U.S. patent application number 12/477852 was filed with the patent office on 2009-12-03 for mounting system for weatherproof surfaces.
Invention is credited to Joseph E. Augenbraun, John K. Cammack, Darrell S. Park.
Application Number | 20090293932 12/477852 |
Document ID | / |
Family ID | 41378238 |
Filed Date | 2009-12-03 |
United States Patent
Application |
20090293932 |
Kind Code |
A1 |
Augenbraun; Joseph E. ; et
al. |
December 3, 2009 |
Mounting System for Weatherproof Surfaces
Abstract
A mounting system for weatherproof surfaces is disclosed.
According to one embodiment, an apparatus comprises a solar panel.
A mounting mechanism is in contact with the solar panel. A bracket
is in contact with a surface to which the solar panel is installed.
The mounting mechanism engages and disengages from the bracket
without use of tools.
Inventors: |
Augenbraun; Joseph E.;
(Foster City, CA) ; Cammack; John K.; (Palo Alto,
CA) ; Park; Darrell S.; (South Pasadena, CA) |
Correspondence
Address: |
ORRICK, HERRINGTON & SUTCLIFFE, LLP;IP PROSECUTION DEPARTMENT
4 PARK PLAZA, SUITE 1600
IRVINE
CA
92614-2558
US
|
Family ID: |
41378238 |
Appl. No.: |
12/477852 |
Filed: |
June 3, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61058472 |
Jun 3, 2008 |
|
|
|
61195257 |
Oct 3, 2008 |
|
|
|
Current U.S.
Class: |
136/244 |
Current CPC
Class: |
Y02B 10/20 20130101;
H02S 40/32 20141201; Y02B 10/10 20130101; H01L 31/02008 20130101;
H02S 20/23 20141201; Y02B 10/12 20130101; Y02E 10/50 20130101 |
Class at
Publication: |
136/244 |
International
Class: |
H01L 31/042 20060101
H01L031/042 |
Claims
1. An apparatus, comprising: a solar panel; and a mounting
mechanism in contact with the solar panel; a bracket in contact
with a surface to which the solar panel is installed, wherein the
mounting mechanism engages and disengages from the bracket without
use of tools.
2. The apparatus of claim 1, wherein the mounting mechanism
comprises a latch including a handle having a first position and a
second position.
3. The apparatus of claim 2, wherein moving the handle from the
first position to the second position engages the bracket.
4. The apparatus of claim 2, wherein the latch further comprises a
first plate connected to the handle; and a second plate connected
to the handle.
5. The apparatus of claim 4, wherein the first plate and the second
plate clamp on the bracket when the handle is in the first
position
6. The apparatus of claim 4, wherein the first plate and the second
plate separate when the handle is in the second position.
7. The apparatus of claim 4 wherein, the first plate is configured
to contact an outer surface of a lip of the bracket when the handle
is in the first position.
8. The apparatus of claim 7, wherein the second plate is configured
to contact an inner surface of the lip of the bracket when the
handle is in the first position.
9. The apparatus of claim 7, wherein the second plate includes
fingers to mate with the lip of the bracket.
10. The apparatus of claim 1, wherein the handle rotates between
the first position to the second position.
Description
[0001] The present application claims the benefit of and priority
to U.S. Provisional Patent Application No. 61/058,472 entitled
"Solar Collector Mounting System" and filed on Jun. 3, 2008, and is
hereby incorporated by reference in its entirety. The present
application also claims the benefit of and priority to U.S.
Provisional Patent Application No. 61/195,257 entitled "Solar
Energy Collector Mounting System" and filed on Oct. 3, 2008, and is
hereby incorporated by reference in its entirety.
FIELD
[0002] The present invention relates to the field of solar energy,
and in particular to a mounting system for weatherproof
surfaces.
BACKGROUND
[0003] With global warming concerns and increased energy costs,
small solar energy collection systems (such as on residential
rooftops) are increasing in popularity. With an increase in volume,
costs of the solar collector hardware and silicon have been and
will continue to fall. The cost of installation, however, has not
been changing dramatically. Prior solar systems also are expensive
and difficult to repair, cause roof repairs to be difficult, and
are expensive to update for newer technology.
SUMMARY
[0004] A mounting system for weatherproof surfaces is disclosed.
According to one embodiment, an apparatus comprises a solar panel.
A mounting mechanism is in contact with the solar panel. A bracket
is in contact with a surface to which the solar panel is installed.
The mounting mechanism engages and disengages from the bracket
without use of tools.
[0005] The features and advantages described in the specification
are not all-inclusive and, in particular, many additional features
and advantages will be apparent to one of ordinary skill in the art
in view of the drawings and specification. Moreover, it should be
noted that the language used in the specification has been
principally selected for readability and instructional purposes,
and may not have been selected to delineate or circumscribe the
inventive subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] The accompanying drawings, which are included as part of the
present specification, illustrate the presently preferred
embodiment of the present invention and together with the general
description given above and the detailed description of the
preferred embodiment given below serve to explain and teach the
principles of the present invention.
[0007] FIG. 1 illustrates an exemplary socket series for solar
energy collectors, according to one embodiment.
[0008] FIG. 2 illustrates a top view of an exemplary socket,
according to another embodiment.
[0009] FIG. 3 illustrates an exemplary socket assembly, according
to one embodiment.
[0010] FIG. 4 illustrates an exemplary socket assembly installed
into shingle roofs, according to one embodiment.
[0011] FIG. 5 illustrates an exemplary socket assembly having
vertical and horizontal spacers, according to one embodiment.
[0012] FIG. 6 illustrates an exemplary socket assembly for an
offset grid, according to one embodiment.
[0013] FIG. 7A illustrates an exemplary installed socket assembly,
according to one embodiment.
[0014] FIG. 7B illustrates installed socket assembly with a second
row of shingles, according to one embodiment.
[0015] FIG. 7C illustrates an exemplary installed socket assembly,
according to another embodiment.
[0016] FIG. 7D illustrates a top view of a socket assembly,
according to one embodiment.
[0017] FIG. 8A illustrates an exemplary wiring diagram for
connections to a socket, according to one embodiment.
[0018] FIG. 8B illustrates an exemplary wiring diagram of a socket,
according to one embodiment.
[0019] FIG. 9 illustrates an exemplary jointed solar collector and
socket combination 900, according to one embodiment.
[0020] FIG. 10A illustrates an exemplary flip-up solar collector
having one joint, according to one embodiment.
[0021] FIG. 10B illustrates an exemplary flip-up solar collector
having two joints, according to one embodiment.
[0022] FIG. 11A illustrates an exemplary solar panel assembly with
a linear wiper, according to one embodiment.
[0023] FIG. 11B illustrates an exemplary solar panel assembly with
an arcing wiper, according to one embodiment.
[0024] FIG. 11C illustrates an exemplary solar panel assembly with
an arcing wiper with linkage, according to one embodiment.
[0025] FIG. 11D illustrates an exemplary solar panel assembly with
an arcing wiper with linkage that follow a track, according to one
embodiment.
[0026] FIG. 12 illustrates an exemplary solar panel system with
adjacent panels plugged together in a daisy chain fashion,
according to one embodiment.
[0027] FIG. 13 illustrates an exemplary solar panel system having
solar panels having both series and parallel connections, according
to one embodiment.
[0028] FIG. 14 illustrates an exemplary wiring diagram for solar
panel system, according to one embodiment.
[0029] FIG. 15 illustrates an exemplary mounting bracket, according
to one embodiment.
[0030] FIG. 16 illustrates an exemplary solar panel system
installed on a roof, according to one embodiment.
[0031] FIG. 17 illustrates an exemplary solar panel installation
using a lower bracket, according to one embodiment.
[0032] FIG. 18A illustrates an exemplary solar panel installation
using a top bracket and latch, according to one embodiment.
[0033] FIG. 18B illustrates an exemplary latch mechanism attached
to an upper bracket, according to one embodiment.
[0034] FIG. 19 illustrates an exemplary plate of a latch mechanism,
according to one embodiment.
[0035] FIG. 20 illustrates an exemplary automatic power transfer
system, according to one embodiment.
DETAILED DESCRIPTION
[0036] A mounting system for weatherproof surfaces is disclosed.
According to one embodiment, an apparatus comprises a solar panel.
A mounting mechanism is in contact with the solar panel. A bracket
is in contact with a surface to which the solar panel is installed.
The mounting mechanism engages and disengages from the bracket
without use of tools.
[0037] Reference in the specification to "one embodiment" or to "an
embodiment" means that a particular feature, structure, or
characteristic described in connection with the embodiments is
included in at least one embodiment. The appearances of the phrase
"in one embodiment" in various places in the specification are not
necessarily all referring to the same embodiment.
[0038] Throughout this specification reference is made to solar
photovoltaic collection and solar panels for residential
applications. This is done for purposes of clarity of explanation.
The present system also applies to commercial, industrial, and
utility-scale solar installations, and reference to residential and
to photovoltaic is not meant to limit the scope of this
application. A solar panel may be any device that collects solar
energy and converts it another form of energy (eg. electricity).
Furthermore, the brackets described herein are not limited to
mounting solar panels, and may also be used for other device
including thermal collectors, condensers, wind mills, etc.
[0039] Throughout this specification reference is made to roofs.
