5. The solar array of claim 4, wherein said second brace is not coupled to a roof anchor.

6. The solar array of claim 4, wherein said second brace is slidably coupled to a second roof anchor.

7. The solar array of claim 4, wherein the second brace supports a fourth frame and fifth frame on a side of the second brace opposite the second frame and the third frame.

8. The solar array of claim 4, wherein the second brace is coupled to a corner of the second frame and a corner of the third frame, the second brace maintaining separation between the corner of the second frame and the corner of the third frame.

11. The solar array of claim 1, wherein each brace further comprises a second lip extending from a bottom portion and configured to engage the downwardly projecting ridge.

12. The solar array of claim 11, wherein the second lip comprises a retention ridge configured to retain the downwardly projecting ridge by snap-fit engagement of the frame with the brace.

9. A kit for assembling a solar array:

a plurality of roof anchors configured to be coupled to a roof; and

a plurality of braces, each brace configured to support one or more frames of a solar module and configured to slidably couple to one of the plurality of roof anchors, each brace being shorter than twice a length of a side of one of the frames,

a plurality of the solar modules, each solar module comprising a frame mounted around edges of each solar module, wherein each frame comprises an upwardly projecting ridge and a downwardly projecting ridge,

wherein each brace comprises a first lip extending from a top portion, the first lip comprising a hook sized and shaped to receive the upwardly projecting ridge of a corresponding frame.

10. The kit of claim 9, wherein each roof anchor comprises:

a base having a hole therein, the hole comprising an inner wall;

a rod inserted in the hole of the base, the rod having an annular groove formed around the circumference of the rod, the annular groove positioned within the hole,

wherein a locking portion of the inner wall extends into the annular groove.

13. The solar array of claim 9, wherein each brace further comprises a second lip extending from a bottom portion and configured to engage the downwardly projecting ridge of the corresponding frame.

14. The solar array of claim 13, wherein the second lip comprises a retention ridge configured to retain the downwardly projecting ridge by snap-fit engagement of the corresponding frame with the brace.