U.S. patent application number 13/325054 was filed with the patent office on 2012-06-21 for discrete attachment point apparatus and system for photovoltaic arrays.
Invention is credited to Brian Atchley, John Raymond West, David Youmans.
Application Number | 20120152326 13/325054 |
Document ID | / |
Family ID | 46232745 |
Filed Date | 2012-06-21 |
United States Patent
Application |
20120152326 |
Kind Code |
A1 |
West; John Raymond ; et
al. |
June 21, 2012 |
Discrete Attachment Point Apparatus and System for Photovoltaic
Arrays
Abstract
An attachment point apparatus and system for photovoltaic arrays
is disclosed. One embodiment provides a rail system for receiving a
PV module, including a first rail, a second rail, a substantially
rectilinear double male connector adapted for coupling an end of
the first rail to an end of the second rail, and a connector
adapted to attach a PV module to the first rail. Another embodiment
provides a PV module including a PV laminate, a frame integral with
and supporting the PV laminate, and a spanner bar adapted to solely
span a width of the PV module, orthogonally connect at various
locations along the frame, and attach to a support structure. A
further embodiment provides a coupling device for a PV module
comprising a first coupling portion adapted to rotatably engage a
PV module, and a second coupling portion adapted to rotatably
engage a rail.
Inventors: |
West; John Raymond; (San
Rafael, CA) ; Youmans; David; (San Rafael, CA)
; Atchley; Brian; (San Rafael, CA) |
Family ID: |
46232745 |
Appl. No.: |
13/325054 |
Filed: |
December 13, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61422429 |
Dec 13, 2010 |
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61445044 |
Feb 22, 2011 |
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Current U.S.
Class: |
136/251 ;
403/164; 403/186 |
Current CPC
Class: |
F24S 2025/807 20180501;
F24S 25/632 20180501; Y10T 403/38 20150115; Y02E 10/50 20130101;
F24S 25/70 20180501; Y02B 10/10 20130101; H02S 20/23 20141201; F24S
2025/801 20180501; F24S 25/33 20180501; F24S 25/636 20180501; F24S
25/613 20180501; Y02B 10/20 20130101; F24S 25/65 20180501; Y02E
10/47 20130101; Y10T 403/32975 20150115 |
Class at
Publication: |
136/251 ;
403/186; 403/164 |
International
Class: |
H01L 31/048 20060101
H01L031/048; F16B 5/00 20060101 F16B005/00 |
Claims
1. A rail system for receiving a PV module, comprising: a first
rail; a second rail; a substantially rectilinear double male
connector adapted for coupling an end of said first rail to an end
of said second rail; and a connector adapted to attach a PV module
to said first rail.
2. The rail system for receiving a PV module of claim 1 wherein
said first and second rails are independently positionable relative
to said PV module and adapted for attachment to a support
structure.
3. The rail system for receiving a PV module of claim 1 wherein
said double male connector is locked to said first rail and freely
insertable into said second rail.
4. A PV module comprising: a PV laminate; a frame integral with and
supporting said PV laminate; and a spanner bar adapted to: (a)
solely span a width of said PV module, (b) orthogonally connect at
various locations along said frame, and (c) attach to a support
structure.
5. The PV module of claim 4 wherein said spanner bar rotatably
connects to said frame.
6. The PV module of claim 4 wherein said spanner bar connects to a
groove in said frame.
7. The PV module of claim 4 wherein said spanner bar pivotally
connects to a groove in said frame.
8. A PV module comprising: a PV laminate; a frame integral with and
supporting said PV laminate; and a spanner bar adapted to
orthogonally connect to various locations along said frame, and to
attach to a support structure, wherein a length of said spanner bar
is substantially an integer multiple of a width of said PV
module.
9. The PV module of claim 8 wherein said spanner bar rotatably
connects to said frame.
10. The PV module of claim 8 wherein said spanner bar connects to a
groove in said frame.
11. The PV module of claim 8 wherein said spanner bar pivotally
connects to said frame.
12. A coupling device for a PV module comprising: a first coupling
portion adapted to rotatably engage a PV module; and a second
coupling portion adapted to rotatably engage a rail.
13. The coupling device for a PV module of claim 12 wherein said
rail attaches said PV module to a support structure.
14. The coupling device for a PV module of claim 12 wherein said
second coupling portion is rotatable around a different axis of
rotation than said first coupling portion.
15. The coupling device for a PV module of claim 12 wherein said
second coupling portion axis of rotation is substantially
perpendicular to said first coupling portion axis of rotation.
16. The coupling device for a PV module of claim 12 wherein said
coupling device is height adjustable.
17. The coupling device for a PV module of claim 12 wherein said
second coupling portion engages said rail by rotation of more than
14 degrees and less than 360 degrees.
18. A PV module comprising: a PV laminate; a frame integral with
and supporting said PV laminate; and a coupling device; wherein
said coupling device comprises an upper engaging portion adapted to
rotatably engage said frame and a lower engaging portion adapted to
rotatably engage a rail.
19. The PV module of claim 18 wherein said rail attaches said PV
module to a support structure.
20. The PV module of claim 18 wherein said lower engaging portion
is rotatable around a different axis of rotation than said upper
engaging portion.
21. The PV module of claim 18 wherein said lower engaging portion
axis of rotation is substantially perpendicular to said upper
engaging portion axis of rotation.
22. The PV module of claim 18 wherein said coupling device is
height adjustable.
23. The PV module of claim 18 wherein said lower engaging portion
engages said rail by rotation of more than 14 degrees and less than
360 degrees.
Description
CROSS REFERENCES
[0001] The present application claims the benefit of the filing
date of U.S. Provisional Patent Application Ser. No. 61/422,429,
filed Dec. 13, 2010; and U.S. Provisional Patent Application Ser.
No. 61/445,044, filed Feb. 22, 2011. The foregoing applications are
incorporated by reference in their entirety as if fully set forth
herein.
BACKGROUND
[0002] Many photovoltaic (PV) arrays are mounted on structures that
require discrete attachment points. For example, tile and slate
roofs and various types of ground mounted structures may include a
support structure for a PV array that requires attachment of the PV
array to the structure at discrete locations in one of or both the
x and y axes of a PV array mounting plane. In the case of tile
roofs, this may be due to the difficulty of installing an
attachment device at anywhere other than a specific place relative
to the tile. For example, some tile products may only allow an
attachment device to be installed within a small range of the
overall reveal (length showing) of the tile and the underlying roof
may require attachment to the rafters, which typically runs on a
discrete schedule. Thus, locations for mounting along the y-axis
may be restricted as by the tile and locations for mounting along
the x-axis may be restricted as by the locations of the rafters.
Ground mount structures may also require discrete attachment points
in the x and/or y axes as may be due to fixed locations of the
structural members and/or the need to line up the structural
members with specific locations on the PV module.
[0003] Some attempts have been made to address the need for
discrete attachment point mounting systems. Most utilize long rails
to span between discrete attachment points, thereby freeing up the
x and/or y axes. The rails may be connected directly to the PV
module frame as by a compression clamp. The rails may be connected
to the support structure below as by means of an attachment device
such as a tile hook, standoff, hanger bolt, false tile, or mounting
foot.
[0004] Such conventional systems suffer from a number of drawbacks.