Those skilled in the art will recognize that solar panels may also
be mounted on decks, lawns, exterior walls, and other surfaces. The
word roof is used in an exemplary manner and is not meant to limit
application of the present system to those other situations.
[0040] Existing solutions for residential grid-tied photovoltaic
power generation is both complicated and expensive. Typically a new
installation requires a level of expertise that demands a specialty
solar company. The specialty solar company may make several visits
to the site, including a site survey, system design, and
installation. Installation involves working on the roof and
significant electrical work to the home or business's main
electrical panel. These firms must charge for their time, resulting
in a significant labor cost. In addition, the overall job typically
will carry a significant markup, necessitated by the cost of sales,
marketing, inventory, etc. incurred by these firms.
[0041] The typical installation involves large solar panels.
Handling and installing these panels requires a crew of 2 or 3
people and sometimes a crane due to the size, weight, and relative
fragility of the panels. The solar panels must be physically
mounted to the roof (either on special racks or directly to the
roof through brackets), and must be wired together by an
electrician. The electrician then wires the panels to an inverter
which interfaces the panels to house's electrical service and to
the power grid. Once these panels are installed they are intended
to remain on the roof for their entire 20 to 30 year life.
[0042] No consideration is provided for panel maintenance. If a
panel were to be damaged (for example due to a tree branch falling
on it), the panel would need to be removed and replaced. Depending
on the details of the installation methodology this could involve
removing one or more other panels, risking damage to these other
panels and incurring large costs. Moreover, the likelihood of being
able to purchase a panel that cosmetically and electrically matches
the existing panels 10 or 15 years in the future is low.
[0043] No consideration is provided for roof maintenance. For
example, if the roof under a solar panel starts leaking one or more
panels would need to be removed to access the roof underneath.
Depending on the details of the installation methodology this could
involve removing and replacing a large number of panels, again
incurring the risk of damaging these panels while they are handled.
Similarly a roof replacement job would require removal and
replacement of the solar panels.
[0044] Installation brackets for some solar panels create roof
penetrations that are sealed with special caulks. These caulks have
limited life, incurring a high risk of roof leaks during the
panels' 20 to 30 year life.
[0045] The economics of residential solar power generation is
dependent on not incurring any new costs after the initial
installation of a solar photovoltaic system. In fact, any roof
maintenance or panel maintenance could require removal and
reinstallation of the entire system, incurring a cost which could
exceed the cost of a new photovoltaic system, ruining the projected
economics of the system.
[0046] Panels are not the only available form factor for solar
collection systems. Solar shingles are available that are installed
with the other shingles on the house. Also available are
peel-and-stick solar collectors that cover an individual shingle.
These products do not address the aforementioned issues with solar
panels, and in fact probably require more installation expertise
and are more difficult to maintain than solar panels.
[0047] A mounting system for solar collectors is described that
includes sockets and/or brackets that accept special photovoltaic
solar energy collection modules. The sockets and/or brackets are
mounted in a regular or offset grid pattern on the roof, providing
mechanical and/or electrical connections for the modules.
[0048] The present system allows for a "solar ready" home. This is
a home which has installed provisions for mounting the solar
collectors and electrically connecting them into the house
electrical system. Generation of solar power just requires
installing solar collection modules and for some embodiments an
inverter and electrical safety hardware. The goal is to make
upgrading a house from "solar ready" to solar as easy and
inexpensive as possible, ideally only requiring the installation of
solar collection modules using no tools or special skills.
[0049] In one embodiment, devices that enable installation of solar
collectors electrically and/or mechanically are preinstalled on the
roof. A socket refers to a device attached to a home that provides
a mechanical attachment point for solar collectors and/or an
electrical connection point for solar collectors.
[0050] Preinstalling a group of sockets onto a home provides the
ability to later install solar collectors. The solar collectors may
also be easily removed from the sockets for maintenance, roof
replacement, etc.
[0051] In one embodiment of the present system, the solar
collectors interconnect electrically to each other. In one
embodiment they interconnect through a cable-and-plug arrangement,
where a cable and plug from one connects into a receptacle in the
next. In one embodiment they interconnect through connectors that
provide automatic interconnection upon installation of adjacent
panels.
[0052] In one embodiment, a receptacle is installed on the house
that allows one solar collector to connect to the house electrical
system. For example, a receptacle could be included under the eaves
of the roof near some of the brackets for the solar collectors.
[0053] In one embodiment, the sockets attach to a bar, rail, slot,
ridge, or other linear feature in the solar collector, eliminating
the need for exact alignment between the bracket and the solar
collector. In one embodiment, the arrangement is reversed, with the
bar, rail, slot, ridge or other linear feature as part of the
socket.
[0054] FIG. 1 illustrates an exemplary socket series for solar
energy collectors, according to one embodiment. Socket series 100
automatically spaces solar energy collectors as desired. In one
embodiment, socket series 100 provides a horizontal series of
sockets that are formed from a single piece of metal. Nail area 110
attaches to a roof underneath roofing shingles using standard
roofing nails. Socket series 100 also has support area 120 and
support area 130 that are at a predetermined angle relative to nail
area 110.
[0055] In one embodiment, the sockets are similar to a standard
light bulb socket, where the solar collector is screwed into the
socket, with integrated electrical connection provided at the
bottom of the socket and/or through the screw threads. In one
embodiment, the sockets are similar to 3-way light bulb sockets,
with multiple electrical connections provided at the bottom of each
socket.
[0056] In one embodiment, the socket includes an arrangement (for
example a protection plate that requires actuation through a slot
to push aside) that prevents people from being able to touch the
areas of active electricity within the socket.
[0057] In one embodiment, the socket includes both legs of a
standard residential power line and the neutral.
[0058] In one embodiment, electrical connection between the solar
collection module and the socket is provided inductively, through a
coupled AC or pulsed DC field.
[0059] FIG. 2 illustrates a top view of an exemplary socket,
according to another embodiment. Socket 200 has concentric threaded
areas that are electrically active but cannot be touched because
the gap needed to reach within the threads is too narrow for a
person's finger to fit within the socket 200. This reduces the risk
of shock.
[0060] In one embodiment, the sockets are manufactured as part of
the roof covering system, e.g., as part of the shingles.
[0061] In one embodiment, the sockets are separate from the
shingles, but are designed to install onto a shingled roof.
[0062] FIG. 3 illustrates an exemplary socket assembly, according
to one embodiment. Socket assembly 300 includes a socket 310 to
connect to a solar energy collector panel. Socket assembly 300 also
has a mounting flange 320 to connect the socket assembly 300 to a
roof.
[0063] Those skilled in the art will recognize that many
configurations of flanges are possible and that in fact different
style roofs (such as Spanish tile or slate) will require a
different flange. Those skilled in the art will recognize that
sockets without flanges will also be needed in some situations.
Throughout this application, reference to "socket assembly" is
meant to refer to any configuration of socket with or without any
possible flange or other mounting mechanism.
[0064] The mounting of the socket assemblies to the roof may
include but are not limited to the following techniques: [0065] a.
Holes and/or slots in a flange through which the socket assembly is
nailed or screwed to the roof [0066] b. A flange that is made of a
material (such as asphalt shingle material, plastic, or thin metal)
through which a nail or screw may be driven at an arbitrary
location. Installation may be performed by directly driving a nail
or screw through this flange, or by this flange becoming part of a
stack of materials that are captured by a nail or screw driven from
a layer that is above the flange (for example driven into a shingle
that is overlayed on top of this flange). [0067] c. A flange that
has bent edges that act as spikes to hold the socket assembly to
the roof. [0068] d. A flange that acts as a clip, for example
capturing the edge of a shingle by being appropriately bent. [0069]
e. A flange that has bends to conform to the material. For example
"Z" flashing is used to waterproof adjacent sheets of T-111 siding.
In some applications the same Z profile for the flange may be
desirable to allow roof or siding material to lay flat. Another
example is roofs with Spanish tile, which will require special
shaped flanges.
[0070] Embodiments of socket assembly 300 may be used for all forms
of roof including but not limited to asphalt shingle, architectural
shingle, metal, tar and gravel, rubber membrane, wood shingles and
shakes, tile, and slate. The mounting system is adapted to mimic
the mounting systems used for other items that attach to the
particular kind of roof. In one embodiment, glue-down sockets are
available for use on appropriate roofs (for example membrane
roofs). In one embodiment, flanges are designed to be embedded in
tar and gravel roofs. In one embodiment, a non-permanent
weight-based configuration is provided for use on flat roofs or
other flat surfaces such as lawns and decks.
[0071] In one embodiment, an embodiment of the socket assembly is
made for installation into existing roofs. This embodiment allows
it to slide under existing shingles and avoid existing nails and/or
provide a bend in the sheet metal that helps hold the socket
assembly in place.
[0072] FIG. 4 illustrates an exemplary socket assembly installed
into shingle roofs, according to one embodiment. Socket assembly
400 has flange 430 affixed to the roof (e.g., by screw or nail)
without affecting the weather tightness of the roof. The fastener
is protected by a shingle.
[0073] In one embodiment, socket assemblies are installed in
standard outlet boxes.
