Integrated photovoltaic rooftop modules

• US 8,307,606 B1
• Filed: 05/24/2012
• Issued: 11/13/2012
• Est. Priority Date: 07/07/2011
• Status: Expired due to Fees

• Current Assignee: Solyco Technology GmbH
• Original Assignee: Solon Se (Nojima Corporation)
• Inventors: Rego, David, Rodowca, Jerrod Quinton, Striner, Ben Michael, Rethans, John W.
• Primary Examiner(s): Gilbert, William
• Assistant Examiner(s): MAESTRI, PATRICK J
• Application Number:
  US13/480,250
• Time in Patent Office: 173 Days
• Field of Search: 521/733, 126/621, 126/622, 126/623, 136/244, 136/251, 136/291, 403/167, 403/168, 403/294, 403/306
• US Class Current: 52/747.1
• CPC Class Codes: F24S 2025/02 Ballasting means
• CPC Class Codes: F24S 25/11 using shaped bodies, e.g. concrete elements, foamed elements or moulded box-like elements
• 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 25/50 comprising elongate non-rigid elements, e.g. straps, wires or ropes
• CPC Class Codes: H01L 31/05 Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells electrodes H01L31/0224; electrical interconnection of thin film solar cells formed on a common substrate H01L31/046; particular structures for electrical interconnecting of adjacent thin film solar cells in the module H01L31/0465; electrical interconnection means specially adapted for electrically connecting two or more PV modules H02S40/36
• CPC Class Codes: H02S 20/24 specially adapted for flat roofs
• CPC Class Codes: H02S 40/36 characterised by special electrical interconnection means between two or more PV modules, e.g. electrical module-to-module connection
• 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
• CPC Class Codes: Y10T 29/49108 Electric battery cell making
• CPC Class Codes: Y10T 29/49355 Solar energy device making

Abstract

Photovoltaic modules including a solar panel integrated with a supporting frame, and which are configured to be installed on a building rooftop. Modules according to the present teachings may be at least partially pre-assembled, with a solar panel oriented at a predetermined angle relative to the rooftop mounting surface of the supporting frame.

Claims

1. A method of installing photovoltaic modules, comprising:

placing at least two photovoltaic modules onto a substantially flat surface;

aligning the modules laterally;

repositioning at least one of the modules longitudinally until a shaped leading edge of one of the modules registers with a shaped trailing edge of another one of the modules; and

physically connecting the modules with a connection member that spans the leading edge and the trailing edge;

wherein the connection member is a u-bolt assembly including a u-shaped bolt and a connecting plate, and wherein physically connecting the modules includes;

a. inserting a first leg portion of the u-shaped bolt into a first aperture in the leading edge, and inserting a second leg portion of the u-shaped bolt into a second aperture in the trailing edge; and

b. engaging each leg portion with a corresponding aperture formed in a connection plate disposed on a side of the leading and trailing edges opposite a direction of insertion of the leg portions into the leading and trailing edges.

2. The method of claim 1, further comprising electrically connecting the modules by pulling a first connecting wire from a wiring aperture formed in a rear wall of a first of the modules, pulling a second connecting wire from a wiring aperture formed in a rear wall of a second of the modules, and connecting the wires.

3. The method of claim 2, wherein the wiring apertures are substantially keyhole-shaped apertures formed in a rear wind deflector of each module, and further comprising placing at least one of the wires into a lower portion of one of the wiring apertures to hold the wire in place with friction, after connecting the wires.

4. The method of claim 2, further comprising repositioning an electrical connection region of the wires behind one of the rear walls, after connecting the wires.

5. The method of claim 1, wherein the leading edge and the trailing edge define complementary planes that are each non-perpendicular to a plane defined by the substantially flat surface.

6. A photovoltaic module comprising:

a first frame portion defining a first plane and including;

a. left and right side members, each side member having a leading edge and a trailing edge; and

b. at least one cross member connecting the left and right side members;

a second frame portion defining a second plane oriented at a predetermined angle relative to the first plane, the second frame portion including left and right support members, each support member connected to one of the side members and having an upper surface lying substantially within the second plane; and

a photovoltaic panel fixedly attached to the upper surfaces of the left and right support members and lying substantially parallel to the second plane;

wherein each leading edge is configured to be connected to a leading edge of a laterally adjacent module and a trailing edge of a longitudinally adjacent module, and each trailing edge is configured to be connected to a trailing edge of a laterally adjacent module and a leading edge of a longitudinally adjacent module.

7. The module of claim 6, wherein each leading edge has a shape complementary to a shape of each trailing edge.

8. The module of claim 7, wherein each leading edge defines a leading edge plane angled at a non-perpendicular angle relative to the first plane, and each trailing edge defines a trailing edge plane angled at 180 degrees minus the angle of the leading edge plane relative to the first plane.

9. The module of claim 6, wherein each leading edge includes a leading edge connection aperture, each trailing edge includes a trailing edge connection aperture, and each connection aperture is configured to receive a connection member configured to connect together at least two adjacent side members.

10. The module of claim 9, wherein the connection member is a self-connecting strap configured to pass through adjacent apertures of two laterally adjacent side members and form a loop.

11. The module of claim 9, wherein the connection member is a u-bolt including leg portions configured to pass through adjacent apertures of two longitudinally adjacent side members and then through a connecting plate that spans an intersection region of the longitudinally adjacent side members.

12. The module of claim 11, wherein the leg portions each include a proximal notch and a distal notch, and wherein each notch is configured to engage a complementary aperture in the connecting plate.

13. The module of claim 12, wherein the proximal notches are configured to engage the connecting plate when the u-bolt connects exactly two longitudinally adjacent modules, and the distal notches are configured to engage the connecting plate when the u-bolt connects two pairs of longitudinally adjacent modules, wherein the pairs are laterally adjacent to each other.

14. A photovoltaic module comprising:

a frame defining a first plane and a second plane oriented at a predetermined angle relative to the first plane, the frame including at least left and right side members; and

a photovoltaic panel fixedly attached to the frame and lying substantially parallel to the second plane; and

a u-bolt connection member assembly configured to connect together two longitudinally adjacent side members;

wherein a leading edge of each side member has a shape which is complementary to a shape of a trailing edge of each side member, so that longitudinally adjacent modules are configured to register with each other.

15. The method of claim 14, wherein each leading edge is oriented at a non-perpendicular angle relative to the first plane, and each trailing edge is oriented at a complementary angle relative to the first plane.

16. The method of claim 14, wherein each leading edge includes a leading edge connection aperture, each trailing edge includes a trailing edge connection aperture, and each connection aperture is configured to receive a connection member configured to connect together at least two adjacent side members.

17. A photovoltaic module comprising:

a frame defining a first plane and a second plane oriented at a predetermined angle relative to the first plane, the frame including at least left and right side members; and

a photovoltaic panel fixedly attached to the frame and lying substantially parallel to the second plane; and

a self-connecting strap assembly connection member configured to connect together two laterally adjacent side members;

wherein a leading edge of each side member has a shape which is complementary to a shape of a trailing edge of each side member, so that longitudinally adjacent modules are configured to register with each other.

18. The method of claim 17, wherein each leading edge is oriented at a non-perpendicular angle relative to the first plane, and each trailing edge is oriented at a complementary angle relative to the first plane.

19. The method of claim 17, wherein each leading edge includes a leading edge connection aperture, each trailing edge includes a trailing edge connection aperture, and each connection aperture is configured to receive a connection member configured to connect together at least two adjacent side members.