The long rails utilized, which can be often 10-20 feet long, may be
difficult to warehouse, ship, and move onto a roof, or other
support surface. These rails may also limit mounting options on
complicated roofs which may have numerous smaller roof surfaces
and/or numerous obstructions (such as vent pipes, chimneys, and so
on) since rails may need to be cut on site, potentially wasting
time and materials. Since rafters typically run in the direction
from ridge to gutter, conventional long rail systems may be less
cost-effective if the PV modules are oriented in "landscape" as
opposed to "portrait" manner, since rails parallel to the rafters
may require more total rail length or be prohibited, as by the PV
module manufacturer or local building codes.
[0005] The mounting technology used to connect PV modules to these
described long rails may also be cumbersome and time-consuming due
to large numbers of small parts, including fasteners. The
attachment devices utilized may also be expensive and
time-consuming to install. Such conventional systems may further
suffer from a lack of adaptability to uneven roof surfaces as well
as time-consuming and unreliable grounding hardware. There may also
be very little integration with other required equipment in the
overall PV system, such as electrical junction and combiner boxes,
wire management devices, and other equipment.
[0006] Prior discrete attachment point systems may frequently
require more attachment devices than needed for acceptable
structural performance of the system. For example, typical tile
roof mounting systems, which may not interconnect the rows, may
require two rows of rails per row of PV modules. This constraint
may limit the ability of a system designer to optimize the
structural support system so that the level of support provided is
substantially matched to the level of support required, based on
various site conditions such as wind, snow, roof structure, and so
on. Lack of structural optimization could waste a significant
quantity of materials relative to a more optimized approach.
[0007] The foregoing examples of the related art and limitations
related therewith are intended to be illustrative and not
exclusive. Other limitations of the related art will become
apparent to those of skill in the art upon a reading of the
specification and a study of the figures.
SUMMARY OF THE INVENTION
[0008] A discrete attachment point apparatus and system for
photovoltaic arrays is disclosed. The following embodiments and
aspects thereof are described and illustrated in conjunction with
systems, apparatus, tools, and methods which are meant to be
exemplary and illustrative, not limiting in scope. In various
embodiments, one or more of the above-described problems have been
reduced or eliminated, while other embodiments are directed to
other advantages or improvements.
[0009] One embodiment provides a rail system for receiving a PV
module, including a first rail, a second rail, a substantially
rectilinear double male connector adapted for coupling an end of
the first rail to an end of the second rail, and a connector
adapted to attach a PV module to the first rail. Another embodiment
provides a PV module including a PV laminate, a frame integral with
and supporting the PV laminate, and a spanner bar adapted to solely
span a width of the PV module, orthogonally connect at various
locations along the frame, and attach to a support structure. A
further embodiment provides a PV module including a PV laminate, a
frame integral with and supporting the PV laminate, and a spanner
bar adapted to orthogonally connect to various locations along the
frame, and to attach to a support structure, wherein a length of
the spanner bar is substantially an integer multiple of a width of
the PV module. Another embodiment provides a coupling device for a
PV module comprising a first coupling portion adapted to rotatably
engage a PV module, and a second coupling portion adapted to
rotatably engage a rail. A further embodiment provides a PV module
including a PV laminate, a frame integral with and supporting the
PV laminate, and a coupling device, wherein the coupling device
comprises an upper engaging portion adapted to rotatably engage the
frame and a lower engaging portion adapted to rotatably engage a
rail.
[0010] In addition to the exemplary aspects and embodiments
described above, further aspects and embodiments will become
apparent by reference to the figures and by study of the following
detailed descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Demonstrative embodiments are illustrated in referenced
figures and drawings. It is intended that the embodiments and
figures disclosed herein are to be considered illustrative rather
than restrictive.
[0012] FIG. 1A shows a perspective view of a PV array on a
roof.
[0013] FIG. 1B shows a perspective view of a portion of an array on
a roof
[0014] FIG. 1C is a perspective view of an interlock.
[0015] FIG. 2 is a perspective view of a PV module with a
skirt.
[0016] FIG. 3 shows a perspective view of a cam foot in contact
with a PV array over spanner bars.
[0017] FIG. 4 is a cutaway view of a spanner bar.
[0018] FIG. 5 is a perspective view of a cam foot inserted into a
cutaway spanner bar.
[0019] FIG. 6A and FIG. 6B is a perspective view of a cam foot.
[0020] FIGS. 7A and 7B is a perspective view of a cam foot inserted
into a spanner bar.
[0021] FIG. 8 is a perspective view of a spanner bar connected to a
tile hook.
[0022] FIG. 9A is a perspective view of two spanner bars with a
double male connector.
[0023] FIG. 9B is a perspective view of two spanner bars, which are
connected.
[0024] FIG. 9C is a perspective view of two spanner bars with a
double male connector.
[0025] FIG. 9D is a perspective view of two spanner bars, which are
connected.
[0026] FIG. 9E is a perspective view of a spanner bar with a double
male connector.
[0027] FIGS. 10A and 10B are side views of a skirt connecting to a
cam foot.
[0028] FIGS. 11A and 11B are side views of a cam foot connecting to
a skirt and a PV module.
[0029] FIG. 12 is a perspective view of a roof with tile hooks.
[0030] FIG. 13 is a perspective view of a roof with tile hooks and
spanner bars.
[0031] FIG. 14 is a perspective view of a roof with tile hooks and
spanner bars.
[0032] FIG. 15 is a perspective view of a roof with tile hooks and
spanner bars.
[0033] FIG. 16 is a perspective view of a roof with tile hooks and
spanner bars and skirts.
[0034] FIG. 17 is a perspective view of a roof with tile hooks,
spanner bars, and a PV modules.
[0035] FIG. 18A is a perspective view of two spanner bars each with
a double male connector.
[0036] FIG. 18B is a perspective view of two connected spanner
bars.
[0037] FIG. 18C is a perspective view of an enlargement of an end
of a spanner bar showing a double male connector.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Terms. With reference to the figure and description
herein:
[0039] Adjacent refers to being positioned next to or adjoining or
neighboring, or having a common vertex or common side. Thus,
adjacent PV panels would include PV panels that have one side close
to (from a few inches apart to abutting) and facing one side of
another PV panel, such as shown in FIGS. 1a and 20. Sometimes, but
not always, the corners of adjacent panels align; so four adjacent
panels would have one corner each that nearly or actually touch the
other three corners, such as exemplified at Point C in FIGS. 1a and
20, and its descriptions.
[0040] Attach or attachment refers to one or more items,
mechanisms, objects, things, structures or the like which are
joined, fastened, secured, affixed or connected to another item, or
the like in a permanent, removable, secured or non-permanent
manner. For example, a tile hook may be attached to a support
structure, such as a roof, as exemplified at tile hook 84 in FIG.
1a, and its descriptions. As another example, a PV module may be
attached to a support span as exemplified at cam foot 101 in FIG. 3
and its descriptions.
[0041] Auto-grounding or automatic grounding refers to electrically
connecting a device, equipment, chassis, frame, or the like to a
metal structure operates in a manner essentially independent of
external influence or control, or working by itself with little or
no direct human control, for ensuring a common electrical
potential; in some situations being connected to the Earth or a
large mass of conductive material which provides a position of zero
potential that. One such automatic grounding device is exemplified
as pin 115 in FIG. 6b, and its descriptions.
[0042] Axis of rotation refers to a center around which something
rotates, sometimes considered a straight line through all fixed
points of a rotating rigid body around which all other points of
the body move in a circular manner. Some exemplar axis of rotations
for coupling portions are exemplified at Point A in FIG. 3, along
with related descriptions.