[0074] In one embodiment, socket assemblies are connected to each
other using horizontal spacers. In one embodiments, these spacers
are an integral part of the group of sockets. For example, the
socket assembly may come from the manufacturer as a set of 8
sockets interconnected horizontally by spacers. In one embodiment,
the spacers and socket assemblies are separate and are attached to
each other in custom configurations in the field.
[0075] In one embodiment, the horizontal spacer includes one or
more mounting flanges. In one embodiment, a mounting flange is
present in every location where a socket is present. In one
embodiment, a flange is present in a subset of the locations where
sockets are present or in places other than where sockets are
present.
[0076] In one embodiment, socket assemblies are connected to each
other using vertical spacers. In one embodiment, these spacers are
an integral part of a group of sockets. For example, the socket
assembly may come from the manufacturer as a set of 8 sockets
interconnected vertically by spacers. In one embodiment, these
spacers are attached to the socket assemblies in the field.
[0077] In one embodiment, vertical and/or horizontal spacers have a
lowered section on each end to allow one type of spacer to be above
the shingles, attaching to other components that are below the
shingles or at shingle level.
[0078] In one embodiment, socket assemblies are connected to each
other using both vertical and/or horizontal spacers. For example, a
group of 8 sockets could come as a unit of 4 sockets by 2 sockets
that are interconnected both vertically and horizontally. In one
embodiment, spacers may be installed in the field both horizontally
and vertically, such that any desired arrangement may be realized,
for example 4 wide by 2 high.
[0079] FIG. 5 illustrates an exemplary socket assembly having
vertical and horizontal spacers, according to one embodiment.
Socket assembly 500 includes horizontal spacer 520 and vertical
spacer 530 that attach to sockets 510 using connectors. Socket
assembly 500 enables the construction of regular grids of sockets,
where the sockets 510 are aligned both horizontally and
vertically.
[0080] In one embodiment, connectors for horizontal and/or vertical
spacers are at different heights to allow those in one direction to
go under the shingles and those in the other direction to be above
the shingles.
[0081] FIG. 6 illustrates an exemplary socket assembly for an
offset grid, according to one embodiment. In one embodiment,
connectors for horizontal spacers 620 are contained on one or both
sides of each socket 610. In addition, each socket 510 may have
connections for vertical spacers 630 that are on the top and/or the
bottom of each socket 610. In one embodiment, another vertical
connection is contained in one or both of the top and bottom of the
center of each horizontal spacer. This enables building an offset
grid, where each horizontal row is offset from the next.
[0082] FIG. 7A illustrates an exemplary installed socket assembly,
according to one embodiment. The socket assembly is installed on
top of roofing shingles 740. Horizontal spacers 720 ensure a
predetermined distance between sockets 710. Vertical spacers 730
may also be used. FIG. 7B illustrates installed socket assembly
with a second row of shingles, according to one embodiment. The
second row of shingles 750 is installed on top of the socket
assembly such that vertical spacers 730 are no longer visible.
[0083] FIG. 7C illustrates an exemplary installed socket assembly,
according to another embodiment. The socket assembly 780 is
installed on top of roofing shingles 740. Socket assembly 780 has
horizontal spacers 770 that ensure a predetermined distance between
sockets 710. Socket assembly 780 also has vertical spacers 760 may
also be used with connectors to mate with horizontal spacers 770.
Socket assembly 780 allows for the horizontal spacers 770 and
vertical spacers 760 to be concealed by the second row of shingles
750. Sockets 710 are accessible just below the edge of the second
row of shingles 750. In another embodiment, horizontal spacers act
as flashing to prevent the flow of water or direct the flow of
water. In another embodiment, the sockets 710 protrude between
slits 790 of the second row of shingles 740.
[0084] The socket assemblies illustrated in FIGS. 7A through 7C may
be pre-built, preconfigured units (for example 4 sockets in a row)
or field-installable configurable.
[0085] In one embodiment, some or all of the spacers also provide
an electrical interconnect function. This electrical
interconnection may include unidirectional or bidirectional power,
data, and/or control signals. In one embodiment, the electrical
connection is automatically made when the spacer is joined to its
mating piece (socket assembly or other spacer). In one embodiment,
this connection is watertight. In one embodiment, the location of
this connection falls within a space that is protected from
weather, such as under a shingle.
[0086] In one embodiment, the sockets are electrically connected in
parallel, so that the electrical current generated by solar
collectors attached to each socket is additive.
[0087] In one embodiment, the sockets are electrically connected in
series, so that the electrical voltage generated by solar
collectors attached to each socket is additive.
[0088] FIG. 7D illustrates a top view of a socket assembly 799,
according to one embodiment. Socket assembly 799 has raised areas
that are the mounting points for a solar panel. Connectors 792 and
794 accept horizontal extensions or may be directly connected to
another socket assembly 799. Socket assembly 799 also includes
electrical connector 791 for a solar panel. Flat area 793 fits
underneath a shingle and may be attached to a roof.
[0089] FIG. 8A illustrates an exemplary wiring diagram for
connections to a socket, according to one embodiment. A common wire
is connected to socket 805, left common connector 810 and right
common connector 811. The live connectors of socket 805 are
connected to each of right 814 and left 813 connectors. In one
embodiment, the sockets are electrically connected in a combination
of parallel and series. In one embodiment, wires are carried to
each socket to allow the configuration of parallel or series to be
made by the devices within the sockets.
[0090] FIG. 8B illustrates an exemplary wiring diagram of a socket,
according to one embodiment. Series socket 851 includes solar panel
853 between node 854 and node 855. Parallel socket 852 includes
circuit 860, which may be a solar panel, or may include both a
solar panel and an inverter, connected in parallel to node 861 and
node 862. In one embodiment, wiring of parallel and series is
determined by the geometric configuration, for example the system
is built such that horizontal interconnections are in series and
vertical interconnections are in parallel. In one embodiment,
wiring of parallel and series is determined by configuration of the
socket assembly. For example, the socket assembly has a switch to
determine parallel or series. Another embodiment, has multiple
connectors on the socket assembly, and parallel or series is
determined by which connector is used. Those skilled in the art
will recognize that other mechanisms could be used for determining
parallel versus serial.
[0091] In one embodiment, a material is embedded within or on top
of the socket assemblies and/or the spacers to hold down shingles
that are resting on top of said component. In one embodiment, this
material is heat-sensitive, activated by the heat and pressure from
the shingle above on a hot and/or sunny day.
[0092] In one embodiment, multiple sockets are built into the same
shingle and are electrically interconnected within the shingle.
[0093] In one embodiment, shingles that have built-in sockets
automatically interconnect to each other when installed on the
roof. The interconnection system includes both shingles that have
built-in sockets and shingles that act as horizontal and/or
vertical conduits for electrical connection between shingles that
contain sockets.
[0094] Those skilled in the art will recognize that any of the
interconnection schemes listed for socket assemblies apply equally
to sockets that are integrated into shingles.
[0095] In one embodiment, the socket assemblies are not attached
directly to the roof, but instead are attached to racks which in
turn are attached to the roof. In one embodiment, the sockets are
an integral part of the racks. In one embodiment, the racks are
pre-wired. In one embodiment, the racks are designed to swing
upward in whole or in sections to allow access to the underlying
roof and to make installation and maintenance of the solar
collection modules easier. The racks may take any of a number of
physical configurations, including but not limited to space frames
consisting of pipes, rods, plates, or solid platforms of wood,
plastic or other materials.
[0096] In one embodiment, fuses, fusible links, circuit breakers or
other overcurrent safety devices are included within the socket
assemblies and/or the spacers to provide overcurrent
protection.
[0097] In one embodiment, each solar collector modules directly
outputs the DC voltage generated by the solar photovoltaic cells
within that module. In one embodiment, the solar collector modules
output a DC voltage that is different from the DC voltage generated
by the solar photovoltaic system within the module, converted to
that voltage through the use of a DC to DC converter.
[0098] In one embodiment, the solar collector modules output AC
voltage that is converted from the DC voltage generated by the
solar photovoltaic system within the module. In a preferred
embodiment, the AC signal is generated within each module to
conform to the parameters and/or meet the safety standards
necessary for direct interconnection to the home's main circuit
panel, and through optional additional safety equipment, to the
grid. In other words, the functions (or a subset of the functions)
of a standard solar power inverter for use in a grid-connected
system is distributed and contained within the solar collection
modules.
[0099] In one embodiment, the functions (or a subset of the
functions) of other types of solar energy inverters, regulators,
converters, chargers, and/or any other type of electronics for use
with solar energy systems are distributed and contained within the
solar collection modules.
[0100] In one embodiment, the power from some solar collector
modules may be switched off by a physical or electronic switch
built into the module and/or the socket.
[0101] In one embodiment, safety features are present in solar
collection modules that eliminate their ability to generate
electricity unless they are properly installed and configured in a
working solar power system. This function is referred to as
"anti-islanding." In one embodiment, the solar collection modules
only put out power when a special control signal is present. This
signal may be (but is not limited to) a signal sent across the
network, and/or the presence of external power at the module
connection points.
[0102] In one embodiment, data is communicated between some or all
solar collection modules and other consumers or generators of data.
