Space and energy efficient photovoltaic array

• US 9,773,933 B2
• Filed: 08/01/2013
• Issued: 09/26/2017
• 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., Korkowski, Kurt, Stover, Lance E., Murnan, Thomas L., Dodd, Orville
• Primary Examiner(s): MARTIN, MATTHEW T
• Application Number:
  US13/957,227
• Publication Number:
  US 20130312812A1
• Time in Patent Office: 1,517 Days
• CPC Class Codes: F24S 2020/16 Preventing shading effects
• CPC Class Codes: F24S 2025/013 Stackable support elements
• 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 2030/16 Hinged elements; Pin connections
• CPC Class Codes: F24S 23/77 with flat reflective plates
• CPC Class Codes: F24S 25/13 Profile arrangements, e.g. trusses F24S25/12 takes precedence
• 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 25/50 comprising elongate non-rigid elements, e.g. straps, wires or ropes
• 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: H01L 31/042 PV modules or arrays of single PV cells supporting structures for PV modules H02S20/00
• CPC Class Codes: H01L 31/0549 comprising spectrum splitting means, e.g. dichroic mirrors
• CPC Class Codes: H02S 20/00 Supporting structures for PV modules
• CPC Class Codes: H02S 20/30 : Supporting structures being movable or adjustable, e.g. for angle adjustment
• 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 embodiment, a solar energy system includes multiple photovoltaic modules, each oriented substantially at a same angle relative to horizontal. The angle is independent of a latitude of an installation site of the solar energy system and is greater than or equal to 15 degrees. The solar energy system defines a continuous area within a perimeter of the solar energy system. The solar energy system is configured to capture at the photovoltaic modules substantially all light incoming towards the continuous area over an entire season.

Claims

1. A solar energy system comprising:

a plurality of photovoltaic modules, each oriented at a same angle relative to horizontal, wherein each of the photovoltaic modules comprises a frame having two upper extensions, including one upper extension extending from each of two upper corners of the photovoltaic module and having two lower extensions, including one lower extension extending from each of two lower corners of the photovoltaic module; and

a racking assembly mechanically interconnecting the photovoltaic modules together, the racking assembly comprising;

a plurality of rails arranged parallel to each other; and

a plurality of fins coupled between the rails and the lower extensions of the photovoltaic modules; and

a plurality of struts coupled between the fins and the upper extensions of the photovoltaic modules;

wherein the system is devoid of structural support elements vertically between the plurality of rails and the photovoltaic modules except;

1 where the lower extensions of each of the photovoltaic modules are coupled to the plurality of rails through the plurality of fins, and 2 where the upper extensions of each of the photovoltaic modules are coupled to the plurality of rails through the plurality of struts;

wherein the two upper extensions and the two lower extensions define a plane oriented at the angle relative to horizontal;

wherein the frame along two edges has extensions in a direction normal to the plane defined by the two upper extensions and the two lower extensions; and

wherein the extensions of the frame along the two edges have notches formed therein to receive a corresponding one of the two upper extensions or two lower extensions of another photovoltaic module when the photovoltaic modules are nestably stacked.

2. The solar energy system of claim 1, wherein each of the plurality of photovoltaic modules lacks any bypass diodes for photovoltaic cells within each of the plurality of photovoltaic modules.

3. The solar energy system of claim 1, wherein each of the photovoltaic modules has a linear power response with respect to illumination area of all photovoltaic cells of the corresponding photovoltaic module.

4. The solar energy system of claim 1, wherein the upper extensions define a slot within which is received a fastener that couples the upper extension to a the strut that supports the photovoltaic module at the angle.

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

each of the photovoltaic modules is substantially rectangular with two short edges and two long edges; and

the extensions of the frame along the two edges are along the two long edges.

6. The solar energy system of claim 1, wherein the plurality of struts include a first strut paired with a second strut to support a first photovoltaic module, and the first strut paired with a third strut to support a second photovoltaic module adjacent to the first photovoltaic module.

7. The solar energy system of claim 6, wherein:

the photovoltaic modules are arranged in module rows;

the solar energy system further comprises a plurality of reflectors arranged in reflector rows interposed between the module rows;

the reflectors are coupled to and supported by the struts such that each reflector is coupled to and supported by a different pair of struts;

for each fin, two corresponding lower extensions, one from each of two adjacent photovoltaic modules, are coupled to the fin on opposing sides of a middle section of the fin and the corresponding strut is coupled to the fin on a side of an upper section of the fin, the upper section being vertically offset upwards from the middle section.