[0043] Bracket refers to a simple, essentially rigid structure in
the general shape of an L, one arm of which extends approximately
70-110 (often close to 90) degrees from the other arm. A Bracket is
often an overhanging member that projects from a structure (such as
a portion of a wall or frame) and may be designed to support a load
with a vertical component, such as a skirt. A bracket may also
refer to a fixture projecting from a wall, column, frame or the
like which may be used for holding, securing, positioning or
supporting another object. One such bracket attaching a groove to a
support span is exemplified as cam foot 101 in FIG. 3, and its
descriptions. As another example, a bracket attaching a PV module
to a support span is exemplified as cam foot 101 in FIG. 11a, and
its descriptions.
[0044] Connect or connecting refers to bringing together or into
contact with or joining or fastening to form a link or association
between two or more items, mechanisms, objects, things, structures
or the like. For example, a spanner bar connected to another
spanner bar may be exemplified at splice 118 in FIG. 9a, and its
descriptions. For another example, a spanner bar connected to a
groove in a PV module frame may be exemplified at cam foot 101 in
FIG. 11b, and its descriptions. For an additional example, a
spanner bar connected to a tile hook may be exemplified at clamp
103 in FIG. 8, and its descriptions.
[0045] Connector refers to an object, item, mechanism, apparatus,
combination, feature, link or the like that links, joins, unites or
fastens two or more things together. May also include a device, an
object, item, mechanism, apparatus, combination, feature, link or
the like for keeping two parts of an electric or electronic circuit
in contact. For example, a connector for connecting or coupling the
end of one rail to an end of rail may be exemplified at splice 118
in FIG. 9a and its descriptions.
[0046] Couple refers to joining, linking, connecting or mating two
or more objects or items, mechanisms, objects, things, structures
or the like together. For example, two modules may be coupled
together, as exemplified at interlock 45 in FIG. 30, and its
descriptions.
[0047] Coupling refers to an object, item, mechanism, apparatus,
combination, feature, link or the like that joins, links, mates or
connects two things together. For example, a two rails may be
coupled together by a coupling device, as exemplified at interlock
45 in FIG. 30, and its descriptions.
[0048] Double male connector refers to a connector (see above)
having two male or insertable members, usually used for connecting
two female or receiving coupling members together. An example
double male connector may be exemplified at splice 118 in FIG. 9a,
and its descriptions.
[0049] Disengage refers to detaching, freeing, loosening,
extricating, separating or releasing from something that
holds-fast, connects, couples or entangles. See Engagement
below.
[0050] End refers to a final part, termination, extent or extremity
of an object, item, mechanism, apparatus, combination, feature, or
the like that has a length. For example, an end of a rail may be
exemplified at Location E in FIG. 7a, and its descriptions.
[0051] Engage refers to interlocking or meshing or more items,
mechanisms, objects, things, structures or the like. See Disengage
above.
[0052] Frame refers to an essentially rigid structure that
surrounds or encloses a periphery of an item, object, mechanism,
apparatus, combination, feature, or the like. For example, a PV
module may have a frame around its edges as exemplified at frame 23
in FIG. 3, and its descriptions.
[0053] Freely refers to being without or exempt from substantial
restriction or interference by a given condition or circumstance.
May also refer to being unobstructed, unconstrained, unrestricted
or not being subject to external restraint. For example, double
male connector which is locked to a rail and freely insertable into
another rail may be exemplified at Location F in FIG. 9a, and its
descriptions.
[0054] Groove refers to a long, narrow cut, rut, indentation,
channel, furrow, gutter, slot or depression often used to guide
motion or receive a corresponding ridge or tongue. Some grooves in
the frame wall of a PV module are exemplified at Area G in FIG. 2,
and its descriptions.
[0055] Height adjustable refers to change or adapt to bring items,
objects, mechanisms, apparatus, combinations, features, components
or the like into a proper, desired or preferred relationship of a
distance or elevation above a recognized level, such as the ground
or a support surface. Some height adjustable devices are
exemplified at Area H in FIG. 5, and its descriptions.
[0056] Insertable refers to an object, item, mechanism, apparatus,
combination, feature, link or the like which is capable of being
put in, entered into, set within, introduced, inset, inserted,
placed, fit or thrust into another an object, item, mechanism,
apparatus, combination, feature, link or the like. An example
double male connector which may be insertable into a support span
is exemplified at splice 118 in FIG. 9a, and its descriptions.
[0057] Integer multiple refers to a product of any quantity and a
member of the set of positive whole numbers {1, 2, 3, . . . }. An
integer multiple of a width of said PV module may actually be
somewhat longer or shorter than the absolute width of the PV
module, so as to permit or facilitate connection to a PV module, as
by attachment to one or more frame members of a PV module, as may
be exemplified at Area I in FIG. 1a, and its descriptions.
[0058] Integral with refers to being essential or necessary for
completeness, constituent, completing, containing, entire, or
forming a unit. May also refer to consisting or composed of parts
that together constitute a whole. An example frame integral with
& supporting a PV laminate is exemplified at frame 23 in FIG.
3, and its descriptions.
[0059] Length refers to the measurement or extent of an object,
item, mechanism, apparatus, combination, feature, link or the like
from end to end, usually along the greater or longer of the two or
three dimensions of the body; in distinction from breadth or width.
An example of a length of a spanner bar is exemplified at Notation
L in FIG. 8, and its descriptions.
[0060] Locked refers to fastened, secured or interlocked. An
example double male connector locked to a support span may be
exemplified at Location K in FIG. 9c, and its descriptions.
[0061] Orthogonally refers to relating to or composed of right
angles, perpendicular or having perpendicular slopes or tangents at
a point of intersection. An example spanner bar orthogonally
connected to one of various locations along a PV module frame is
exemplified at cam foot 101 in FIG. 3, and its descriptions.
[0062] Perimeter refers to an essentially continuous line forming
the boundary, periphery or circuit of a closed geometric figure;
the outer limits of an area. An example perimeter of a PV laminate
surrounded by a frame is exemplified at frame 23 in FIG. 1a, and
its descriptions.
[0063] Pivotally refers to or relates to an object, item,
mechanism, apparatus, combination, feature, link or the like
serving as a pivot or the central point, pin, shaft or contact on
which another object, item, mechanism, apparatus, combination,
feature, link or the like turns, swings, rotates or oscillates. An
example spanner bar pivotally connected to a PV module frame is
exemplified at spanner bar coupling 302 in FIG. 23, and its
descriptions.
[0064] Positionable refers to an object, item, mechanism,
apparatus, combination, feature, link or the like which is capable
of being positioned, placed or arranged in a particular place or
way. An example of rails which are independently positionable
relative to a PV module are exemplified at span bar 102 in FIG. 3,
and their descriptions.
[0065] PV laminate refers to a photovoltaic device having an
interconnected assembly of solar cells, also known as photovoltaic
cells which is frequently, but not always, laminated with glass
and/or other materials. A PV laminate with an integral frame which
may support the PV laminate is sometimes referred to as a PV module
(see below). An example PV laminate is exemplified at laminate 300
in FIG. 1a, and its descriptions.
[0066] PV module refers to a photovoltaic module (sometimes
referred to as a solar panel or photovoltaic panel) is a packaged
interconnected assembly of solar cells, also known as photovoltaic
cells, frequently, but not always, laminated with glass and other
materials and sometimes surrounded by a frame. A plurality of PV
modules are commonly used to form a larger photovoltaic system
referred to as a PV array (see below), to provide electricity for
commercial, industrial and residential applications. An example PV
module is exemplified at module 10 in FIG. 1a, and its
descriptions.