The consumers and generators of data may include but are not
limited to: [0103] a. Other solar collection modules on the same
roof [0104] b. A house controller that monitors and/or displays
and/or manages energy generation and/or consumption within the home
[0105] c. A gateway device that interfaces the solar collection
modules to another device, such as a device that provides an
internet connection [0106] d. PCs and any software on said PCs
[0107] e. Other embedded devices within the home, such as the
thermostat [0108] f. Information sources and/or providers on the
Internet, such as the local power generation company
[0109] In one embodiment, this data is used to perform one or more
of the following functions: [0110] a. Display data on energy
generation and/or usage [0111] b. Generate billing that takes into
account solar energy generation [0112] c. Monitor solar collectors
for proper functioning and/or isolate faults [0113] d. Confirm
proper installation of socket assemblies and/or solar collection
modules. [0114] e. Allow utility-scale load balancing [0115] f.
Allow load balancing within the home [0116] g. Reducing peak energy
usage by timing large electrical loads (such as air conditioner
startup) to occur only during high solar power generation [0117] h.
Provide a signal that is used to implement anti-islanding, wherein
the external device monitors the presence of external power, and
communicates the presence to the solar panels
[0118] In one embodiment, wires that are separate from power wires
are used to carry data to or from the socket and/or the device
plugged into the socket.
[0119] In one embodiment, wireless networking is used to carry data
to or from the socket and/or the device plugged into the
socket.
[0120] In one embodiment, carrier current technology, in which a
data signal is superimposed on the power wires, is used to carry
data to or from the socket and/or the device plugged into the
socket. In a preferred embodiment, Ethernet protocols are used with
this carrier current methodology.
[0121] In one embodiment, serial numbers are associated with each
solar collection module. In one embodiment, serial numbers are
associated with each socket. Socket serial numbers and module
serial numbers may or may not match. In one embodiment, serial
numbers are bar-coded (or coded using other machine-readable coding
system) on socket assemblies and/or on solar collection
modules.
[0122] In one embodiment, serial numbers may be queried by devices
on the network.
[0123] In one embodiment, devices within the network (for example,
other solar collection modules) note the existence of all serial
numbers as they are installed. In one embodiment, each device on
the network sends a periodic "I'm alive" signal indicating proper
functioning. In one embodiment, if any working device on the
network (such as another solar collection module) notes a fault
with any of the devices with serial numbers (the device reports
itself as faulty or stops its "I'm alive" signal altogether) the
working device may perform (but is not limited to) one or more of
the following actions: [0124] a. Sound an audible alarm [0125] b.
Provide a visual alarm (such as a flashing LED) [0126] c. Send a
network signal to a device on the network, or across the Internet
[0127] d. Send an e-mail [0128] e. Cause another device on the
network (such as the home thermostat or PC) to indicate the
fault
[0129] In one embodiment, other information is available across the
network connection. This information may include, but is not
limited to: [0130] a. Instantaneous power generated (volts and/or
amps) by the module [0131] b. Historical (average, histogram, power
versus time of day, etc.) power generated by the module [0132] c.
Frequency of power [0133] d. Faults
[0134] In one embodiment, information necessary for successful
interconnection to house power is provided via the data network to
the solar collection modules. This information could include but is
not limited to voltage, phase, and frequency information.
[0135] In one embodiment, information collected from the data
network is used to optimize solar power. For example, if modules in
one area of the roof receive reduced solar radiation at certain
times of the day relative to modules on other parts of the roof, a
message could be sent to the homeowner indicating that the
homeowner should check for trees or other obstacles that shade that
part of the roof during that part of the day.
[0136] In one embodiment, GPS technology is used to associate
particular sockets and/or solar collection modules with particular
physical locations on the roof.
[0137] In one embodiment, time-domain reflectometry is used to
create a topographical map of the sockets and/or the solar
collection modules. This map may be used (but is not limited) to
verify correct installation or monitor the system for wiring or
other faults.
[0138] FIG. 9 illustrates an exemplary jointed solar collector and
socket combination 900, according to one embodiment. Solar
collection module 910 contains a joint 911 that allows module 910
to be statically aimed at installation time in the best direction
for collecting sunlight.
[0139] In one embodiment, the solar collection modules are able to
track the sun for maximum efficiency. This tracking may either be
in one dimension (typically used for tracking sun position during
the course of the day) or in two dimensions (this allows for
tracking across the seasons as well).
[0140] In one embodiment, the tracking utilizes electronic
detectors for the position of the sun.
[0141] In one embodiment, the tracking utilizes bimetal strips that
are heated by the sun. Bimetal strips bend or straighten according
to their temperature. The strips are arranged such that the bending
of the strips due to heating changes the aim of the solar
collection module. The optics and geometry of the module is
designed such that heat from the sun deforms the strips so that
they keep the solar collection module aimed at the sun.
[0142] In one embodiment, tracking is based on a timer (time of
day) and/or a calendar. In one embodiment, time and/or date is
downloaded from a remote data source using the data communications
function described earlier.
[0143] In one embodiment, longitude, latitude, and baseline
orientation are determined using electronic sensors that measure
the position of the sun and compare it to date and time of day. In
one embodiment, a single solar collection module contains the
necessary sensors and uses the data network to tell other solar
collection modules the necessary information. This lowers system
cost since the sensor system need only exist in a single solar
collection module within an installation.
[0144] In one embodiment, solar collection modules use solar
concentration technology.
[0145] Those skilled in the art will recognize that the functional
division between the socket and the solar collection module is
arbitrary, and that any functions described as being within one may
be within the other and vice versa. Description in this patent of
any given function being within one does not mean this patent does
not apply if the system is configured for the function to be within
the other, and in particular this patent still applies if the
functions of the socket and the solar collection module are
integrated together.
[0146] In one embodiment, solar collection modules are available in
a number of different shapes, including but not limited to one or
more of square, triangle, trapezoid, hexagonal, and/or round
shapes.
[0147] FIG. 10A illustrates an exemplary flip-up solar collector
having one joint, according to one embodiment. Flip-up solar
collector 1000 connects physically to a socket 1010. Solar panel
1041 is connected to fixed member 1040 via joint 1020. FIG. 10B
illustrates an exemplary flip-up solar collector having two joints,
according to one embodiment. Flip-up solar collector 1050 connects
physically to a socket 1010. Solar panel 1051 is connected to a
moveable member 1060 via joint 1020. Moveable member 1060 is
connected to joint 1030, as well. In one embodiment, the top face
of the solar collection modules may flip up to facilitate
installation and/or roof maintenance.
[0148] In one embodiment, the sockets are connected to the home's
electrical system through an interface module. This interface
module provides (but is not limited to) one or more of the
following functions: [0149] a. Monitoring [0150] b. Safety (circuit
breaker, etc.) [0151] c. Inverter [0152] d. Capability to remotely
enable and/or disable the solar energy collection system through an
external signal, including (but not limited to) signals across the
network or through the cell phone network [0153] e.
Testing/verification [0154] f. Controlling other functions of the
system
[0155] In one embodiment, some or all of the functions on the
interface module are performed by units contained within the
following form factor(s): [0156] a. Separate enclosure [0157] b.
Same form factor as a circuit breaker within a standard electrical
panel [0158] c. Integrated into the solar collectors [0159] d.
Integrated into the socket assemblies, spacers, or other components
of the roof system [0160] e. Integrated into a conduit
[0161] In one embodiment, the interface module is located near the
house electrical panel and is wired to the socket assemblies using
a modular plug-together system that does not require an
electrician. In one embodiment, this interface module enclosure is
modular, and may be installed without some components. In this
embodiment these components may be added later. This is useful for
saving cost at installation time or eliminating the need for a
licensed electrician, since the components that are installed when
sockets are installed are mechanical (e.g., the enclosure) rather
than electrical.
[0162] In one embodiment, not all sockets are wired to each other
or to the house electrical service. These non-wired sockets provide
mechanical support to solar collection modules without providing
electrical connection. These non-wired sockets may or may not have
the same physical form factor and/or mounting system for the solar
collection modules as wired sockets. When non-wired sockets are
used, solar collection modules are interconnected to each other
externally from the sockets. In one embodiment, the solar
collection modules are interconnected to each other using a
physical interconnection scheme, which could involve (but is not
limited to) a mating connector or component that is used to attach
adjoining solar collection modules to each other. In one
embodiment, the solar collection modules are electrically
interconnected to each other using inductive techniques.
[0163] In one embodiment, a device is available that turns a single
socket into multiple sockets. For example, a device could be
available that screws into one socket and provides three sockets
with wiring and with the correct physical spacing. There is no
limitation on the number of sockets that may act as a mounting and
electrical connection point for this device and the number of
sockets provided. For example, a device may be constructed that
screws into 4 sockets that provides 8 sockets in an appropriately
spaced manner.
[0164] In one embodiment, solar collection modules are mechanically
interconnected to each other to enhance mounting rigidity. This
interconnection may take the form of physical interconnection (such
as a latch, a bolt, a screw, glue, sticky pad, etc.) or through
other means (such as magnetic).
[0165] In one embodiment, the socket assemblies contain mechanical
features that enhance the mechanical stability of the modules.
These features may include (but are not limited to) hold-down ties,
guy wires, cradle rests that limit rocking, outrigger structures
that the collectors rest on, pads, magnetic attachment points,
etc.
[0166] In one embodiment, other types of solar collectors are
attached to the socket system. In particular, standard rectangular
solar panels may be attached to a roof using any standard mounting
system and electrically attached to the home via a socket. In one
embodiment, adapter components are provided that allow flat panels
to be mounted mechanically on the socket system.