8. The solar energy system of claim 7, wherein each of the fins is thicker in the middle section than in the upper section, the racking assembly further comprising a pin mechanically coupling an upper end of each strut between two corresponding upper extensions, one from each of two adjacent photovoltaic modules.

9. The solar energy system of claim 8, wherein the solar energy system has a nonlinear resistive force versus displacement profile and tolerates surface unevenness of an installation surface up to a predetermined surface unevenness.

15. The solar energy system of claim 6, further comprising a plurality of pads disposed between the rails and an installation surface, each of the rails including one or more features that engage a corresponding pad and prevent translational movement of the rails with respect to the pads in a first dimension.

16. The solar energy system of claim 15, further comprising a plurality of detaining members disposed between the rails and the pads and configured to prevent translational movement of the rails with respect to the pads in a second dimension orthogonal to the first dimension.

17. The solar energy system of claim 6, wherein each of the rails has a substantially triangular cross-sectional shape, a substantially trapezoidal cross-sectional shape, or a substantially circular cross-sectional shape.

18. The solar energy system of claim 6, wherein the rails are arranged in parallel rows, each row of rails including two or more rails arranged end-to-end, the solar energy system further comprising a plurality of tension stiffeners mechanically coupling each row of rails to an adjacent row of rails, each of the tension stiffeners being arranged diagonally to the parallel rows of rails.

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

the photovoltaic modules are arranged in module rows;

the solar energy system further comprises a plurality of reflectors arranged in reflector rows interposed between the module rows;

each of the photovoltaic modules generally faces south if installed in the Northern Hemisphere or generally faces north if installed in the Southern Hemisphere;

each of the reflectors generally faces north if installed in the Northern Hemisphere or generally faces south if installed in the Southern Hemisphere; and

each of the reflectors is oriented substantially at a same second angle relative to horizontal.

20. The solar energy system of claim 19, wherein each of the reflectors comprises:

a glass substrate or a glass superstrate;

a wavelength selective reflective layer; and

an adhesive layer between the wavelength selective reflective layer and the glass substrate or glass superstrate.

21. The solar energy system of claim 19, wherein each of the reflectors has patterning that affects a direction in which incident light is reflected from the corresponding reflector, wherein the patterning includes one of a one-dimensional vertical or horizontal pattern, or a two-dimensional pattern.

22. The solar energy system of claim 21, wherein each of the reflectors has a transmittance spectrum and a reflectance spectrum, the patterning being configured to evenly distribute transmitted light beneath the solar energy system.

23. The solar energy system of claim 19, wherein each of the reflectors has a vertical patterning such that each light ray reflected by a corresponding reflector has an eastward or westward velocity component after being reflected that is altered compared to before being reflected.

24. The solar energy system of claim 19, wherein the plurality of struts include a different pair of struts supporting each photovoltaic module at the angle, the solar energy system further comprising a plurality of stiffeners including, for each reflector:

an upper stiffener coupled between a corresponding pair of struts, the upper stiffener supporting an upper edge of the corresponding reflector; and

a lower stiffener coupled between the corresponding pair of struts, the lower stiffener supporting a lower edge of the corresponding reflector.

25. The solar energy system of claim 24, wherein:

each reflector includes a first side edge and an opposing second side edge, the upper edge, first side edge, lower edge, and second side edge defining a perimeter of the reflector; and

for each reflector, the upper stiffener and the lower stiffener each extend beyond the first side edge and the second side edge before being coupled to a corresponding strut in the corresponding pair of struts.

26. The solar energy system of claim 24, wherein:

each reflector and corresponding upper stiffener and lower stiffener forms an assembly such that the solar energy system has a plurality of assemblies;

each assembly has a substantially same thickness per assembly;

the assemblies have a nestable geometry such that the assemblies can be stacked in a stack occupying a first volume that is three to six times smaller than a second volume, the second volume being proportional to a number of assemblies times the thickness per assembly; and

in the stack, each assembly contacts an adjacent assembly only through corresponding upper stiffeners and lower stiffeners.

27. The solar energy system of claim 19, further comprising a plurality of lockers configured to lock the reflectors into the solar energy system.

28. The solar energy system of claim 19, further comprising one or more interconnection devices electrically coupled to the plurality of photovoltaic modules, the one or more interconnection devices being disposed substantially beneath one or more of the photovoltaic modules and/or one or more of the reflectors.