[0067] PV array refers to s plurality of photovoltaic modules (see
above) connected together often in a pattern of rows and columns
with module sides placed close to or touching other modules. An
example PV array is exemplified at array 81 in FIG. 1a, and its
descriptions.
[0068] Quarter turn or 1/4 turn refers to an angle of rotation of
an object, item, mechanism, apparatus, combination, feature, link
or the like which is usually measured in degrees or radians having
a range of between approximately 70 to 110 degrees, or sometimes
between 80 to 100 degrees. An example of a coupling receiving a 1/4
turn when connecting to a rail is shown or described at cam foot
101 in FIG. 3, and its descriptions.
[0069] Rail refers to refers to a relatively straight, usually
essentially evenly shaped along its length, rod, beam, girder,
profile or structural member or the like, or plurality of such, of
essentially rigid material used as a fastener, support, barrier, or
structural or mechanical member. For example, a two rails coupled
together by a coupling device are exemplified at span bar 102 in
FIG. 23, and its descriptions.
[0070] Removeable refers to one or more items, mechanisms, objects,
things, structures or the like which are capable of being removed,
detached, dismounted from or taken-away from another item or the
like, or combination.
[0071] Rectilinear refers to one or more items, mechanisms,
objects, things, structures or the like which are essentially
bounded by, characterized by or forming a straight line. An example
rectilinear double male connector may be exemplified at splice 118
in FIG. 9a, and its descriptions.
[0072] Rigidly couples refers to joining, linking, connecting or
mating two or more objects or items, mechanisms, objects, things,
components, structures or the like together in a non-flexible
manner that is difficult to bend or be forced out of shape. For
example, two span bars may be rigidly coupled together, as
exemplified at splice 118 in FIG. 9a, and its descriptions.
[0073] Roof refers to a structure or protective covering that
covers or forms the upper covering or top of a building. The upper
surface of a roof is often used as a support surface for mounting,
connecting or otherwise attaching a PV module or a PV array. For
example, some roofs are exemplified at Roof 83 in FIG. 1a, and its
descriptions.
[0074] Rotatably refers to one or more items, mechanisms, objects,
things, structures or the like which are capable of being rotated,
revolved or turned around or about an axis or center. For example,
a portion of a coupling adapted to rotatably engage a PV module is
exemplified at coupling 107 in FIG. 3, and its descriptions.
[0075] Skirt refers to an edging, molding or covering that may be
fixed to the edge of a PV module to conceal or block the bottom
area under a PV array when the PV array is mounted to a support
surface. Some skirts are exemplified at skirt 104 in FIG. 10a, and
its descriptions.
[0076] Span refers to an extent or measure of space between, or the
distance between two points or extremities. For example, a spanner
bar which solely spans a width of a PV module is exemplified at
span bar 102 in FIG. 10a, and its descriptions.
[0077] Spanner bar refers to a relatively straight, usually evenly
shaped along its length, rod, beam, girder, profile or structural
member of essentially rigid material used as a fastener, support,
barrier, or structural or mechanical member which spans a distance
between an edge of a PV module and an attachment device, such as a
tile hook, stand-off, hanger bolt or the like. For example, a
spanner bar which spans a width of a PV module is exemplified at
span bar 102 in FIG. 10a, and its descriptions.
[0078] Support or supporting refers to one or more items,
mechanisms, objects, things, structures or the like which are
capable of bearing weight or other force, often to keep the item or
the like from falling, sinking, slipping or otherwise moving out of
a position. For example, a frame which is shown as integral with
and supporting a PV laminate is exemplified at frame 23 in FIG. 2,
and its descriptions.
[0079] Support structure refers to a structure, such as a roof,
table or the ground which may provide a base for securing PV
modules to form a PV array. Some support surfaces are exemplified
at roof 83 in FIG. 1a, and its descriptions.
[0080] Threaded refers to one or more items, mechanisms, objects,
things, structures or the like which have, embody or include an
essentially helical or spiral ridge or rib, as on a screw, nut, or
bolt. An example of a threaded adjustment member for varying
distance between a point on module and a rail may be exemplified at
threaded stud 113 in FIG. 5, and its descriptions.
[0081] Various locations refers to places, positions or sites that
are different from one another, more than one, individual or
separate. For example, a spanner bar which may connect at various
locations along a frame of a PV module is exemplified at span bar
102 in FIG. 3, and its descriptions.
[0082] Vertical height adjustment refers to change or adapt to
bring items, mechanisms, objects, things, components, structures or
the like or components into a proper, desired or preferred
relationship of a distance or elevation above a recognized level,
such as the ground or a support surface. Some vertical height
adjustment devices are exemplified at Area J in FIG. 5, and its
descriptions.
[0083] Width refers to the state, quality, or fact of being wide or
a measurement or extent of something from side to side; in
distinction from breadth or length. For example, a spanner bar
which spans a width of a PV module is exemplified at span bar 102
in FIG. 3, and its descriptions.
[0084] Referring now to FIG. 1A, there is shown a perspective view
of a PV array including a plurality of PV modules 100 laid out in
an x-y reference plane on a roof or support structure 81 such as a
roof. PV modules 100 are shown in various Figs. with an integral
frame 23 and as being faced with clear glass instead of a typical
PV laminate with encapsulated PV cells in order to enable a view
beneath PV modules 100 that reveals the mounting system hardware.
One skilled in the art will recognize that PV modules 100 may
comprise various types and numbers of PV cells. FIG. 1A also shows
typical roofing tiles, such as tiles 82 and typical batons such as
batons 83. Other types and forms of batons and tiles are hereby
expressly contemplated, such as roofing materials that are flat
tiles, rolled-on or other flat or shaped materials. Various tiles
82 are shown in the Figs. only partially covering support structure
81 in order to enable a more complete view of support structure 81
and hardware beneath tiles 82. Support structure 81 is herein shown
as including a generally planar surface, however it may be a
structure with thickness, width, depth, length and/or other
dimension(s). In reference to any appropriate mounting structure,
such as support structure 81, the height adjustment of a coupling
described hereinafter is considered relative to any essential
surface or essential plane, such as a top surface. For ease of
understanding this embodiment, a y-direction corresponds to the
north-south dimension of the array, and an x-direction corresponds
to the east-west direction. In the embodiment of FIG. 1A, the
reference plane is effected as being coextensive with a surface of
various PV modules 10, when PV modules 100 are positioned in their
final installed positions. However, in further and various other
embodiments, some of which are illustrated below, a reference plane
may be above an upper surface of PV modules 10, or below the lower
surfaces of PV modules 100.
[0085] A PV array 80 may be assembled together and attached to
support structure 81 as by means of a discrete attachment point
mounting system, which may comprise any or many of: cam feet,
spanner bars, array skirts, double-tongue feet, brackets, feet,
leveling feet, interlocks, parallel couplings, double-key
couplings, key couplings and/or the like, some of which are
explained in more detail below. Other components may be coupled to
array 80 such as for example a grounding coupling, also further
explained below. The PV array 80 of FIG. 1A is shown by way of
example only. It is understood that PV array 80 may have more or
less PV modules 100, such as in the x and/or y direction. In the
embodiment shown in FIG. 1A, the support structure 81 may be a
roof, such as a slanted roof of a residential dwelling or the like.