[0167] In one embodiment, unused sockets are covered by caps that
protect the socket and/or help the sockets blend into the roof.
[0168] In one embodiment, an indicator is included as part of the
socket, cap, and/or solar collector module, which indicates
successful interconnection to other sockets and/or to the house
electrical system. In a preferred embodiment, this indicator is
positioned on the socket and/or cap in such a way that it can be
seen from the ground below the roof. In a preferred embodiment,
this indicator is an LED, wired in series with a resistor to light
when the socket is provided with standard house voltage. In one
embodiment, this indicator is included on the solar panel.
[0169] In one embodiment, a device or feature is provided in the
interconnect system of the sockets to the house electrical system,
which allows an on-off sequence of house current to be applied to
the sockets. This enables flashing of socket or cap indicator
lights, which is useful for verifying proper installation of the
system. In one embodiment, this feature is included on the solar
panel.
[0170] In one embodiment, the sockets and/or the solar panel
assemblies include one or more display lights that are addressed
through the network. This, for example, enables the collectors to
become animated Christmas light displays that are controlled
through the network.
[0171] In one embodiment, the socket is formed by stamping two
pieces of sheet metal that are interconnected with insulating
material (such as a plastic shell). One piece of sheet metal is
stamped to form one connection of the socket and one pin for each
of the interconnection connectors, and the other piece of sheet
metal is stamped to form the other connection of the socket and the
second pin for each of the interconnection connectors.
[0172] In one embodiment, the sockets provide two-way water
connection instead of or in addition to electrical connection.
Interconnection of sockets includes all of the configurations
listed for electrical interconnection, but instead involves liquid
interconnection. The present system may be used for domestic space,
water, or swimming pool heating, potentially in combination with
electricity.
[0173] One embodiment has the following components: [0174] a.
Socket assembly with flange for 3-tab asphalt shingle roof,
including 2 flush horizontal and 2 raised vertical connections.
[0175] b. Horizontal spacers with integrated electrical wires
designed to be installed under shingles. These spacers include 2
raised vertical connections in the center. [0176] c. Vertical
spacers with integrated electrical wires. [0177] d. Round solar
photovoltaic collectors that screw into the sockets and have all
electronics necessary to interface to house electrical system built
in. These collectors also have carrier-current Ethernet capability
built in. [0178] e. Adapter that allows interface of vertical
spacer plug to standard waterproof conduit. [0179] f. Interface
unit that plugs into house's main breaker panel realized in the
form factor of a circuit breaker for that brand electrical panel.
[0180] g. Carrier current Ethernet adapter that can be plugged into
any outlet in the house and adapt carrier current Ethernet to
standard RJ-45 ethernet.
[0181] In one embodiment, the sockets and socket installation are
provided to the homeowner at a reduced price or for free in
exchange for the homeowner committing to use a particular brand
and/or type of solar collector and/or a particular vendor and/or
installer when solar collectors are installed on the house.
Fire Safety System
[0182] The present system relates to novel features and mechanisms
for improving the fire safety of roof-mounted solar electricity
generation systems and components, which include, but are not
limited to, photovoltaic panels and concentrating
photovoltaics.
[0183] Building mounted solar electricity generation (solar) is
greatly desired both by property owners and for the overall public
good created by clean, renewable solar power. There are many safety
related challenges associated with mounting solar panels on a
building. One challenge relates to the ability of fire safety and
emergency response personnel to quickly and easily access the areas
where the solar panels are mounted, without fear of inadvertent
contact with a live electrical line once the building's access to
an external electrical source (the grid) is disconnected.
[0184] In an emergency, fire safety or emergency response personnel
may be required to access the interior of the building through the
roof or to cut holes in the roof to allow heat and/or gasses to
escape. Currently, solar is mounted on rooftops in a way that
requires special tools, special knowledge and considerable time to
remove. Furthermore, individual collectors are connected in series,
and the DC output of the collector panels are fed through an
inverter that converts the DC output of the system to 60 Hz AC.
When the electrical connection to the building is turned off by
fire safety or emergency personnel during an emergency, the AC
output of the inverter is also stopped, but the DC output of the
solar panels and the DC side of the inverter are still live.
[0185] Today, if the fire safety or emergency response personnel
wish to cut through the roof of a building with solar panels,
either to gain access through the portion of roof under the solar
panels or to cut a hole without fear of electrocution due to
inadvertent contact with the live DC wiring, they are limited to
two options that allow quick access to the roof during an
emergency--(1) limiting the total area of allowable rooftop
coverage by solar panels through regulation or (2) simple avoidance
of any rooftop with solar panels mounted on it. Both of these
options are onerous to building owners. In the first option,
building owners are prevented from full use of their property, and
the overall availability of renewable energy generation options is
dramatically reduced. In the second, property owners are
effectively forced to make a choice between having access to clean
renewable energy or having access to the full range of available
emergency response services.
[0186] Thus, there is a strong need for improvements in the manner
in which solar is mounted to a rooftop and for improvements in the
electrical interconnection of the components of a rooftop solar
system. One area not specifically addressed by the prior systems is
the ability to quickly and effectively provide both the easy and
quick connection and disconnection of solar components to and from
the rooftop solar system.
[0187] Throughout this specification, reference is made to metal
beams. Those skilled in the art will recognize that metal beams are
common construction materials. A beam is a structural element that
is capable of withstanding load primarily by resisting bending.
Beams are characterized by their profile (the shape of their
cross-section), their length which is commonly much larger in the
dimension perpendicular to the cross section, and their material.
The terms beam and metal beam are used in exemplary manner and not
meant to limit the application of this invention.
[0188] For the purpose of this specification, beam profiles include
those commonly known to those skilled in the art and include, but
are not limited to, (1) 1-beams, (2) H-section beams, (3) wide
flange beams, (4) universal beams, (5) HSS-Shape (Hollow structural
section) or SHS (structural hollow section) beams, a term which
includes beams with square, rectangular, circular (pipe) and
elliptical cross sections, (6) Angle or L-shaped cross-section,
beams, (7) Channel or C-channel beams with a C-shaped
cross-section, (8) Tee or T-shaped cross-section beams, (9) Rail
profile or asymmetrical I-beams, including, but not limited to,
Railway rail, Vignoles rail, Grooved rail, Flanged T rail, (10)
Bars, (rectangular cross sectioned beams) (11) Rods (round or
square beams), (12) Open web joist and (13) proprietary beam shapes
such as uni-rail or uni-strut.
[0189] Beam materials include metals, alloys and materials in
common use as structural materials, including, but not limited to,
steel, aluminum, Carbon steel, Stainless steel, Maraging steel,
titanium and carbon fiber.
[0190] Existing methods and materials for mounting solar on
residential and small commercial roofs is both complicated and time
consuming. Typically installation requires a level of expertise
that demands special training and tools. Furthermore, the tools
required may be proprietary and specific to the particular brand of
mounting hardware. Removal of the solar panels from the roof
requires the same tools as installation and a similar amount of
time, which, at a minimum is measured in tens of minutes per panel.
However, in the event of a fire, a delay of even a minute in
gaining proper access or properly ventilating a building may result
in injury or even death.
[0191] Under existing methods and practices, no consideration is
provided for removal of solar system components such as, for
example, photovoltaic panels, by fire safety personnel. The
firefighter is required to break through the components, which
commonly are made of aluminum framed glass and silicon that can be
an inch or more thick with an axe in order to get to the roof under
the solar system components. The only other option is to simply
forego any attempt to penetrate the roof under the solar
system.
[0192] The present mounting systems for solar components such as
photovoltaic panels that include mechanical and/or electrical
connections for the components that can be quickly and easily
removed or moved without the need for special tools or training,
but which would require no tools or training other than those in
current common use by fire safety personnel.
[0193] In a preferred embodiment, the attachment of the solar
components to the roof includes a quick release device which
includes an easily visible handle, grip or latch, all of which are
hereafter referred to as "handles." The preferred embodiment
further provides a mechanism by which operation of the handle
causes the component to detach from the roof or mounting system or
weakens the attachment such that with a relatively small effort,
the components can be detached from the roof.
[0194] In the embodiment above, detachment refers to the breaking
of some or all points of attachment of the component to the roof or
to a roof mounting device, including, but not limited to (1) metal
beams supported by feet, flanges or stanchions, (2) metal feet,
flanges, stanchions or beams directly attached to the roof, (3)
metal brackets. For the purposes of this disclosure, any point of
attachment of the component that is broken by the release is
referred to as a "mounting point." Beams may include, but are not
limited to (1) I-beams, (2) H-section beams, (3) wide flange beams,
(4) universal beams, (5) HSS-Shape (Hollow structural section) or
SHS (structural hollow section) beams, a term which includes beams
with square, rectangular, circular (pipe) and elliptical cross
sections, (6) Angle or L-shaped cross-section, beams, (7) Channel
or C-channel beams with a C-shaped cross-section, (8) Tee or
T-shaped cross-section beams, (9) Rail profile or asymmetrical
I-beams, including, but not limited to, Railway rail, Vignoles
rail, Grooved rail, Flanged T rail, (10) Bars, (rectangular cross
sectioned beams) (11) Rods (round or square beams), (12) Open web
joist and (13) proprietary beam shapes such as uni-rail or
uni-strut. Furthermore, the term "metal" may include, but is not
limited to steel, aluminum, aluminum alloys, carbon steel,
stainless steel, maraging steel, titanium as well as plastics and
composite materials, such as delrin, polycarbonate, fiberglass, and
carbon fiber.
