U.S. patent application number 12/275147 was filed with the patent office on 2009-05-28 for system and method of mounting a removable and adjustable photovoltaic ballast frame device.
Invention is credited to Chris M. Meier, Collin J. Rhodes.
Application Number | 20090134291 12/275147 |
Document ID | / |
Family ID | 40668886 |
Filed Date | 2009-05-28 |
United States Patent
Application |
20090134291 |
Kind Code |
A1 |
Meier; Chris M. ; et
al. |
May 28, 2009 |
SYSTEM AND METHOD OF MOUNTING A REMOVABLE AND ADJUSTABLE
PHOTOVOLTAIC BALLAST FRAME DEVICE
Abstract
A photovoltaic (PV) module mounting system comprises a plurality
of PV modules, support brackets disposed under the modules and a
ballast frame disposed under and attached to the support brackets.
The ballast frame is supported on conventional building rooftops
and attached thereto by conventional methods. The support bracket
consists of front and rear supports, which can be adjusted to alter
the desired tilt angles of the overlying PV modules. The ballast
frames can be adjusted to varying widths and lengths. The system is
effective in reducing the net effect of wind uplift force when
modules are mounted on building rooftops. Additionally, the system
provides the advantage of ease of use with less components and
minimal roofing penetrations.
Inventors: |
Meier; Chris M.;
(Albuquerque, NM) ; Rhodes; Collin J.;
(Albuquerque, NM) |
Correspondence
Address: |
WILMERHALE/DC
1875 PENNSYLVANIA AVE., NW
WASHINGTON
DC
20006
US
|
Family ID: |
40668886 |
Appl. No.: |
12/275147 |
Filed: |
November 20, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60996486 |
Nov 20, 2007 |
|
|
|
Current U.S.
Class: |
248/222.14 ;
248/220.21 |
Current CPC
Class: |
F24S 2025/02 20180501;
Y02E 10/47 20130101; F24S 25/632 20180501; Y02E 10/50 20130101;
Y02B 10/20 20130101; Y02B 10/10 20130101; F24S 25/13 20180501; F24S
25/61 20180501; H02S 20/24 20141201; F24S 25/16 20180501 |
Class at
Publication: |
248/222.14 ;
248/220.21 |
International
Class: |
A47B 96/06 20060101
A47B096/06 |
Claims
1. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object, comprising: a bracket wherein
the bracket can be positioned in a plurality of angles; a ballast
frame, wherein the ballast frame consist of a plurality of
longitudinal and latitudinal members and further wherein a
plurality of brackets can be attached; and a hardware system,
wherein the bracket can be connected to at least one of the flat
object or to the ballast frame.
2. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein a
weighted object can be attached to the ballast frame.
3. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
hardware system comprises at least one of a bolt, nut or
washer.
4. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein at
least a portion of the bracket is mounted to a flat object.
5. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 3, wherein the
flat object is grounded to at least one of the tilt bracket or the
ballast frame.
6. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
weighted object comprises at least one concrete block.
7. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
members are arranged in a plurality configurations.
8. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
members comprises at least one of a longitudinal or latitudinal
member.
9. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
bracket comprises a channel and further wherein the channel is made
of aluminum or other material such as steel, wood or plastic.
10. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein a
metallic substance is affixed to the channel by at least one of
welding, a rivet, an adhesive or a bolt.
11. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 7, wherein a
metallic substance is affixed to at least one end of the channel by
at least one of welding, a rivet, an adhesive or a bolt.
12. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 1, wherein the
ballast frame comprises holes in which the bracket can be
attached.
13. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 8, wherein the
longitudinal and latitudinal members are assembled into a
rectangular configuration.
14. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 13, wherein
the members are configured to support a plurality of sizes of
weighted objects.
15. A system for removably and adjustably mounting a photovoltaic
module or flat panel on an object according to claim 13, wherein
the rectangular configuration is dimensioned to house a plurality
of concrete blocks.
16. A method of installing a photovoltaic module or flat panel on
an object comprising the steps of: constructing a ballast frame;
attaching a ballast frame to a plurality of brackets; attaching the
ballast frame affixed to the brackets to a surface.
17. The method of installing a photovoltaic module or flat panel on
an object according to claim 16, wherein at least one weighted
object is inserted into the ballast frame to weight the
photovoltaic system to the flat surface.
18. The method of installing a photovoltaic module or flat panel on
an object according to claim 16, wherein the brackets are attached
to the ballast frame by at least one of a hex bolt, a washer or a
flange nut.