However, it is understood that the PV array 80 may be supported on
a wide variety of other support surfaces, such as for example a
flat roof, a ground-mounted structure, a vertical support
structure, or other structures which are understood by one of skill
in the art. The defined x-y reference plane for the PV array 80 is
substantially parallel to support structure 81, and may be oriented
in any of a wide variety of angles from horizontal to vertical. In
other embodiments an x-y reference plane may be at an angle to
support structure 81.
[0086] FIG. 1A further shows a series of tile hooks 84 attached to
rafters 85 in any usual manner, such as with a lag screw (not
shown) or the like. Tiles 82 are connected to battens 83 in any
reasonable or usual manner. As seen on the right side of FIG. 1A,
tile hooks 84 may slip between tiles 82 at approximately the low
point of curved tile 82 profile. The exposed y-axis length,
commonly referred to as a "reveal", of one or more tiles 82 may set
a distance A between available discrete attachment points in the
y-axis; and rafter location may set a distance B between available
discrete attachment points along the x-axis. Therefore PV array 80
may be said to comprise discrete, rather than continuous,
attachment points.
[0087] FIG. 1B shows PV array 80 from a perspective up-roof from PV
array 80 and shows an installed interlocking device, such as
interlock 95, which may provide a structural and ground bond
connection between PV modules 100 at PV module 100 corner
locations. Interlocks are discussed in further detail below.
[0088] FIG. 1C shows interlock 95 which provides both X and Y axis
structural and ground bond connections. Interlock 95 may be
installed by inserting into frame grooves 11A and rotating frame
coupling components 45A roughly 90 degrees. It is specifically
contemplated that interlock 95 may be made of aluminum and steel,
but other reasonably rigid materials, such as other metals or
plastics, may be suitable as well.
[0089] FIG. 2 shows a side view of a photovoltaic module, such as
PV module 100. As shown, attached to PV module 100 is a connector,
such as a cam foot 101. As will be discussed in more detail below,
cam foot 101 pivots into a groove of a PV module 100 frame 23, such
as frame groove 105. Cam foot 101 is also connected, as by a cam
nut 111, to an underlying support, such as a spanner bar 102, as
discussed in greater detail below. As described in more detail
below, cam foot 101 may also be connected to a skirt or other
visual blocking or fire limiting device, such as an array skirt
104, and may connect array skirt 104 to PV module 100. Spanner Bar
102 may be coupled or otherwise connected to adjacent Spanner Bar
102a, as by way of a press-fit, slip fit, or other connection as
discussed further below. Spanner Bar 102 may also be inserted
through a clamp, such as bar clamp 103, as shown in FIG. 2, the
function of which will be described further below. It is
specifically contemplated that frame 23 of PV module 100 may be
made of aluminum, but other reasonably rigid materials, such as
other metals or plastics, may be suitable as well. It is also
contemplated that cam foot 101, spanner bar 102, bar clamp 103, and
array skirt 104 may be made of aluminum, steel, or a combination
thereof, but other reasonably rigid materials, such as other metals
or plastics, may be suitable as well.
[0090] FIG. 3 shows cam foot 101 with a short tongue side, such as
short tongue side 106, and a long tongue side, such as long tongue
side 107. Also shown is a hump on the lower side of short tongue
side 106, such as hump 108. Short side tongue 106 of cam foot 101
is shown connecting to a frame groove, such as frame groove 105 by
means or way of a pivot-fit. A fully engaged home position of cam
foot 101 may be defined by a slight rise 131 in the curved portion
of hump 108. Slight rise 131 may provide resistance to forces that
would tend to rotate cam foot 101 back out of engagement with frame
23. In the shown embodiment of FIG. 3, installation may be
tool-free, that is, installation of PV array 80 of PV modules 100
may be effected without using mechanical or electrical tools. The
installation of cam foot 101 into frame groove 105 provides a
rapid, tool-free (in some embodiments), auto-grounding (in some
embodiments), means or system for adjustably connecting cam foot
101 to PV module 100. Cam foot 101 is adjustable in the x-axis as
by variably attaching to frame groove 105 to line up with rafter 85
or location of attachment, such as a tile hook, as further
described below. As described below, cam foot 101 may further
provide pivot-fit or drop-in connections to up-roof modules. In
other embodiments, cam foot 101 may connect to frame groove 105 via
a 1/4 turn key-in and may require a tool. Other embodiments
discussed below may also provide auto-grounding connections; for
example whereby a stainless steel pin (not shown here) in short
tongue side 106 may pierce frame 23 to create a ground bond
connection.
[0091] FIG. 4 shows a cross-sectional view of spanner bar 102 and a
groove feature such as spanner groove 109. Spanner groove 109 may
comprise upper key slots 142, 143, lower key slots 144, 145, and
lips 146, 147. In some embodiments a shape of an upper portion of
spanner groove 109 may be substantially similar to a shape of frame
groove 105, thereby enabling compatible equipment, such as such as
spring clips for retaining wires, snap-in electrical boxes, PV
module electronic devices, and so on, to be capable of connecting
to both frame groove 105 and spanner groove 109.
[0092] FIG. 5 shows cam foot 101 installed in spanner groove 109.
Also shown are various sub-components of cam foot 101. A cup point
or cone point bonding feature may be provided, such as cone point
110, which is shown in FIG. 5 as contacting a bottom surface of
spanner groove 109. The connection between cone point 110 and
spanner groove 109 may be accomplished by compression (see below)
which causes cone point 110 to cut into spanner bar 102 to create a
ground bond connection. A cam nut, such as cam nut 111, is shown
partially inserted into spanner groove 109. A camming surface, such
as camming surface 112, is shown engaged in spanner groove 109. Cam
nut 111 and camming surface 112 will be described in more detail
below. A threaded stud, such as stud 113, may be rotatably captured
by cam nut 111 at a first end and threaded into coupling such as
double tongue coupling 114 at a second end. Stud 113 causes
coupling 114 to fall and rise in the z-axis when stud 113 is
rotated clockwise and counter-clockwise respectively. In another
embodiment (not shown), the direction of rotation of stud 113 will
cause coupling 114 to rise and fall when stud 113 is rotated
clockwise and counter-clockwise respectively. Such rotation may
provide a simple mechanism to enable rapid height adjustment of PV
module 100, and other height adjustment mechanisms, such as
ratchets or other devices, are hereby expressly contemplated.
[0093] FIG. 6a and FIG. 6b show another embodiment whereby a metal
pin, such as pin 115, may be installed in short tongue side 106 of
cam foot 101 and may create a ground bond connection between
coupling 114 and PV module 100 groove 105 by cutting into module
groove 105. FIG. 6a shows pin 115 protruding from a bottom side of
short tongue 106; and FIG. 6b shows pin 115 protruding from a top
side of short tongue 106. In other embodiments pin 115 only
protrudes from either the top or bottom of short tongue 106. In
combination with the grounding action of cone point 110 (see
above), the grounding action of pin 115 may create a reliable
grounding path from spanner bar 102 to module frame 105.
[0094] FIG. 7a shows cam foot 101 inserted into spanner groove 109.