[0195] The action of the panel following release may include (1)
complete detachment of the component from all mounting points
thereby allowing the component to be lifted or thrown off the roof,
(2) detachment from one or more, but not all, mounting points,
allowing the component to hinge, pivot around or swivel around the
remaining mounting point or points, (3) detachment from one or
more, but not all, mounting points, allowing two or more components
to be folded together in such a manner as to allow access to the
roof under the components.
[0196] In an embodiment, two components detach from the mounting
points on adjacent sides of components connected by a spring or
hinge, and the remaining mounting point attachments on one
component are free to move horizontally. Horizontal pressure on the
detached components moves the hinge up and away from the roof.
[0197] In an embodiment, the action of the release handle
permanently distorts the attachment mechanism, such that the
component is free to move. By using the release handle, the
component, attachment brackets, and/or the release handle may
deform so that it can not be used again. An example of this would
be a brace that clamps a rail, including a handle that when
actuated permanently deforms the brace so that it no longer clamps
the rail.
[0198] In an embodiment the release handle is brightly colored and
visible from above the component. Furthermore the form of the
handle may be one of several known to those skilled in the art,
including, but not limited to, a latch, a wire pull, spring bar,
and trigger. The motion of the handle may be in the direction of
perpendicular to the surface of the component, in the vertical axis
of the roof and parallel to the surface of the component, in the
horizontal axis of the roof and parallel to the surface of the
component, a helical or twisting motion, or a combination two or
more of the above motions.
[0199] Rooftop solar components are required by law to be connected
by a continuous, low gauge (large diameter) conducting wire in
direct contact with the frame of the component for the purpose of
providing an electrical ground for the entire system. In a
preferred embodiment, the ground wire described above is held to
the solar component by a U-shaped washer that is designed to deform
and release the ground wire when sufficient force is applied.
[0200] Preferably, the aforementioned U-shaped washer has a
breaking strength between 75 and 5 pounds, more preferably between
50 and 25 pounds, most preferably between 37.5 and 27.5 pounds.
[0201] In a preferred embodiment, the point of contact for the
ground wire uses a copper washer, tab, via or other connector
crimped, welded or otherwise permanently affixed to the frame of
the component. Preferably, at the point of connection to the ground
wire, the copper connection has a breaking strength between 75 and
5 pounds, more preferably between 50 and 25 pounds, most preferably
between 37.5 and 27.5 pounds.
[0202] Solar electric generation systems require electrical
interconnection to transport power from the generating components
to the building electrical system. Adjacent components in a rooftop
solar system are most commonly connected by electrical wiring or
cables. Exposed connections between components are required by
regulation to have a breaking strength of not less than 35
pounds.
[0203] In a preferred embodiment, the electrical wiring, cabling or
interconnect incorporates a break-away connection on the underside
of the component. Preferably the break-away portion of the
connection has a breaking strength of not less than 20 pounds and
not more than 40 pounds.
[0204] In an embodiment, the electrical wiring, cabling or
interconnect incorporates a break-away connection where the
cabling, wiring or interconnect connects to the micro-inverter or
junction box on the underside of the panel. The break-away junction
consists of a pair of mated connectors. In one embodiment, the act
of utilizing the break-away junction of the electrical connectors
is "non-reversible," that is, the cabling, wiring or interconnect
cannot be reconnected without new parts, special expertise, special
tools or all three. In a preferred embodiment, the action of
utilizing the break-away junction of the electrical connection does
not break the connectors and following detachment, the cabling can
be reconnected without special tools, special expertise or
both.
[0205] In an embodiment, the electrical wiring, cabling or
interconnect incorporates a break-away connection where the
cabling, wiring or interconnect connects to the micro-inverter or
junction box on the underside of the panel. The wiring is held in
place by running it through a guide consisting of a slot, tab or
hole in the component frame. In a preferred embodiment, the guide
described above has a slot or hole with a thinner bottom edge than
the rest of the frame. Preferably, the thin section of frame around
the hole or slot has a breaking strength between 75 and 5 pounds,
more preferably between 50 and 25 pounds, most preferably between
37.5 and 27.5 pounds.
[0206] In an embodiment, the release mechanism may be a spring
mechanism, spring loaded latch, a direct latch to the mount point,
a structural element, such as a tab that is broken by the action of
the release handle, a rotating connection, or a screw mechanism.
The release mechanism may detach the component directly from the
mounting point or detach a portion of the component frame or
separate the component from a connector to the mounting point.
[0207] In an embodiment, the act of releasing or engaging a latch
physically severs the electrical connection, e.g. using a
knife-like arrangement. In an embodiment this latch is the same
latch that releases the solar component from its physical
mount.
Wiper/Fluid System
[0208] Dirt and grime can reduce solar panel output by 15 to 25%.
For small residential installations, cleaning services are only
marginally economically viable. Example, if each cleaning costs
$75, and a cleaning every 6 months improves average efficiency of a
5 kw system by 15%, if the value of electricity is 15 cents/kw-h,
the cleaning will result in $180/year of extra electricity, barely
exceeding the $150/yr cost of a cleaning service.
[0209] In one embodiment, a windshield wiper and fluid pump for the
solar panel clean it at either regular intervals (controlled by a
timer), or irregular intervals (controlled by a sensor, such as
dirt or rain, or by monitoring panel output for reduced efficiency,
possibly compared to internet-based sunlight data).
[0210] In one embodiment, wiper blade and fluid are replaceable by
the owner or a service company. The anticipated cost is a little
more than the cost of a normal cleaning ($75 per visit), but could
be over a much longer interval (amount of time wiper blade and
fluid lasts), perhaps 5 years, resulting in much better
economics.
[0211] In one embodiment, no physical wiper is present. Instead,
either a self-clearing fluid is sprayed onto the solar panel, or a
combination of air and fluid is sprayed onto the solar panel. The
air may be entrained in the fluid, or may be sprayed after the
fluid. These items may be sprayed from a fixed spray head, or from
a moving arm. There may be one or more nozzles.
[0212] In one embodiment, rainwater is collected by the system for
use in cleaning the solar panels. Rainwater that is collected is
mixed with detergent for cleaning the solar panel. The detergent
may be either solid or liquid.
[0213] In one embodiment, the fluid is contained within a
replaceable cartridge. In one embodiment, the fluid is contained
within a replaceable bag. In one embodiment, fluid is contained in
a refillable reservoir. In one embodiment, fluid containers are
interconnected between panels.
[0214] In one embodiment, a replaceable wiper blade includes an
integrated fluid container that includes enough fluid to last the
life of the wiper blade.
[0215] In one embodiment, the fluid nozzle is replaceable. The
nozzle may be integrated into the replaceable wiper and/or fluid
components described above.
[0216] In one embodiment, an air blower is incorporated, for
removal of large debris such as leaves.
[0217] In one embodiment, fluid reservoirs may be filled by
connecting to the building's existing water supply via pipe, hose
or other connection. In one embodiment, any water required for
operation of the device is directly taken from the building's
existing water supply via pipe, hose or other connection.
[0218] FIG. 11A illustrates an exemplary solar panel assembly with
a linear wiper, according to one embodiment. Solar panel assembly
1110 includes a solar panel 1101. A motor operates to move wiper
1102 in a linear motion to clean solar panel 1101.
[0219] FIG. 11B illustrates an exemplary solar panel assembly with
an arcing wiper, according to one embodiment. Solar panel assembly
1120 includes a solar panel 1101. A motor 1121 operates to rotate
wiper 1122 in a arcing motion to clean solar panel 1101.
[0220] FIG. 11C illustrates an exemplary solar panel assembly with
an arcing wiper with linkage, according to one embodiment. Solar
panel assembly 1130 includes a solar panel 1101. A motor 1131
operates to rotate linkage 1133. Linkage 1133 keeps wiper 1132
traveling at a predetermined angle across the face of solar panel
1101. Solar panel assembly 1130 has wiper 1132 and linkage 1133 at
both extremes of motion, at the top and bottom of solar panel
1132.
[0221] FIG. 11D illustrates an exemplary solar panel assembly with
an arcing wiper with linkage that follows a track, according to one
embodiment. Solar panel assembly 1140 includes a solar panel 1101.
A motor 1141 operates to rotate linkage 1143. Linkage 1143 in
combination with track 1144 keeps wiper 1142 traveling at a
predetermined angle across the face of solar panel 1101.
Wiring and Cabling System
[0222] FIG. 12 illustrates an exemplary solar system with adjacent
panels plugged together in a daisy chain fashion, according to one
embodiment. Solar system 1200 has solar panel assembly 1210
adjacent to solar panel assembly 1220. Solar panel assembly 1210
has a plug and socket 1231 that electrically connects to plug and
socket 1232 of solar panel assembly 1220.
