Highly efficient solar arrays

• US 8,829,330 B2
• Filed: 08/10/2011
• Issued: 09/09/2014
• Est. Priority Date: 02/23/2010
• Status: Active Grant

• Current Assignee: Spectrum Solar, LLC
• Original Assignee: Tenksolar, Inc.
• Inventors: Meyer, Dallas W., Berg, Lowell J., Stover, Lance E., Dodd, Orville D., Murnan, Thomas L.
• Primary Examiner(s): MARTIN, MATTHEW T
• Application Number:
  US13/207,164
• Publication Number:
  US 20120204935A1
• Time in Patent Office: 1,126 Days
• Field of Search: 136243-251, 521/733
• US Class Current: 136/246
• CPC Class Codes: F24S 2020/14 Stepped arrangements, e.g. in parallel planes, without module overlapping
• CPC Class Codes: F24S 2020/16 Preventing shading effects
• CPC Class Codes: F24S 2025/803 having a central web, e.g. I-shaped, inverted T- shaped
• CPC Class Codes: F24S 2025/807 having undercut grooves
• CPC Class Codes: F24S 23/77 with flat reflective plates
• CPC Class Codes: F24S 25/16 Arrangement of interconnected standing structures; Standing structures having separate supporting portions for adjacent 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 25/37 forming coplanar grids comprising longitudinal and transversal profiles
• CPC Class Codes: F24S 25/632 Side connectors; Base connectors
• CPC Class Codes: F24S 25/65 for coupling adjacent supporting elements, e.g. for connecting profiles together
• 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: F24S 40/80 Accommodating differential expansion of solar collector elements
• CPC Class Codes: F24S 40/85 Arrangements for protecting solar collectors against adverse weather conditions F24S40/10 takes precedence
• CPC Class Codes: G02B 7/183 specially adapted for very large mirrors, e.g. for astronomy, or solar concentrators
• CPC Class Codes: H02S 20/22 specially adapted for buildings
• CPC Class Codes: H02S 40/22 Light-reflecting or light-concentrating means directly associated with the PV cell or integrated with the PV cell H01L31/054
• 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 10/52 PV systems with concentrators

Abstract

In an example, a solar energy system includes multiple PV modules, multiple reflectors, and a racking assembly. Each of the reflectors is positioned opposite a corresponding one of the PV modules. The racking assembly mechanically interconnects the PV modules and the reflectors to form an interconnected system. The racking assembly defines gaps within the racking assembly and between adjacent PV modules and reflectors. The interconnected system includes multiple contact points associated with the gaps. The gaps and contact points configure the interconnected system to accommodate surface unevenness of an installation surface up to a predetermined surface unevenness.

Claims

1. A solar energy system, comprising:

a plurality of photovoltaic modules;

a plurality of reflectors, each of the plurality of reflectors positioned opposite a corresponding one of the plurality of photovoltaic modules; and

a racking assembly mechanically interconnecting the plurality of photovoltaic modules and the plurality of reflectors to form an interconnected system;

wherein;

the photovoltaic modules and reflectors are arranged in adjacent rows;

the adjacent rows include reflector rows interposed between module rows;

each reflector row includes multiple reflectors;

each module row includes multiple photovoltaic modules;

the racking assembly defines gaps within the racking assembly and between adjacent photovoltaic modules and reflectors, the gaps between adjacent photovoltaic modules and reflectors including a module-to-module gap between the adjacent photovoltaic modules within each module row and a reflector-to-reflector gap between the adjacent reflectors within each reflector row;

the interconnected system includes a plurality of contact points associated with the gaps;

the racking assembly comprises;

a plurality of rails arranged orthogonally to and beneath the adjacent rows; and

a plurality of fins that interconnect the photovoltaic modules and the reflectors to the rails; and

the fins define the module-to-module gap between the adjacent photovoltaic modules within each module row and the reflector-to-reflector gap between the adjacent reflectors within each reflector row.

2. The solar energy system of claim 1, wherein the interconnected system has a nonlinear resistive force versus displacement profile.

3. The solar energy system of claim 1, wherein:

each photovoltaic module and each reflector has two lower corners, each lower corner being connected to the racking assembly through a corresponding fin;

each photovoltaic module has two upper corners, each connected to a respective one of two upper corners of a corresponding reflector positioned behind the photovoltaic module; and

adjacent lower corners of adjacent photovoltaic modules within each module row and of adjacent reflectors within each reflector row are connected to each other through a corresponding one of the fins.