FIG. 7b shows cam foot 101 fully engaged with spanner groove 109
and with cam nut 111 rotated approximately 90 degrees (for example,
from between 50 to 130 degrees, or 60 to 120 degrees, or 70 to 110
degrees) from its position in FIG. 7a. When cam nut 111 is rotated
approximately 90 degrees from its position in FIG. 7a, camming
surface 112 may press against and spread spanner groove 109. This
action may be complemented by lower key 138 on cam nut 111 jamming
into lower key slots 144, 145 and cone point 110 cutting into
spanner bar 102 to form a substantially rigid connection between
cam nut 111 and spanner bar 102. This connection arrangement may
provide a rapid, auto-grounding connection that may require less
than 360.degree. of rotation, such as approximately 90.degree.,
with between 70.degree. to 110.degree. of rotation (see description
above), and may provide adjustability in the y-axis since cam foot
101 may be able to be connected to spanner bar 102 at essentially
any point substantially along its whole length. In other
embodiments the orientation of spanner bars is rotated 90.degree.
from the orientation of FIG. 1, thereby enabling cam foot 101 to
spanner bar 102 connections substantially anywhere along the x-axis
of PV array 80. In another embodiment, cam nut 111 may comprise a
camming surface that expands against other surfaces of spanner
groove 109, such as upper key slots 142, 143, lower key slots 144,
145 or other walls of spanner groove 109.
[0095] FIG. 8 shows bar clamp 103 connected to a tile hook, such as
tile hook 116. In other embodiments, bar clamp 103 may be connected
to other types of tile hooks or other components such as
stand-offs, stanchions, threaded rods, and/or the like. Bar clamp
103 may be connected to tile hook 116 via a carriage bolt 103a and
nut (not shown). In other embodiments, bar clamp 103 may be
connected as by other fastener types such as snap-in, press-fit,
cam lock, or other mechanical connections known in the art. FIG. 8
also shows surface 117 of bar clamp 103. Surface 117 may, in
various embodiments, be oriented perpendicular or in other manner
to its orientation as shown in FIG. 8. For example, tile hook 116
may be replaced by a tile hook with a substantially flat plate top
surface, instead of a vertical wall as shown in FIG. 8, and bar
clamp 103 may be rotated approximately 90.degree. counter-clockwise
to connect to it. The variable orientations in which bar clamp 103
may be installed, may allow it to be mated with a wide variety of
roof tile hooks and other roof attachment types or mechanisms. The
connection of bar clamp 103 to tile hook 116 or other attachment
hardware types as described above, may provide simple and rapid
means for connecting bar clamp 103 to standard roof attachment
systems such as tile hooks, stand-offs, stanchions, threaded rods,
and others which are common or known in the art.
[0096] FIG. 8 also shows bar clamp 103 connected to spanner bar
102. Spanner bar 102 may be inserted through bar clamp 103 as
shown. The connection between spanner bar 102 and bar clamp 103 may
be made via a wrap-around friction connection, whereby a bolt 103a
may deform the approximately square shape of bar clamp 103 as it
may be tightened around approximately square spanner bar 102. In
other embodiments, other connection types such as snap-in,
press-fit, cam lock, and other mechanical connections known in the
art may be used. Some embodiments may provide dimples (not shown)
on bar clamp 103 to ensure proper angular alignment with x-y
reference plane. The connection between spanner bar 102 and bar
clamp 103 may provide a means for rapid and rigid connection of
these components.
[0097] FIG. 9a shows spanner bars 102 and 102a and a splicing
device, such as double male connector 118, which is installed at
one end of spanner bar 102. FIG. 9b illustrates how spanner bar 102
and spanner bar 102a may be coupled together by pressing end 119 of
spanner bar 102a onto double male connector 118. This connection
may be accomplished by means of an interference or press fit but
may, in other embodiments, be accomplished by a slip-fit, bolted
connection or the like.
[0098] FIG. 9e shows spanner bar 102 with one double male connector
118 removed. Double male connector 118 may have two male or
insertable members for inserting into female portions near or at
the ends of spanner bars 102. Double male connector 118 as shown in
FIG. 9e may comprise a resilient rubber or spring material 318b
covered by a protective layer (not shown). Spring material 318b may
help to take up dimensional variations in the materials utilized
and/or prevent rattle. Protective cover may help to prevent damage
to spring material 318b during insertion. Double male connector 118
may also comprise a substantially rectilinear shape along its
length that is primarily characterized by straight and
substantially parallel lines. Other embodiments contemplate
chamfered or tapered forms. Approximately half of a length of
double male connector 118 may be inserted into spanner bar 102. The
remaining approximately half of double male connector 118 may be
inserted into spanner bar 102a. While spanner bar 102 comprises 2
double male connectors 118, other embodiments (whether shown or not
shown herein) comprise spanner bars with only one double male
connector 118.
[0099] As shown in FIGS. 10a and 10b, array skirt 104 may be
connected to cam foot 101 for rapid, snap-on installation. FIG.
1A0a shows a groove, such as skirt groove 121, placed onto short
tongue side 106 of cam foot 101. FIG. 1A0b shows the final position
of installed array skirt 104. FIGS. 10a and 10b illustrate a method
of installation, whereby array skirt 104 may be pivoted downward
from the position illustrated in FIG. 10a to the position
illustrated in FIG. 10b. When in the fully engaged position, as
shown in FIG. 10b, a lip of skirt groove snaps into recess formed
by slight rise 131 on lower side of short tongue 106 (as discussed
above). In the embodiment shown in FIGS. 10a and 10b, installation
may be tool-free. The installation of cam foot 101 into frame
groove 105 may provide a rapid, tool-free (in some embodiments),
auto-grounding (in some embodiments), means and method for
adjustably connecting cam foot 101 to array skirt 104. In still
other embodiments coupling 114 may further comprise a lock or an
anti-rotation component which may be inserted full skirt engagement
in order to resist disengagement of skirt 104.
[0100] FIG. 11a and FIG. 11b show a pivot-fit method of
installation whereby frame groove 105 may be placed on long tongue
side 107 of cam foot 101 at a first angle of approximately 15-60
degrees (as in FIG. 11a) and rotated downward to a second angle of
approximately 0.degree. (as in FIG. 11b). Offset bearing points in
frame groove 105 may allow insertion of long tongue into frame
groove 105 at the first angle, then restrict movement in the z-axis
between frame groove 105 and long tongue 107 at the second angle.
Long tongue may be inserted into frame groove 105 to various depths
in order to align PV module 100 with adjacent PV modules 100 (not
shown). This installation method may offer rapid, tool-free (in
some embodiments), auto-grounding (in some embodiments), means and
method for adjustably connecting PV module 100 to cam foot 101.
This installation method may allow adjustability in the x-axis by
variably positioning PV module 100 onto cam foot 101 to line up
with roof rafters or a location of attachment means, such as tile
hook 116 described further above and below.
[0101] FIGS. 12 through 17 show a method of installing a PV array
such as PV array 80 shown in FIG. 1A. In such a method, PV modules
100 (similar to PV modules 100 shown in FIG. 2) may be installed on
tile roofs 81 using the following set of procedures: [0102] 1.
Place tile hooks 84 at pre-determined north-south (N-S) and
east-west (E-W) locations, as shown. These locations may be
determined by referencing load tables (such as incorporated herein
by reference) that present calculated N-S and E-W spacing based on
inputs such as average wind speed, wind category, roof slope and
snow load (see especially FIG. 12). [0103] 2. Attach first row of
spanner bars 102 to tile hooks 84 by slipping bar clamp 103 over
front row spanner bar 102, aligning tile hook slot 84A with a slot
123 in bar clamp 103, and using a bolt 103a and nut (not shown) or
other common fasteners (see especially FIG. 13). [0104] 3. Attach
second row of spanner bars 102 (see especially FIG. 14) by
inserting spanner bar double male connector 118 into female end of
spanner bar 102a. (see especially FIGS. 9a, 9b) Attach spanner bar
102 to a second row of tile hooks 84 (see especially FIG. 14) by
once again slipping bar clamp 103 over spanner bar 102 and aligning
tile hook slot 122 with spanner bar clamp slot 123 and using a bolt
103a and nut (not shown) or other common fasteners (see especially
FIG. 8). [0105] 4. Attach cam foot 101 to spanner bar 102 located
on the front row by inserting cam nut 111 into spanner groove 109
(see especially FIG. 8a) and rotating cam nut 111 a quarter turn
within spanner groove 109 to widen groove 109 and create a spring
force lock onto cam nut 111 (see especially FIG. 8b). [0106] 5.