19. The method of installing a photovoltaic module or flat panel on
an object according to claim 16, wherein the ballast frame affixed
to the flat surface is attached by at least one of a hex bolt, a
washer or a flange nut.
20. The method of installing a photovoltaic module or flat panel on
an object according to claim 16, wherein a grounding washer is
inserted between more than one constructed ballast frames.
Description
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to provisional application Ser. No. 60/996,486, filed Nov.
20, 2007, the contents of which are incorporated by reference.
FIELD OF INVENTION
[0002] The present invention is directed generally to an apparatus
and methods for use in a removable or adjustable mounting or
assembling photovoltaic (PV) ballast frame system for use on flat
surfaces.
BACKGROUND OF INVENTION
[0003] Prior art PV module ballast frame structures typically has
the disadvantage of having many parts and multiple penetrations to
a roofing structure upon which it is installed. Accordingly, light
weight components, minimal penetration, ease of installation and
reduced labor costs are major concerns of customers in the PV
module ballast frame market. Specifically, the number of
penetrating roofing attachments can decrease the effectiveness of
expensive roofing surfaces. As a result, there is an increasing
need to develop PV mounting frame systems that eliminate or reduce
roofing penetration. There is an additional necessity to develop a
PV mounting system, whereas to ensure that the installed system is
less susceptible environmental stresses such as wind-loading.
SUMMARY OF INVENTION
[0004] The present invention in one embodiment provides a method
and apparatus for mounting solar modules and other flat objects
onto a relatively flat surface. Among the advantages to this
embodiment includes that it has relatively few components and easy
assembly. Further, parts can be configured to accommodate a
plurality of sizes of flat objects. The present invention can
comprise a bracket for maintaining flat objects, e.g. PV solar
panels, at a plurality of angles, a ballast frame, which has the
ability to be secured to a flat surface and bolt and nut hardware
for attaching the bracket to the flat object and ballast frame.
Additionally, embodiments of the present invention provide for
minimal or zero penetrations of the flat surface upon which the
system is being mounted. The minimal or zero penetrations of the
flat surface, i.e., rooftop can be achieved by any fastening
technique, including methods such as use of nuts, washers and bolts
or adhesives. Alternatively, the present invention can be installed
without the use of any fastening devices, wherein weighted objects
attached to the ballast frame are used instead.
[0005] The photovoltaic ballast frame system incorporates
horizontal and vertical members, at least one bracket and hardware
components to attach the bracket to at least one member of the
ballast frame. The ballast frame system allows for movement of the
members to alter the configuration of a particular frame or
collection of frames. Specifically, multiple frames can be attached
to each other, as well as multiple brackets. Additionally, the
ballast frame system can be constructed to accommodate varying
sized or type of weighted objects. Also, the ballast frame system
can incorporate grounding means between the plurality of
components.
[0006] The method for constructing the photovoltaic ballast frame
system includes constructing a ballast frame system, constructing
at least one bracket, attaching the ballast frame to at least one
bracket and attaching the ballast frame to a roofing surface.
Additionally, the method includes grounding one or more components
of the ballast frame system. Further, the method can include
attaching a weighted object to the constructed ballast frame.
BRIEF DESCRIPTION OF DRAWINGS
[0007] The present invention will be understood and appreciated
more fully from the following detailed description, taken in
conjunction with the drawings in which:
[0008] FIG. 1 is a depiction of a two bay ballast frame;
[0009] FIG. 2 is a depiction of a single bay ballast frame;
[0010] FIG. 3 is a depiction of a support bracket used to support a
PV module;
[0011] FIG. 4 is an embodiment of hardware used to attach the
support bracket to the ballast frame and flat surface: e.g., a hex
bolt, a washer or flange nut;
[0012] FIG. 5 is an inverted PV module fastened to a support
bracket with a plurality of hardware components;
[0013] FIG. 6 is a PV module fastened to a double bay ballast
frame;
[0014] FIG. 7 is a depiction of the fastening hardware components
being used to affix the support bracket to the double bay ballast
frame in FIG. 6;
[0015] FIG. 8 is a second PV module and support brackets fastened
to a double bay ballast frame;
[0016] FIG. 9 is one PV module and support brackets mounted to a
double bay ballast frame and a second PV module and support
brackets mounted to the front end of the double bay ballast frame
in the rear and a single bay ballast frame in the front;
[0017] FIG. 10 is two attached columns of PV modules and support
brackets mounted to single bay ballast frames;
[0018] FIG. 11 is an exploded view of the connection of two columns
of PV modules mounted to single bay ballast frames;
[0019] FIG. 12 is an alternative view of the PV module being
connected to two connected ballast modules by a plurality of
support brackets;
[0020] FIG. 13 is an alternative configuration of a non-extended
single bay ballast frame design;
[0021] FIG. 14 is an exploded view of the connection of a plurality
of non-extended single bay ballast frames; and
[0022] FIG. 15 is a 2 by 2 array comprising four modules and six
single ballast frames.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
[0023] Embodiments consistent with the present invention utilize
varying configurations of ballast frames to support PV modules for
personal or residential energy needs. In particular, these ballast
frames can be constructed to accommodate varying sizes of PV
modules as well as more than one frame can be configured to attach
to each other. Typically, the ballast frames are installed on
roofing structures. Accordingly, weighted objects, e.g., concrete
blocks, can be placed in ballast frames to combat natural lift
forces, which can be created by wind.