4. The solar energy system of claim 3, wherein:

sides of each of the adjacent photovoltaic modules and adjacent reflectors on opposing sides of each module-to-module gap or reflector-to-reflector gap include the contact points associated with the module-to-module gap or reflector-to-reflector gap;

each rail has a top defining a longitudinal channel;

each fin has a base received within the longitudinal channel;

a longitudinal gap is defined between the base of each fin and a bottom of the longitudinal channel of each rail;

a bottom of each longitudinal channel and a bottom of each base include contact points associated with each longitudinal gap.

5. The solar energy system of claim 4, wherein:

the plurality of rails includes a plurality of rail columns;

within each rail column, multiple rails are longitudinally aligned and connected end-to-end to each other;

a rail-to-rail gap is defined between adjacent longitudinally-connected rails; and

ends of adjacent longitudinally-connected rails on opposing sides of each rail-to-rail gap include contact points associated with each rail-to-rail gap.

6. The solar energy system of claim 5, wherein one or more of the module-to-module gaps, reflector-to-reflector gaps, longitudinal gaps or rail-to-rail gaps allow the components of the interconnected system to accommodate in-plane and out-of-plane displacement relative to one another until the contact points associated with a corresponding module-to-module gap, reflector-to-reflector-gap, longitudinal gap or rail-to-rail gap come in contact with each other;

wherein a stiffness of the interconnected system is much greater when the contact points are in contact with each other than when the contact points are not in contact with each other.

7. The solar energy system of claim 1, wherein the racking assembly further comprises a plurality of compliant pads, each compliant pad being positioned between a rail and the installation surface, wherein a coefficient of friction between the compliant pads and the installation surface is greater than a coefficient of friction between the rails and the installation surface.

8. The solar energy system of claim 7, wherein each of the compliant pads comprises expanded polyethylene having a thickness in a range of 0.5 inches to 2 inches.

9. The solar energy system of claim 8, wherein each of the compliant pads further comprises a bottom layer including at least one of butyl rubber, ethylene propylene diene Monomer (EPDM) rubber, or polyurethane adhesive, the bottom layer having a thickness in a range of 0.05 to 0.5 inches.

10. The solar energy system of claim 7, wherein each of the compliant pads comprises ethylene propylene diene Monomor (EPDM) rubber having a thickness in a range of 0.1 inches to 1 inch.

11. The solar energy system of claim 1, wherein the racking assembly is configured to permit individual removal or positional adjustment of any one of the photovoltaic modules or reflectors without removing or otherwise supporting any of the other photovoltaic modules or reflectors during the removal or positional adjustment.

12. The solar energy system of claim 11, wherein the reflectors are configured to be individually adjusted at least twice annually between a first position and a second position, the reflectors being positioned at a first angle relative to horizontal in the first position and a second angle relative to horizontal in the second position, the second angle being different than the first angle.

13. The solar energy system of claim 12, wherein:

each photovoltaic module has two upper corners, each connected to a respective one of two upper corners of a corresponding reflector positioned behind the photovoltaic module such that each corresponding reflector can rotate, relative to the photovoltaic module, about a first axis of rotation that is parallel to a top edge of the photovoltaic module and to a top edge of the corresponding reflector;

each lower corner of each photovoltaic module is coupled to a corresponding fin;

each lower corner of each reflector is coupled through a corresponding connector to the same fin as the corresponding lower corner of the photovoltaic module positioned opposite the reflector; and

at least one of;

each fin defines a slot in which a corresponding connector can travel between a first endpoint corresponding to the first position and a second endpoint corresponding to the second position, a corresponding reflector rotating about a corresponding first axis of rotation when the corresponding connector travels between corresponding first and second endpoints in a slot of a corresponding fin;

each connector is configured to support a bottom edge of a corresponding reflector at a first predetermined location relative to a corresponding fin when in the first position and at a second predetermined location relative to the corresponding fin when in the second position, wherein the first and second predetermined locations are configured to prevent the corresponding fin from shadowing the corresponding reflector in morning or afternoon lighting conditions;

or

each connector is rotatably coupled to a corresponding fin and is rotatable between a first connector position in which the connector is configured to support a corresponding reflector in the first position, and a second connector position in which the connector is configured to support the corresponding reflector in the second position.