Attach remaining rows of spanner bars 102 by again inserting
spanner bar double male connectors 118 and attaching spanner bars
102 as previously described (see especially FIG. 15). [0107] 6.
Once all spanner bars 102 have been attached in place (see
especially FIG. 16), install array skirt 104 (similar to skirt 104
in FIG. 16) to the front row of cam foot 101 (see especially FIGS.
10a, 10b). [0108] 7. Install first row of PV modules 100 (similar
to PV modules 100 shown in FIG. 2) onto cam foot 101 (see
especially FIGS. 11a, 11b). Connection of PV module 100 to cam foot
101 may create a continuous ground path from frame groove 105 to
cam foot 101 and thus to the spanner bar 102 (see especially FIG.
11b). [0109] 8. Ensure PV modules 100, (similar to PV modules 100
in FIG. 2) are essentially level to each other and parallel to the
rooftop 81. If they are sufficiently out of alignment, rotate
threaded studs 113 in cam foot 101, to raise or lower appropriate
PV module edges. [0110] 9. Install the next row of PV modules 100
(similar to PV modules 100 in FIG. 2) by first attaching cam foot
101 to frame groove 105 (see especially FIG. 28), and then
attaching cam foot 101 (see especially FIG. 3) to spanner groove
109 (see especially FIG. 4). [0111] 10. Repeat these procedures
until entire PV array 80 is installed and level. (see especially
FIG. 1A)
[0112] FIGS. 12 through 17 show a method of installing a PV array
such as PV array 80 shown in FIG. 1A. In such a method, PV modules
100 (similar to PV modules 100 shown in FIG. 2) In other
embodiments spanner bars 102 may be run horizontally instead of
vertically on the roof and in still other embodiments PV modules
100 (similar to PV modules 100 in FIG. 2) may be oriented in
portrait orientation instead of landscape as shown. Other and
similar arrangements are explicitly considered, including PV
modules not being oriented in a N-S or E-W plan.
[0113] FIG. 18 shows an embodiment of a spanner bar, such as
spanner bar 202. Spanner bar 202 may be similar to spanner bar 102
except that double male connector 118 is replaced by a necked down
portion 218 of spanner bar 202 and there is no spanner groove 109.
Necked down portion 218 may fit into a female portion 203 at an
opposite end from necked down portion 218. Thus, spanner bar 202
may comprise a one-piece construction with one male end and one
female end. Spanner bars 202 may be capable of mating end-to-end,
in a manner similar to conventional tent poles. One skilled in the
art will recognize that spanner bar 202 may comprise an inside
diameter sized to fit bar clamp 103 as discussed above. In some
embodiments spanner bar 202 may comprise a spanner groove 109. In
embodiments where spanner bar 202 comprises a spanner groove 109,
spanner bar 202 may mate with cam foot 101 as described above for
spanner bar 102. In embodiments where spanner bar 202 does not
comprise a spanner groove 109 (as depicted in FIG. 18), spanner bar
202 may connect to PV module 100 by way of a typical square tube
clamping mechanism as are known in the art.
[0114] One or more additional benefits that the above described
hardware, systems and methods may facilitate include the following:
[0115] May provide a system that simplifies the hardware and/or
installation procedure required to mount PV modules on a support
structure that requires discrete attachment points, such as a tile
roof or ground mount structure; [0116] May reduce or eliminate the
need for long mounting rails beneath module arrays, thereby
reducing problems associated with warehousing, shipping, and
maneuvering long rails onto a roof; [0117] May increase layout
flexibility and simplify installations on complicated roofs that
may have numerous smaller roof surfaces and/or numerous
obstructions (such as vent pipes, chimneys, and so on) since rails
may not need to be cut on site; [0118] May enable more
cost-effective mounting in landscape orientation since two rows of
rail are not required for every row of PV modules as in
conventional systems; [0119] May reduce total part count and total
number of fasteners required; [0120] May improve the speed of
installation and overall reliability of the PV array grounding
system; [0121] May provide greater integration with other required
equipment in the overall PV system, such as electrical junction and
combiner boxes, wire management devices, and other equipment since
some embodiments provide mounting hardware that may utilize similar
male and female mating parts as other equipment in the system;
[0122] May reduce a total length of spanner bar and/or rail
material as compared to conventional systems due to optimization of
structural support system; [0123] May reduce a total number of
attachment points as compared to conventional systems due to
optimization of structural support system; [0124] May enable faster
PV array system installations due to the ability of a single
installer to place and mount PV modules on support structure 81
[0125] May allow for easy on site changes to array layout when an
actual rooftop does not accurately match the one used for a planned
PV array system design; [0126] May provide ability to adapt to
uneven roof surfaces.
[0127] FIGS. 19 through 32 show an embodiment of a discrete
attachment point mounting system.
[0128] FIG. 19 shows a spanner bar assembly 340 comprising a
connector such as a spanner bar coupling 301, a module spanning bar
such as a spanner bar 302, and a module spanning bar clamp such as
a bar clamp 303 that may mount to tile hooks 350 or other common
tile mount hardware, as with common fasteners such as bolts, nuts,
and washers which may be fastened through holes or slots such as
clamp holes 303A and tile hook slot 350A. Spanner bar 302 may span
one or two PV modules 309, but typically no more; as it may not be
intended to replace a long rail which are commonly used in the art.
Spanner bar 302 may be provided in lengths that are substantially
close to one or two times the length or width of PV module 309
(herein referred generally referred to as "width"). Spanner bar 302
being relatively short and produced in a length that is essentially
an integer multiple of the module dimension (noted as "width"
above) may yield significant benefits in terms of ease of transport
and speed of installation. In some embodiments spanner bar 302 may
also provide a simple means to span from two PV module 309 frame
311 sides over to a tile hook 350, thereby freeing up either the x
or y axis for positioning flexibility on a roof 308. In some
embodiments spanner bar 302 spans the distance between frame 311
side on a first PV module 309 over to frame 311 side on an adjacent
PV module 309, while crossing under first PV module 309. For
example, an east frame 311 side on first PV module 311 may be
effectively coupled to an east frame 311 side on second PV module
311 by way of spanner bar 302 and associated spanner bar couplings
301. In still other embodiments spanner bar 302 spans between two
parallel frame sides of PV module 309.
[0129] Clamp holes 303A may be in various quantities and may be
round, oval, slotted, or the like. As shown in more detail below,
spanner bar coupling 301 may connect to spanner bar 302 via a nut
380 that locks in a groove such as spanner groove 302A within the
top surface 302B of spanner bar 302 and a machine screw or bolt
running through bar coupling 1 (not visible in this view). In other
embodiments nut 380 and bolt are replaced by a quarter turn cam
nut.