[0223] The plug and sockets 1231 and 1232 may be male and female,
respectively, or they may be androgynous. Solar system 1200 has an
arrangement where the plug and socket 1231, 1232 are each connected
to a cable, but those skilled in the art will recognize that the
arrangement will work equally well if one side is a panel-mount
connection on the solar panel.
[0224] In one embodiment, the wires are spring-loaded, such that
when not connected, the plugs retract towards the solar panel.
[0225] In one embodiment, the wires 1240 are spring-loaded, such
that after connecting, the plugs 1231, 1232 retract towards the
solar panel collectors 1250, 1260.
[0226] FIG. 12B illustrates an exemplary solar system with
disconnected panels, according to one embodiment. In one
embodiment, solar system 1299 has plug and sockets 1231, 1232
disconnected. Sockets 1231, 1232 stick out from the solar panel
assemblies 1250, 1260 making identification of the sockets 1231,
1232 as well as handling of the sockets 1231, 1232 easier to
connect. The wires are retracted within solar panel assemblies
1250, 1260.
[0227] In one embodiment, when the wires are connected to each
other, they rotate 90 degrees, allowing them to be placed or
spring-retracted into a position below the solar panel.
[0228] Those skilled in the art will recognize that a full range of
wiring accessories can be made available and may be needed. These
include extension cords that allow solar panel assemblies that are
on different rows or are on different parts of the roof to be
connected, Y-connectors, gender changers, or special cables for
connection to the electrical panel.
[0229] In one embodiment, a cord connects to the electrical panel.
The cord has one end that has a connector that mates to the solar
panel assemblies, and another that has bare wires for connection
inside an electrical panel. In one embodiment, the cable is
shielded with rigid or flexible metal conduit, such that it meets
electrical code standards for outdoor wiring in an unprotected
location.
[0230] In one embodiment the connector system is hermaphroditic, in
which the same cable for connecting to the electrical panel may
connect to either connector on the solar panel assembly.
[0231] In one embodiment, connecting rows of solar panel assemblies
to each other requires no extension cable because the
fully-extended length of the cable from the solar panel is long
enough to reach from row to row.
[0232] The solar panel assemblies may be wired together in series
(which is used if the direct DC output of the panels is desired) or
in parallel (which is used if the panel power is internally
converted to AC or to some form of normalized DC). This electrical
system applies to both situations, although the schematic of wiring
is a little different for each.
[0233] FIG. 13 illustrates an exemplary solar system having solar
panels having both series and parallel connections, according to
one embodiment. Solar system 1300 has solar panel assemblies
1301-1305. Solar panel assembly 1301 and solar panel assembly 1302
have a series connection 1310. Solar panel assembly 1302 and solar
panel assembly 1304 have a parallel connection 1320. Thus, solar
panel assemblies group 1 and solar panel assemblies group 2 are
connected using parallel connection 1320. In one embodiment, two
separate connector systems are used, one for the series connection,
and another for the parallel connection. In this embodiment, groups
of solar panel assemblies are connected to each other in series,
and the groups of series connected panel assemblies are connected
together in parallel.
[0234] FIG. 14 illustrates an exemplary wiring diagram for a solar
system, according to one embodiment. Solar system 1400 has solar
panel assemblies 1401-1403. Each solar panel assembly 1401-1403 has
a solar cell 1410. Solar panel assemblies 1401-1403 are
electrically connected in a series configuration using connectors
1420. Connectors 1420 may be plug and sockets, as described above.
Solar panel assembly 1401 has an inverter 1430, whereas solar panel
assemblies 1402 and 1403 do not have inverters. Connector 1421 may
be shorted to complete the circuit of panels. In another
embodiment, inverter 1430 is switched to connector 1421 for
connection to the load through connector 1421. Connector 1422 is
automatically shorted when connector 1422 is unplugged.
[0235] In one embodiment, the same connector carries both the
series and the parallel connections. Solar panel assemblies that do
not have an inverter built in simply pass the parallel connection
through themselves.
[0236] The US national electrical code (NEC) requires solar panels
to have a "continuous ground." Many inspectors interpret this as
the need for an uncut ground wire to go from the electrical panel
or a ground rod to each of the solar panels (usually a single wire
snaking uncut from panel to panel through the entire group). In one
embodiment, the wire that goes from the set of solar panel
assemblies to the electrical panel includes a ground wire that
emerges from the connector that attaches to the solar panels. This
ground wire is long enough to snake around all of the solar panel
assemblies, each of which it is attached to.
[0237] For fire safety it is desirable that the solar panels be
easily removable. In one embodiment, the electrical cables are
breakaway, in that the panel assemblies' electrical cables will
break their connection if pulled apart.
[0238] In one embodiment, the ground wire will release from a solar
panel assembly when pulled with enough force. In one embodiment,
this is implemented by using a washer of a soft metal that is
compatible with electrical wiring (e.g. copper) to hold the wire to
the panel.
Practical Mechanical Configurations
[0239] FIG. 15 illustrates an exemplary mounting bracket, according
to one embodiment. Mounting bracket 1500 is a roof-mounted bracket
that accommodates expansion and contraction of the roof. Mounting
bracket 1500 includes expansion breaks 1510.
[0240] To make it easier to attach to the rafters on the roof, the
screw holes 1520 may be marked for easy periodic installation.
Examples include but are not limited to installation of a screw or
screws every 16 inches or 24 inches to match rafter spacing. In one
embodiment, screw holes 1520 are physically laid out in a
geometrically repeating pattern or a non-repeating pattern to make
the needed periodic installation easier.
[0241] Using such an arrangement, once one rafter is located all
subsequent rafters can be located simply by placing subsequent
screws in the right place. For example if rafters are on 16 inch
centers, and a screw placed in the third hole down entered a
rafter, a screw in the third hole down in a group that is four
groups to the right should also hit a rafter.
[0242] In one embodiment, an installation process involves: [0243]
a. Driving a screw into the hole that is likely to hit a rafter.
This may be based on the measurement of the distance from a
previous screw that hit a rafter, or by using a joist detector, or
any other methodology. [0244] b. Driving screws into the two
adjacent holes
[0245] This process guarantees that at least one of the three
screws in each group will hit the rafter as long as the rafters
meet the target spacing (16 inch or 24 inch on center) within a
tolerance of 1.5 inches. (Typical construction tolerances are 1/4''
for rough framing like rafters).
[0246] Mounting bracket 1500 also includes slots 1530 to avoid
having water or ice pool behind the bracket 1500. Slots 1530 allow
water to filter through bracket 1500.
[0247] FIG. 16 illustrates an exemplary solar system installed on a
roof, according to a preferred embodiment. Solar system 1600 has a
solar panel assembly 1610 mounted on roof 1601. Solar panel
assembly 1610 is attached to roof 1601 using upper bracket 1620 and
lower bracket 1630. The brackets 1620, 1630 are installed in
between rows of shingles. Solar panel assembly 1610 includes
electrical connectors 1640. Brackets 1620, 1630 are connected to
rafters 1660.
[0248] FIG. 17 illustrates an exemplary solar panel installation
using a lower bracket, according to one embodiment. Solar panel
assembly 1700 has solar panel 1710 attached to lower bracket 1720.
Bracket 1720 is attached to the roof and installed between rows of
shingles 1730 and 1740 such that the bracket-to-roof fasteners are
concealed and protected under the row of shingles 1740. Solar panel
1710 has bracket connection mechanism 1750 that has fingers 1751
that grab the bracket 1720 as the solar panel 1710 is rotated into
place.
[0249] FIG. 18A illustrates an exemplary solar panel installation
using a top bracket and latch, according to one embodiment. Solar
panel assembly 1800 has a solar panel 1810 attached to upper
bracket 1820 using latch mechanism 1860. Solar panel assembly 1800
also has an electrical connector 1821 that may be a plug and socket
as described above. Upper bracket 1820 is attached to the rafters
1870 using fasteners that are covered by a row of shingles 1840.
Latch mechanism 1860 is a quick release mechanism as described
above. Latch mechanism 1860 allows for firefighters to quickly
remove solar panel 1810 in case of an emergency without risk of
electrocution. Latch mechanism 1860 is easily identifiable with a
bright color to aid rescue workers.
[0250] FIG. 18B illustrates an exemplary latch mechanism attached
to an upper bracket, according to one embodiment. Latch assembly
1899 illustrates solar panel assembly without the solar panel and
other items that obscure the latch mechanism 1860. Latch mechanism
1860 has plate 1861 and plate 1862 that attach to bracket 1820.
Plate 1862 has a lip that mates with the lip of bracket 1820 to
lock solar panel 1810 securely in place.
[0251] FIG. 19 illustrates an exemplary plate of a latch mechanism,
according to one embodiment. Details of the actuation of plates
1861 are shown. Referring plate and bracket assembly 1900, latch B
pivots on pin A, which is rigidly attached to the solar panel
through a bracket that is not shown. Rotating latch B moves pin C
through an arc within slot F in the plate D. The arc-shaped motion
causes plate D to move forward and backward (up and down in the
illustration), allowing grasping and releasing of roof bracket E.
Plate 1862 is actuated in a similar manner in the opposite
direction.
[0252] The aforementioned latch system accommodates: [0253] a. The
roof not being co-planar at the top and bottom bracket. [0254] b.