14. The solar energy system of claim 1, wherein a length of each rail is in a range between 15 and 30 feet.

15. A solar energy system comprising:

a plurality of photovoltaic modules;

a plurality of reflectors, each of the plurality of reflectors positioned opposite a corresponding one of the plurality of photovoltaic modules;

a racking assembly comprising a plurality or rails mechanically interconnecting the plurality of photovoltaic modules and the plurality of reflectors to form an interconnected system; and

a rainwater collection subsystem;

wherein;

the racking assembly defines gaps within the racking assembly and between adjacent photovoltaic modules and reflectors;

the interconnected system includes a plurality of contact points associated with the gaps;

the photovoltaic modules and reflectors are positioned such that top surfaces thereof are at one or more angles relative to horizontal; and

the rainwater collection subsystem comprises;

an extruded drip gutter extending from a bottom edge of each photovoltaic module and of each reflector, the extruded drip gutter configured to collect rainwater that runs down the surface of the corresponding photovoltaic module or reflector and to channel the collected rainwater towards one or both ends of the extruded drip gutter, one or both ends of the extruded drip gutter being open to expel the collected rainwater therefrom;

edge extensions extending upwards from a base of each rail to define rail channels on opposing sides of each rail, the rail channels being positioned beneath ends of the extruded drip gutters such that expelled rainwater is captured in the rail channels; and

one or more storage reservoirs in fluid communication with the rail channels, the one or more storage reservoirs being configured to receive and store the rainwater captured by the rail channels.

16. A solar energy system comprising:

a plurality of photovoltaic modules;

a plurality of reflectors, each of the plurality of reflectors positioned opposite a corresponding one of the plurality of photovoltaic modules; and

a racking assembly mechanically interconnecting the plurality of photovoltaic modules and the plurality of reflectors to form an interconnected system;

wherein;

the racking assembly defines gaps within the racking assembly and between adjacent photovoltaic modules and reflectors;

the interconnected system includes a plurality of contact points associated with the gaps;

each of the photovoltaic modules and reflectors includes a frame;

each frame comprises two side members positioned on opposing sides of a corresponding photovoltaic module or reflector;

each side member for each reflector frame has a double-wall-box construction including an inner box aligned lengthwise side-by-side with an outer box along at least most of the length of each side member, one side of each box being a common wall shared between the inner and outer boxes;

each side member for each module frame has a single-wall-box construction;

each side member has a length greater than a length of the corresponding photovoltaic module or reflector and is arranged such that top and bottom ends of each side member respectively extend beyond upper and lower edges of a corresponding photovoltaic module or reflector;

the outer wall box is absent from the top end of each side member in each reflector frame; and

the top end of each of two side members in a frame of each photovoltaic module is removably coupled to the top end of each of two side members in a frame of a corresponding reflector positioned behind the photovoltaic module.

17. The solar energy system of claim 16, wherein:

the side members in each photovoltaic module frame and the racking assembly are electrically conductive; and

the bottom end of each side member in each photovoltaic module frame is mechanically and electrically coupled directly to the racking assembly to provide a direct grounding connecting from each photovoltaic module to the racking assembly.

18. The solar energy system of claim 17, further comprising at least one of:

a plurality of star washers, each star washer positioned between the bottom end of a corresponding side member in a corresponding photovoltaic module frame and a portion of the racking assembly to which the bottom end is attached, each star washer being configured to electrically couple the bottom end of the corresponding side member in the corresponding photovoltaic module frame to the corresponding portion of the racking assembly;

or

a plurality of cam locking devices, each configured to mechanically and electrically couple the bottom end of the corresponding side member in the corresponding photovoltaic module frame to the racking assembly.

19. The solar energy system of claim 16, wherein the bottom end of each side member in each reflector frame defines an L-shaped slot, and wherein the top and bottom end of each side member in each module frame defines an L-shaped slot.

20. The solar energy system of claim 19, wherein:

each reflector frame further comprises two plastic inserts, each plastic insert positioned in the outer box at the bottom end of a corresponding side member;

each plastic insert is configured to prevent the outer box of the bottom end of the corresponding side member from being crushed;

the bottom end of the corresponding side member of a corresponding reflector frame is configured to be coupled to a fin of the racking assembly by a corresponding connector; and

each plastic insert is configured to retain the corresponding connector in a particular region of the L-shaped slot such that any loads transferred to or from the corresponding reflector frame through the corresponding connector are transferred directly between the bottom end of the corresponding side member and the corresponding connector.