[0024] FIG. 1 is an exemplary non-limiting embodiment of double bay
ballast frame 10. The double bay ballast frame 10 consists of
horizontal members 1-4 and vertical connection members 5 and 6.
Extensions 100a-d extend vertical connection members 5 and 6 for
the purpose of connecting a plurality of ballast frame members.
Extensions 100a and 100b are created by altering the position of
horizontal members 1 and 2 within vertical members 5 and 6. A
single bay ballast frame is created by horizontal members 1 and 2
and an end of 5 and 6. Similarly, another single bay ballast frame
is created by horizontal members 3 and 4 and the opposite end of
vertical members 5 and 6. Middle portions 101a and 101b are shown
between the two single bay ballast frames.
[0025] Typically, solar panels are positioned to face a southern
direction. Therefore, it should be appreciated that "vertical"
connection members 5 and 6 are generally oriented in a north/south
direction; whereas "horizontal" members 1 and 2 are generally
positioned in an east/west direction. Generally, the "vertical"
member extends perpendicularly from the "horizontal" member.
Further, the ballast frame can be oriented such that it lies flat
or at an angle. See FIG. 6.
[0026] The adjustable nature of the present invention can be
demonstrated by FIG. 2, which is an embodiment of a single bay
ballast frame 20. In this embodiment, a single row is created by
horizontal members 7 and 8, wherein weighted objects can be placed.
Horizontal members 7 and 8 are connected with short vertical
members 9 and 10. Extension members 102a-102d are created within
vertical members 9 and 10 by altering the position of horizontal
members 7 and 8. An alternative embodiment of a single bay ballast
frame is provided in FIG. 13.
[0027] Referring to FIG. 3, a schematic embodiment of a support
bracket 30 used to support PV module on a flat surface is shown. A
portion of support bracket 30 would be attached to a PV module and
the other end would attach to a ballast frame as shown in FIG. 1 or
2. The bracket 30 comprises a horizontal chamber 14, a front
support 16 and a rear support 15, which can both be made of folded
metal, e.g., aluminum. In an alternative embodiment, front and rear
supports 16 and 15 respectively, can also consist of a singular
angled, e.g., a cylindrical post. Support members 15 and 16 can be
attached to horizontal chamber 14 in a variety of manners including
welds or mechanical means such as rivets, adhesive, bolts or other
fasteners. If the support members are welded to the horizontal
chamber, welds are executed at end 104 of rear support 15 and 103a
and 103b for front support 16.
[0028] FIG. 4 is a non-limiting embodiment of 3 fastening elements,
which are used to attach the support bracket 30 to either a PV
module or a ballast frame, e.g., FIGS. 1 and 2. These elements
consist of a bolt or screw 11, a washer 12 and a nut 13. As
previously stated, these elements can be used to attach support
members 15 and 16 to horizontal channel 14, or in any other place
in the system where fastening is desired.
[0029] Referring to FIG. 5, an inverted view is shown of a PV
module 19 being attached to two support brackets 17 and 18. In this
embodiment, bolt 11, washer 12 and nut 13 are used to fasten
brackets 17 and 18 to PV module 19.
[0030] As previously stated, a PV module can be attached to a
plurality of constructed ballast frames. FIG. 6, for example, is an
embodiment of a PV module 19 being attached to a double bay ballast
frame 10, utilizing support brackets 106a and 106b attached. As
previously described, double bay ballast frame can be comprised of
two single bay ballast frames. Also, this embodiment demonstrates
the double bay ballast frame attached to a roofing structure 200.
