Brace for solar module array

• US 8,943,765 B2
• Filed: 06/25/2012
• Issued: 02/03/2015
• 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., Lee, Wayman
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): MAESTRI, PATRICK J
• Application Number:
  US13/532,733
• Publication Number:
  US 20130340811A1
• Time in Patent Office: 953 Days
• Field of Search: 521/733, 525/060.3, 525/060.6, 525/060.7, 522201-2203, 521/265, 521/256, 521/267, 521/261.1, 524/67, 524/68, 527/66, 527/72, 527/80, 524/64
• 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: 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 brace for connecting the frames of adjacent solar modules can include one or more lower lips and one or more upper lips configured to capture an outer edge of a solar module frame. The brace can include a removable top so as to facilitate connection and disconnection of the couplers and solar modules. Additionally, the brace can be configured to allow a solar module to be engaged and disengaged by hooking the frame onto the brace then tilting the frame relative to the brace. The brace can include features for achieving a snap fit with solar module frames.

Claims

1. A solar array comprising:

a plurality of solar modules, each solar module having at least four sides and comprising a solar module frame extending around at least a portion of a periphery of the solar module;

at least a first brace member having a first support surface extending below at least a first solar module frame of a first solar module;

at least a second brace member having a second support surface extending over the first solar module frame;

a first connector connecting the first brace member to the second brace member such that the first solar module frame is captured between the first and second support surfaces;

an adjustment mechanism configured to adjust a height of the first solar module, the adjustment mechanism comprising an outer sleeve and an inner rod disposed at least partially within the outer sleeve, the outer sleeve extending through an aperture in a bottom surface of the first brace member; and

a base configured to attach to a support structure, the adjustment mechanism mechanically coupled to the base.

2. The solar array according to claim 1, wherein both the first and second brace members are shorter than a length of the first solar module frame.

3. The solar array according to claim 2, wherein the first brace member includes a third support surface extending below a second solar module frame adjacent to the first solar module frame, the second brace member having a fourth support surface extending over the second solar module frame, such that the second solar module frame is captured between the third and fourth support surfaces.

4. The solar array according to claim 3, wherein a third solar module frame is captured between the first and second support surfaces and a fourth solar module frame is captured between the third and fourth support surfaces.

5. The solar array according to claim 4, wherein the second support surface includes at least one notch.

6. The solar array according to claim 5, wherein the second support surface includes a second notch, the first notch being wider than the second notch.

7. The solar array according to claim 1, wherein the first brace member extends below a first side of the first solar module frame, the solar array additionally comprising a third brace member having a third support surface extending below a second side of the first solar module frame and a fourth brace member having a fourth support surface extending above the second side of the first solar module frame and a second connector connecting the third brace member to the fourth brace member so as to capture the second side of the first solar module frame therebetween.

8. The solar array according to claim 7 wherein four of the plurality of solar modules are disposed adjacent to the four sides of the first solar module frame, respectively, and wherein the first, second, third, and fourth brace members are configured to allow the first solar module to be removed from the array by removing the first and second connectors and lifting the first solar module without the need to slide the first solar module laterally.

9. The solar array according to claim 1, wherein the second brace member comprises first and second segments, the first segment extending over about first half of the first brace member, the second segments extending over about a second half of the first brace member.

10. The solar array according to claim 1 wherein the base has a first end secured to the support surface which supports the solar array and a second end connected to the first brace member so as to support the first brace member at a position spaced above the support surface.

11. The solar array according to claim 10, wherein the adjustment mechanism is configured to allow adjustment of the spacing between the first brace member and the support surface.

12. The solar array according to claim 11, wherein the adjustment mechanism is positioned so as to be accessible from a position above the second brace member with the second brace member connected to the first brace member with the first connector.

13. The solar array according to claim 12, wherein the second brace member includes an aperture disposed above the adjustment mechanism and sized to allow an adjustment tool to be inserted through the second brace member into operational engagement with the adjustment mechanism.

14. The solar array according to claim 1, wherein the first and second brace members are configured to capture any portion of the first solar module frame along each of the four sides of the first solar module frame.

15. The solar array according to claim 1 additionally comprising a second solar module frame mounted adjacent to and spaced from the first solar module frame, the first and second solar module frames comprising first and second upwardly extending lips, respectively, extending around an upper surface of the first and second solar module frames, respectively, the second support surface of the second brace member extending over and around both the first and second upwardly extending lips.

16. The solar array of claim 1, wherein the adjustment mechanism is disposed in an aperture of the base.

17. The solar array of claim 16, wherein the adjustment mechanism comprises an annular groove, and wherein an inner wall of the aperture is deformed to extend inwardly into the annular groove to prevent the adjustment mechanism from vertically translating relative to the base.

18. The solar array of claim 17, wherein the adjustment mechanism is free to rotate relative to the base.

19. A solar array comprising:

at least first, second, third, fourth and fifth solar modules, each solar module having at least four sides, wherein the first, second, third, and fourth solar modules are respectively disposed adjacent to the four sides of the fifth solar module; and

means for removeably bracing the juxtaposed sides of the solar modules to each other so that the fifth solar module can be disconnected from the first, second, third, and fourth solar modules and lifted upwardly without the need to slide the fifth solar module laterally,

wherein the removeably bracing means comprises means for swinging and snapping together the juxtaposed sides of the first solar module and the fifth solar module to removeably couple the first solar module and the fifth solar module.

20. The solar array according to claim 19 additionally comprising means for adjustably mounting the means for removeably bracing at a position spaced above a support surface that supports the solar array.

21. A brace for connecting solar modules, comprising:

a body member having first and second sides spaced from each other, a first lip extending outwardly from and along the first side of the body and configured to extend below a frame of a first solar module disposed adjacent to the first side and a second lip extending outwardly from and along a second side of the body and configured to extend below a frame of a second solar module disposed adjacent to the second side, wherein the first lip includes a retention ridge configured to receive a downwardly projecting ridge of the first solar module and to retain the downwardly projecting ridge by snap-fit engagement of the frame of the first solar module with the brace;

at least a first top member configured to be connected to the body member and having a first engagement portion extending outwardly from and along a first side of the first top member, the first engagement portion configured to engage an upwardly extending ridge of the frame of the first solar module, and a second engagement portion extending outwardly from and along a second side of the first top member, the second engagement portion configured to engage an upwardly extending ridge of the frame of the second solar module disposed adjacent to the first solar module; and

a connector configured to connect the first top member to the body member so as to press the frames of two adjacent solar modules disposed along the first and second sides of the body member between the lips of the body member and the engagement portions of the top member,

wherein the first engagement portion includes a downwardly extending distal portion shaped so as to capture the upwardly extending ridge of the frame when the first solar module is tilted and while the first solar module is swung downwardly until the downwardly projecting ridge is captured by the retention ridge by snap-fit engagement with the upwardly extending ridge of the frame captured by the downwardly extending distal portion.

22. The brace according to claim 21, wherein the first engagement portion includes at least a first gap that is wider than a thickness of the upwardly extending ridge of the first solar module.

23. The brace according to claim 22, wherein the first gap is wider than a spacing between the first and second sides of the body member.