Brackets that are not set perfectly parallel. [0255] c. Shingles
that have different exposure. Two exposure distances are in common
use: 5'' and 55/8'' between rows
Automatic Transfer Switch System
[0256] Grid-tied photovoltaic solar systems are required by
electrical safety regulations to discontinue generation of
electrical power when grid power is not available. This is to avoid
injection of electricity into wires that electric company repairmen
would expect to be unpowered.
[0257] During a daytime power failure it is desirable to utilize
the electricity generated by the domestic solar system. Generators
that are wired into the house introduce the same safety problems
that solar power during a blackout would. These generators are
required to be connected to the house using a transfer switch that
disconnects house loads from electricity from the utility company
to electricity generated by the generator.
[0258] Prior transfer switches are available as manual devices or
as automatic devices (that automatically switch during a power
failure). They are all bulky and relatively expensive to
install.
[0259] Often the desired load is a subset of the full house load.
For example, the refrigerator, well head, and sump pump may be
connected to the generator while the air conditioner, water heater,
etc. are not. Rewiring of the house electrical panel with the
possibility of an entire new electrical panel may be required to
achieve this.
[0260] Load transfer of solar power that does not include battery
backup is more complicated. Without battery backup, the solar
system is limited in instantaneous output to whatever power is
generated at the moment. The number of loads that can be handled
changes from moment to moment.
[0261] FIG. 20 illustrates an exemplary automatic power transfer
system, according to one embodiment. Power transfer system 2000 may
be incorporated into a standard home electrical panel 2030 having
main power and solar power inputs. Power transfer system 2000 has
an automatic transfer switch 2010 that switches between the main
power and solar power inputs. Automatic transfer switch 2010 may
also include a circuit breaker. Power transfer system 2000 has:
[0262] a. An automatic transfer switch 2010 In a preferred
embodiment it is form and function compatible with the main circuit
breaker module in the electrical panel, requiring an electrician to
merely switch out the original circuit breaker to this new circuit
breaker. [0263] b. Smart circuit breakers 2021-2023. These circuit
breakers include a communication path to the automatic transfer
switch 2010. During times of normal power, they operate as prior
circuit breakers, providing electricity to their load until and
unless overcurrent is detected. During transfer to solar power,
they would operate intelligently using control software. In a
preferred embodiment smart circuit breakers 2021-2023 have the
form, fit, and function of standard circuit breakers, allowing
installation by the electrician merely by switching out standard
circuit breakers for these special circuit breakers. [0264] c.
Control software. This software controls the smart circuit breakers
2021-2023. It includes priority settings (e.g. first priority is to
the sump pump, second priority to the well-head, third priority to
the refrigerator), through which it chooses which circuit breakers
to turn on and off. The smart circuit breakers 2021-2023 may
include a current measurement function in which they measure needed
power for their branch circuit, and the solar panels may include a
current measurement function in which it measures available power.
This control software would utilize this information to optimize
operation. (e.g. if the sump pump is first priority, but there is
not adequate power for it, redirect power to the refrigerator, for
which there is enough power).
[0265] The control software may include more sophisticated priority
settings. For example certain kinds of loads do not respond well to
quick power cycling (refrigerators and air conditioners). Other
types of loads may have high priority for a total amount of time,
but low priority to be on at any given moment (refrigerators fall
into this category--they will keep their contents cold as long as
they receive power 30% of the time, but which 30% of the time is
arbitrary).
Energy Monitor System
[0266] In one embodiment the present solar system has a
wall-mounted energy monitor display. Getting power and data to
existing systems requires expensive electrical retrofit work that
it would be desirable to avoid.
[0267] In one embodiment the energy monitor uses wireless data
(e.g. zigbee or Wifi) and battery power. In one embodiment,
adequate battery life is achieved by using a display that only
requires power during display changes (e.g. bistable displays), or
by using a touchscreen, motion detector, or other proximity
detector to enable the display. When the display is off, the
wireless data service may also be off.
[0268] In one embodiment, a display that only uses power when the
display changes is combined with a proximity detector. In this
embodiment, the display shows information that requires infrequent
refreshes (such as monthly power savings) when there is no
proximity, and shows real-time data updates when there is
proximity.
[0269] The sensor/control unit receives and displays data from the
solar system and/or from an internet-based data source, which may
include data such as electric rates, weather, etc. In one
embodiment, fusing and processing of data from the solar system and
the internet-based data source occurs within the home, eg. in the
sensor/control unit. In one embodiment fusing and processing of
data is performed remotely at a processing resource located on the
Internet.
Software System
[0270] According to one embodiment, software aids installation of
the present solar system. This software may include a web-based
application to show an animation of where the sun is over the
course of a day and how the shadows move on the roof of the house
of interest.
[0271] Data for this application may be from a combination of
satellite images (including images from straight above, as well as
from the south, west, and east), as well as direct measurements of
heights of items on the ground from distance sensing satellites
(using LIDAR).
[0272] In one embodiment, data from Google street view or other
similar mechanism is used to determine heights of trees and other
shadow-generating obstructions.
[0273] In one embodiment, image processing algorithms determine the
location of pipes and other obstructions on the roof which will
determine possible placement of solar panels.
[0274] In one embodiment, the placement of the panels is
automatically determined by analyzing shadow data combined with
pipes and other obstructions on the roof.
[0275] In one embodiment, the data is automatically fed into
modules that generate a solar system quote, as well as
automatically generating a building permit application for the
local community (layout of building permit may be database-driven
for the local community), as well as rebate application and
interconnect agreement (which may also be database driven for
format).
Packaging for Site Delivery
[0276] The present packaging is related to novel features and
mechanisms for packaging and delivery of roof-mounted solar
electricity generation systems and components, which include, but
are not limited to, photovoltaic panels and concentrating
photovoltaics, to the roof via conveyor belt, forklift, or lift
truck, which are common methods for delivery of robust roofing
materials such as nails and shingles.
[0277] Building mounted solar electricity generation (solar) is
greatly desired both by property owners and for the overall public
good created by clean, renewable solar power. There are many
challenges associated with mounting solar on a building. One
challenge relates to the ability to deliver the components and
systems to the areas where the solar is being physically mounted,
using tools and methods for delivery of less delicate materials,
such as shingles and nails, without fear of loss due to
breakage.
[0278] In most residential solar installations, the system
components, commonly solar panels or solar panel assemblies, are
deliver to the site in one of two ways--they are either delivered
by courier to site address and placed on the ground by the courier,
requiring the installation crew to manually move the components to
the roof, or they are delivered to the site address by the
installer and then either manually moved to the roof or placed on
the roof with a crane. A less common method for delivery of solar
systems and components is the use of a portable conveyor belt
system, because it is associated with rough handling and can easily
result in the breakage of expensive components due to the fact that
the packaging materials and methods in current use are designed for
delivery by courier. However, the conveyor belt delivery system is
growing in usage as the market for rooftop solar increases. Thus
new methods of packaging photovoltaic panels specifically designed
to use conveyor belt delivery systems are desired and needed.
[0279] In one embodiment, two or more solar panels or solar panel
assemblies are packaged together in such a way that the weight of
the package does not exceed 125 pounds for transport on the
conveyor belt. Preferably, the weight of the package does not
exceed 100 pounds. Most preferably, the weight of the package does
not exceed 75 pounds.
[0280] In one embodiment, two solar panels or solar panel
assemblies are packaged such that the faces of the panels exposed
to the sun under operating conditions (the upward face), for both
panels, are facing each other. In another embodiment, the downward
faces (the opposite side from the upward face) are facing each
other. In another embodiment, the panels all face the same
direction such that the upward face of one panel faces the downward
face of the next.
[0281] In one embodiment, a box can contain two or more solar
panels or solar panel assemblies. Preferably the box has a hinged
lid. Alternately lid may be completely detachable. In either
embodiment, the lid can be locked in place such that it can only be
opened with special tools, keys, code or combination.
[0282] In one embodiment, the box is no more than 52 inches wide in
one dimension parallel to the opening upon removal of the lid. More
preferably it is no longer than 48 inches in said dimension.
[0283] In one embodiment, the solar panels or solar panel
assemblies are inserted such that they lie in a plane parallel to
the opening formed upon removal of the lid. Preferably, in this
case, the solar panels or solar panel assemblies lie in a plane
[0284] In one embodiment, corner blocks are attached to the solar
panels or solar panel assemblies to allow rougher handling than
would otherwise be possible. These blocks may be made of expanded
foam type materials such as polystyrene, or may be made of
cellulose based materials, such as cardboard. These corner blocks
may be attached with adhesive tapes, straps, sleeves, or any other
method that guarantees secure attachment of the corner blocks.
These corner blocks may be internal or external to a box or other
wrapping or shipping materials.
[0285] In one embodiment, a delivery process involves: [0286] a.
Placing solar panels or solar panel assemblies onto a conveyer belt
at ground level [0287] b. Using the conveyer belt to carry the
solar panel or solar panel assemblies to the roof [0288] c.
Unloading the solar panels or solar panel assemblies from the
conveyer belt onto the roof
[0289] While particular embodiments and applications have been
illustrated and described herein, it is to be understood that the
invention is not limited to the precise construction and components
disclosed herein and that various modifications, changes, and
variations may be made in the arrangement, operation, and details
of the methods and apparatuses of the present embodiments without
departing from the spirit and scope of the invention.
* * * * *