The ballast frame 200 can be attached to roofing structure 200 in
any desired manner, including mechanical means, adhesives etc. As
shown, roofing surface 200 is a relatively flat surface; however,
it should be appreciated that the present invention can be utilized
in conjunction with any surface upon which the present invention
can be attached.
[0031] In an effort to further depict the attachment of support
bracket 106b to double bay ballast frame 10 in FIG. 6, an exploded
view of such attachment is provided in FIG. 7. In this embodiment,
horizontal chamber 24 is attached to rear support 25 by use of
fastening elements bolt 11, washer 12 and nut 13. Support member
106b is also attached to horizontal member 2.
[0032] As previously discussed multiple PV modules can be attached
to a ballast frame. Accordingly, FIG. 8 is an embodiment of an
additional PV module being attached to a double bay ballast frame.
PV modules 31 and 33 attached to double bay ballast frame 10.
Similar to previous embodiments, support brackets 32a, 32b are
attached to horizontal member 4. Support bracket 34 is attached to
horizontal members 2 and 3.
[0033] Multiple PV module columns can be created by attachment of
additional ballast frames to PV modules attached to other ballast
frames. As shown in FIG. 9, an embodiment of PV module 41 attached
to double bay ballast frame 10. Also, in this embodiment an
additional PV module 42 is attached to via support brackets 45 and
46 to the front of double bay ballast frame 10 and the rear of
single bay ballast frame 20. Support members 45 and 46 are attached
to horizontal member 8. Additionally, a third PV module could be
attached to horizontal member 7 of single bay ballast frame 20.
Thus, an extended column of alternating PV modules and ballast
frames can be attached to each other.
[0034] Embodiments of the present invention provides for multiple
configurations or arrays of PV modules. FIG. 10 is an embodiment of
alternating single bay ballast frames 51 and 54 connected to PV
modules 47 and 50 respectively. In this embodiment, ballast frames
52 and 53 are attached to single bay ballast frames (and the
attached PV modules 48 and 49 respectively). This configuration
shows a 2 by 2 array. FIG. 11 is an exploded view of the connection
of single bay ballast frames 53 and 54. As shown in previous
non-limiting embodiments, the connection of ballast frames is made
by use of bolt 11, washer 12 and nut 13.
[0035] Embodiments of the present invention provide for multiple
configurations of PV module arrays, i.e., 1.times.2, 2.times.2 etc.
arrays. FIG. 12 is an embodiment of a 1 by 2 array of PV modules
62a and 62b. In this embodiment, support brackets 63a-d are
attached to ballast frames 641a-d.
[0036] Embodiments of the present invention also allow for a
plurality configurations of ballast frames. For example, FIG. 13 is
an alternative ballast frame design for single bay ballast frames
65a-d. In this embodiment, extensions are not affixed to vertical
members 108a-d, as shown in FIG. 2. An exploded view of the
connection of ballast frames 65c and 65d is shown in FIG. 14. The
frames are attached by bolt 11, washer 12 and nut 13. A grounding
washer 67 is also shown between the ballast frames 65c and 65d.
Grounding washer 67, which can be used in any embodiment of the
present invention, allows for grounding of one single bay ballast
frames 65c and 65d. Grounding washers can also be used for
grounding a PV module to the support bracket or from the support
bracket to the ballast frame. Grounding washers provide the
advantage of minimizing the number of grounding wires, which would
otherwise be necessary for each module and frame member.
Integration of grounding washers provides a continuous ground path
throughout a PV array.
[0037] FIG. 15 is a 2 by 2 module array consisting of four PV
modules 69a-d and six single bay ballast frames 70a-f. In this
embodiment, a plurality of ballast blocks 71 are shown, which
provides weight to counterbalance the lift force of wind when the
present invention is situated on a flat surface such as a rooftop.
An example of ballast blocks are concrete blocks.
[0038] While the foregoing describes various embodiments of the
present invention, those of ordinary skill in the relevant arts
will recognize the many variations, alterations, modifications,
substitutions and the like as are readily possible, especially in
light of this description, the accompanying drawings and claims
drawn thereto. In any case, because the scope of the present
invention may be much broader than a particular embodiment, the
foregoing detailed description should not be construed as a
limitation of the scope of the present invention, which is limited
only by the claims appended hereto.
* * * * *