U.S. patent application number 14/605780 was filed with the patent office on 2015-05-14 for electrical connectors for solar modules.
This patent application is currently assigned to Andalay Solar, Inc.. The applicant listed for this patent is Andalay Solar, Inc.. Invention is credited to Alexander W. Au, David Baker, Barry Cinnamon, Wilson W. Leong.
Application Number | 20150129021 14/605780 |
Document ID | / |
Family ID | 45098632 |
Filed Date | 2015-05-14 |
United States Patent
Application |
20150129021 |
Kind Code |
A1 |
Cinnamon; Barry ; et
al. |
May 14, 2015 |
ELECTRICAL CONNECTORS FOR SOLAR MODULES
Abstract
A solar module is disclosed that has one or more integrated
electrical connectors. In addition, a solar module electrical
connector holder is disclosed that has resilient wing portions and
axial portions that mate with a first connector window in a frame
of a solar module and allow the position of an electrical connector
to be moved one of vertically, horizontally and angularly with
respect to the frame. In addition, a solar module frame is
disclosed that has a first connector window in one of the side
frame members that is capable of accepting an electrical connection
so that the electrical connection is integrated into the frame of
the solar module.
Inventors: |
Cinnamon; Barry; (Saratoga,
CA) ; Baker; David; (San Jose, CA) ; Leong;
Wilson W.; (San Carlos, CA) ; Au; Alexander W.;
(Campbell, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Andalay Solar, Inc. |
Campbell |
CA |
US |
|
|
Assignee: |
Andalay Solar, Inc.
|
Family ID: |
45098632 |
Appl. No.: |
14/605780 |
Filed: |
January 26, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12796466 |
Jun 8, 2010 |
8938919 |
|
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14605780 |
|
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|
11859724 |
Sep 21, 2007 |
8813460 |
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12796466 |
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Current U.S.
Class: |
136/251 ;
439/131 |
Current CPC
Class: |
H01L 31/05 20130101;
Y02B 10/10 20130101; H02S 40/34 20141201; Y02B 10/12 20130101; F24S
25/61 20180501; H02S 40/36 20141201; H02S 30/10 20141201; F24S
25/20 20180501; H02S 20/23 20141201; Y02B 10/20 20130101; F24S
2025/014 20180501; F24S 20/67 20180501; H01L 31/0201 20130101; H01R
13/73 20130101; Y02E 10/47 20130101; H01L 31/048 20130101; Y02E
10/50 20130101; F24S 2025/6004 20180501 |
Class at
Publication: |
136/251 ;
439/131 |
International
Class: |
H01L 31/02 20060101
H01L031/02; H02S 20/23 20060101 H02S020/23; H01R 13/73 20060101
H01R013/73 |
Claims
1. A solar module system with a retractable electrical connector;
comprising: a first and second side frame members; a top frame
member; a bottom frame member wherein the first and second side
frame members, the top frame member and the bottom frame member are
connected together to form a frame that surrounds the solar panel;
an electrical connector with a mating region that is connected to
at least one of the first and second side frame members, the top
frame member and the bottom frame member; and wherein the
electrical connector has a retracted position in which the mating
region of the electrical connector is within the frame and
protected from damage and an install position in which the mating
region of the electrical connector is extended beyond the frame so
that the mating region can be mated with an electrical connector of
an adjacent solar panel.
2. The system of claim 1 further comprising a second solar module
having a first and second side frame members, a top frame member, a
bottom frame member wherein the first and second side frame
members, the top frame member and the bottom frame member are
connected together to form a frame that surrounds the solar panel
and an electrical connector with a mating region that is connected
to at least one of the first and second side frame members, the top
frame member and the bottom frame member of the second solar
module; and wherein the electrical connectors of the solar module
and the second solar module are mated to each other by the mating
regions of the electrical connectors.
3. The system of claim 1, wherein the side members further
comprises a first connector window in one of the side frame members
and the electrical connection is coupled to the first connector
window so that the electrical connection is integrated into the
frame of the solar module.
4. The system of claim 1, wherein the side members further
comprises a second connector window in the one of the side frame
members adjacent to the first connector window, and a second
electrical connection being coupled to the second connector window
so that the first and second electrical connections are integrated
into the frame of the solar module.
5. The system of claim 4, wherein the first electrical connection
is a female electrical connection and the second electrical
connection is a male electrical connection that ensure the
electrical connection to the solar module is properly made.
6. The system of claim 3, wherein the first electrical connection
further comprises an electrical connector and a connector holder
wherein the electrical connector is seated in the connector holder,
the connector holder mates with the first connector window and the
connector holder allows a position of the electrical connector to
be moved one of vertically, horizontally, axially and angularly
with respect to the frame.
7. The system of claim 6, wherein the connector holder further
comprises a body portion, a first resilient wing portion attached
to the body portion and a second resilient wing portion attached to
the body portion wherein the first and second resilient wing
portions mate with the first connector window.