[0130] Bar clamp 302 may be connected to tile hook 350 via carriage
bolt and nut. In other embodiments, bar clamp 2 may be connected
via other fastener types, such as snap-in, press-fit, cam lock,
and/or other mechanical connections known in the art. FIG. 19 also
shows surface 303B of bar clamp 303. Surface 303B may, in other
embodiments, be oriented perpendicular to its orientation as shown
in FIG. 19. The variable orientations in which bar clamp 303 may be
installed may allow it to be mated with a wide variety of roof tile
hook and other roof attachment types. The connection of bar clamp
303 to tile hook 350 or other attachment hardware types as
described above, may provide simple and rapid means for connecting
bar clamp 303 to standard roof attachment systems such as tile
hooks, stand-offs, stanchions, threaded rods, and/or others common
in the art.
[0131] FIG. 19 also shows bar clamp 303 connected to spanner bar
302. Spanner bar 302 may be inserted through bar clamp 303 as
shown. The connection between spanner bar 302 and bar clamp 303 may
be made as by a wrap-around friction connection, whereby a bolt may
deform the approximately square shape of bar clamp 303 as it may be
tightened around the approximately square spanner bar 302. In other
embodiments, other connection types such as snap-in, press-fit, cam
lock, and/or other mechanical connections known in the art may be
used. Some embodiments may provide dimples on bar clamp 303 to
ensure proper angular alignment with a plane of the mounting
surface. The connection between spanner bar 302 and bar clamp 303
may provide a means for rapid and rigid connection of these
components.
[0132] It is contemplated that spanner bar assembly 340 comprises
components made from aluminum, steel, or other hard metals, or
plastic may be suitable as well.
[0133] FIG. 20 shows a photovoltaic module array such as PV array
330 mounted on a roof 308 with tile hooks 350 and spanner bar
assemblies 340. PV Array 330 comprises a plurality of photovoltaic
modules such as PV module 309. As in previous figures, a PV
laminate is shown as clear glass so that components below may be
viewed. FIG. 20 also shows an interlocking device, such as
interlock 345, which may provide both structural and ground bond
connections at the corners of PV modules 309. Interlock 345 is
described in more detail below.
[0134] FIG. 21 shows a portion of PV module 309. As is common in
the art, PV module 309 comprises a PV laminate 310 with an aluminum
frame 311 to provide additional strength and a location for
attachment of mounting hardware. Spanner bar assemblies 340 may be
used with module frames that have a groove on the outer surface
such as frame groove 311A. Other embodiments comprise spanner bar
assemblies optimized for use with non-grooved PV modules frames. In
such embodiments, spanner bar coupling 301 may comprise a hold-down
clamp or end clamp as are common in the art for non-grooved frame
PV modules.
[0135] FIG. 21 also shows spanner bar coupling 301 connected to
spanner bar 302 through the use of a bolt and nut 380 that
interlocks with spanner groove 302A. As with cam foot 101 in FIG.
5, spanner bar coupling 301 may contain a cup or cone point bonding
feature such as cone point 110. Spanner bar coupling 301 may be
attached to module frame 311 using a geometrically compatible part
feature 301A that interlocks with the groove 311A located on the
outer surface of the module frame 311 by way of a rotational
tool-free motion. In other embodiments a standard T nut may be used
instead of cam nut 307.
[0136] FIGS. 22 through 32 show the steps required for installing a
photovoltaic array such as PV array 330.
[0137] In FIG. 22, four typical tile hooks 350 are shown mounted to
a rooftop surface. One familiar with the art may recognize that
other tile roof mounting hardware besides tile hooks could be used
for the same function. A frame mount component 314 that allows for
a direct attachment to tile hooks through use of standard fasteners
such as nuts, bolts washers and the like may be installed on the
first row of tile hooks 350. FIG. 22 also shows the attachment of
spanner bar 302 to tile hook 350 through the use of bar clamp
303.
[0138] FIG. 23 shows a method of installing PV module 309 in its
desired location upon a rooftop as by a pivot-fit, drop in action
as discussed above. This method allows for rapid installation that
does not require the use of tools, therefore saving installation
time.
[0139] FIG. 24 shows spanner bar coupling 301 inserting into frame
groove 311A. Also depicted is the alignment of cam nut 307 with
spanner groove 302A. Once spanner bar coupling 301 has been
rotationally engaged frame groove 311A, nut 380 may be secured as
described above.
[0140] FIGS. 25 through 27 show how additional spanner bar
assemblies 340 may continue to be connected once the first PV
module 309 has been installed.
[0141] FIG. 25 depicts spanner bar assembly 340 being installed as
by connection to frame groove 311A of PV module 309. This
connection may be accomplished via a drop-in, pivot-fit action and
serves to lengthen the run of structural material, which spans
between tile hooks 350.
[0142] FIG. 26 shows a close up view of geometrically compatible
part feature 301A of spanner bar coupling 301 pivoting into frame
groove 311A in the direction of the arrow.
[0143] FIG. 27 shows spanner bar assembly 340 in its installed
position on a rooftop.
[0144] FIG. 28 shows additional PV module 309 being installed via a
drop-in, pivot-fit action as described and shown in FIG. 23
above.
[0145] FIG. 29 shows additional PV module 309 in its installed
position on a rooftop.
[0146] FIG. 30 shows installed interlock 345. Interlock 345 may be
installed by inserting into frame grooves 311A and rotating frame
coupling components 345A approximately 90 degrees. Interlock 345
may provide structural and/or grounding connections between PV
modules 309.
[0147] FIG. 31 Shows a fully assembled PV array 390 (roof not
shown). Note that spanner bars 302 may, in some cases, not be
installed under each module. In this case interlock 345 provides
the necessary structural connection between modules 309 to minimize
or eliminate the need for spanner bar 302 underneath PV module 355.
FIG. 31 shows an example 355 of a PV module 309 that does not have
a spanner bar 302 underneath it.
[0148] FIG. 32 shows an alternate embodiment where spanner bars 302
are replaced by spanner bars 395 which span two modules 309 instead
of one module 309.
[0149] In other embodiments, spanner bars 302 may be run vertically
instead of horizontally on a roof and in still other embodiments PV
modules 309 may be oriented in landscape orientation, or other
orientation, instead of portrait as shown.
[0150] FIGS. 33-47 show additional embodiments. FIGS. 33-37 show an
alternate double male coupling such as double male coupling 410.
Double male coupling may couple spanner bars 420A and 420B and may
provide tapped holes 412, 414 for connection to a double tongue
coupling 430. Spring clip 415 may provide retention and grounding
between components and may be secured to spanner bar 420A.
[0151] FIGS. 38-44 an embodiment where a double male connector such
as double male connector 510 comprises a channel-shaped member 525
for coupling adjacent spanner bars 520A, 520B and for connecting to
double male PV module coupling 514. FIGS. 42-44 show an embodiment
where double male module couplings 514 interlock PV modules 510 on
a ground mount structure 540 and connect to double male connectors
525 which link to spanner bars 520A, 520B. Spanner bars 520A, 520B
connect to discrete attachment points on mounting structure 540.
Interlocks 560 may comprise connections to double male connectors
525 in alternate embodiments instead of double tongue couplings
514.
[0152] While a number of exemplary aspects and embodiments have
been discussed above, those of skill in the art will recognize
certain modifications, permutations, additions and sub-combinations
thereof. It is therefore intended that the following appended
claims and claims hereafter introduced be interpreted to include
all such modifications, permutations, additions, and
sub-combinations as are within their true spirit and scope.
* * * * *