10. A solar energy system comprising:

a plurality of photovoltaic modules arranged in module rows, each oriented substantially at a same angle relative to horizontal, wherein each of the photovoltaic modules comprises a frame having two upper extensions, including one upper extension extending from each of two upper corners of the photovoltaic module and having two lower extensions, including one lower extension extending from each of two lower corners of the photovoltaic module;

a racking assembly mechanically interconnecting the photovoltaic modules together, the racking assembly comprising;

a plurality of rails arranged parallel to each other;

a plurality of fins coupled between the rails and the lower extensions of the photovoltaic modules; and

a plurality of struts coupled between the fins and the upper extensions of the photovoltaic modules, the plurality of struts including a first strut paired with a second strut to support a first photovoltaic module, and the first strut paired with a third strut to support a second photovoltaic module adjacent to the first photovoltaic module; and

a plurality of reflectors arranged in reflector rows interposed between the module rows, the reflectors coupled to and supported by the struts such that each reflector is coupled to and supported by a different pair of struts;

wherein;

for each fin, two corresponding lower extensions, one from each of two adjacent photovoltaic modules, are coupled to the fin on opposing sides of a middle section of the fin and the corresponding strut is coupled to the fin on a side of an upper section of the fin, the upper section being vertically offset upwards from the middle section;

each of the fins is thicker in the middle section than in the upper section, the racking assembly further comprising a pin mechanically coupling an upper end of each strut between two corresponding upper extensions, one from each of two adjacent photovoltaic modules; and

for each fin, the side of the upper section is laterally offset from a reference plane centered between the opposing sides of the middle section such that a lower end of the corresponding strut coupled to the fin on the side of the upper section is nominally centered laterally between lower ends of the two corresponding adjacent photovoltaic modules having corresponding lower extensions coupled to the fin on the opposing sides of the middle section.

29. The solar energy system of claim 10, wherein the solar energy system defines a continuous area within a perimeter of the solar energy system, the solar energy system is configured to capture at the plurality of photovoltaic modules substantially all light incoming towards the continuous area over an entire season, and substantially all light incoming towards the continuous area over an entire season comprises 80%-95% of all light incoming towards the continuous area over the entire season.

11. A solar energy system comprising:

a plurality of photovoltaic modules arranged in module rows, each oriented substantially at a same angle relative to horizontal, wherein each of the photovoltaic modules comprises a frame having two upper extensions, including one upper extension extending from each of two upper corners of the photovoltaic module and having two lower extensions, including one lower extension extending from each of two lower corners of the photovoltaic module;

a racking assembly mechanically interconnecting the photovoltaic modules together, the racking assembly comprising;

a plurality of rails arranged parallel to each other;

a plurality of fins coupled between the rails and the lower extensions of the photovoltaic modules; and

a plurality of struts coupled between the fins and the upper extensions of the photovoltaic modules, the plurality of struts including a first strut paired with a second strut to support a first photovoltaic module, and the first strut paired with a third strut to support a second photovoltaic module adjacent to the first photovoltaic module; and

a plurality of reflectors arranged in reflector rows interposed between the module rows, the reflectors coupled to and supported by the struts such that each reflector is coupled to and supported by a different pair of struts;

wherein;

for each fin, two corresponding lower extensions, one from each of two adjacent photovoltaic modules, are coupled to the fin on opposing sides of a middle section of the fin and the corresponding strut is coupled to the fin on a side of an upper section of the fin, the upper section being vertically offset upwards from the middle section; and

each strut comprises a first flange and a second flange on opposite sides and at least partially along a length of the strut, the first flange supporting an edge of one of the reflectors and the second flange supporting an edge of an adjacent reflector.

12. The solar energy system of claim 11, wherein each strut further comprises a ridge at least partially along a length of the strut, the first and second flange extending away from the strut on opposite sides of the ridge, the ridge preventing the corresponding edge of the corresponding reflector supported by the first flange from contacting the corresponding edge of the corresponding adjacent reflector supported by the second flange.

13. The solar energy system of claim 11, further comprising, for each strut, a first compliant material disposed between the first flange and a back surface of the corresponding edge of the corresponding reflector and a second compliant material disposed between the second flange and a back surface of the corresponding edge of the corresponding adjacent reflector.

14. The solar energy system of claim 11, wherein:

each of the rails comprises an upper surface and two lips along a length of the rail that extend upward from the upper surface and partially overhang the upper surface, the upper surface and the lips defining a channel;

each of the fins comprises a base having a shape that is complementary to a shape of the channel;

the solar energy system further comprises a plurality of bolts; and

when the base of a fin is inserted within the channel of a rail, a corresponding bolt is threadably engaged in a hole defined in the base to bias the base of the fin against the overhanging lips of the rail.