8. The system of claim 7, wherein the connector holder further
comprises a first axial portion attached to the body portion and a
second axial portion attached to the body portion wherein the first
and second axial portions permits the electrical connector to be
moved axially within the connector holder.
9. The system of claim 4, wherein the first electrical connection
and second electrical connection each further comprise an
electrical connector and a connector holder wherein the electrical
connector is seated in the connector holder, the connector holder
mates with the first connector window and the connector holder
allows a position of the electrical connector to be moved one of
vertically, horizontally, axially and angularly with respect to the
frame.
10. The system of claim 9, wherein the connector holder further
comprises a body portion, a first resilient wing portion attached
to the body portion and a second resilient wing portion attached to
the body portion wherein the first and second resilient wing
portions mate with the first connector window.
11. The system of claim 10, wherein the connector holder further
comprises a first axial portion attached to the body portion and a
second axial portion attached to the body portion wherein the first
and second axial portions permits the electrical connector to be
moved axially within the connector holder.
12. The system of claim 1, wherein the mating region further
comprises a first axial portion attached to the body portion and a
second axial portion attached to the body portion wherein the first
and second axial portions permits an electrical connector to be
moved axially within the connector holder and allow the position of
an electrical connector to be moved axially with respect to the
frame.
13. A method for electrically connecting a solar module, the method
comprising: providing a first and second side frame members, a top
frame member, a bottom frame member wherein the first and second
side frame members, the top frame member and the bottom frame
member are connected together to form a frame that surrounds the
solar panel, an electrical connector with a mating region that is
connected to at least one of the first and second side frame
members, the top frame member and the bottom frame member;
retracting the electrical connector of the solar module so that the
mating region of the electrical connector is within the frame and
protected from damage; and extending the electrical connector of
the solar module so that the mating region of the electrical
connector is extended beyond the frame so that the mating region
can be mated with an electrical connector of an adjacent solar
panel.
14. The method of claim 13 further comprising seating the
electrical connector in a connector holder that allows a position
of the electrical connector to be moved one of vertically,
horizontally, axially and angularly with respect to the frame.
Description
PRIORITY CLAIMS
[0001] This application is a continuation and divisional of and
claims priority under 35 USC 120 and 121 to U.S. patent application
Ser. No. 12/796,466 filed on Jun. 8, 2010 which in turn is a
continuation in part of and claims priority under 35 USC 120 to
U.S. patent application Ser. No. 11/859,724 filed on Sep. 21, 2007
and entitled "Mounting System for Solar Panels" which is
incorporated herein by reference.
FIELD
[0002] The system and method relate generally to solar panels and
more particularly to electrical connectors used during the assembly
and mounting of a solar panel.
BACKGROUND
[0003] Solar electric systems are the most environmentally friendly
way of generating electricity. To provide such solar electric
systems, typically there is a solar panel, which comprises a
plurality of solar modules, which are coupled together. The solar
panels are typically assembled directly on the roof of a building,
assembled on the ground and then mounted on a roof of a building,
or installed on a dedicated ground or pole mounted frame. FIG. 1
illustrates a conventional solar panel assembly 10. The solar panel
in this embodiment comprises three solar modules, 12A-12C. However,
one of ordinary skill in the art recognizes there could be any
number of modules and they could be in any configuration to form a
solar panel.
[0004] Each of the solar panel modules 12A-12C includes a junction
box 14A-14C which receives cables 16, which are applied in serial
fashion from one module to the next. Also included within each of
these modules 12A-12C is an electrical ground wire assembly 18,
which is used to ground the modules and the underlying frame at the
appropriate points. In addition, each of the modules includes extra
wiring from nearby modules that must be wrapped and tied down in
between, as shown at 20A and 20B to ensure that the wires do not
get damaged. FIG. 1A is a view of the grounding screw for the solar
panel. The screw or bolt assembly 22, which must be provided in
several places, attaches the ground wire assembly 18 to each piece
of equipment in the assembly at least once, in this case five (5)
places, on each of the solar modules 12A-12C and underlying frame,
thereby creating a grounded assembly.
[0005] Referring back in FIG. 1, there are two metal rails 24 that
extend in parallel with and along the length of the solar modules
12A-12C. These rails form the underlying support structure for the
solar modules. The rails are attached to the roof so that the
entire solar panel can be mounted in a single rigid geometric plane
on the roof, thereby improving the durability and aesthetics of the
installation. In some cases the rails are mounted to the roof first
(attached to the roof with L shaped brackets and lag bolts to the
underlying rafters), and then the modules are attached to the rails
with bolt-fastened clips, In other cases, as shown in FIG. 1B, the
rails are attached to the modules first (in this case with hex nuts
and bolts or in other cases clips), and then the entire module-rail
assembly (or panel) is attached to the roof with L shaped brackets
26 (FIG. 1) and lag bolts to the underlying rafters. These rails 24
are also electrically grounded as indicated above.
[0006] For ventilation and drainage purposes it is beneficial to
mount the panel above the roof with a small air gap between the
roof surface and underside of the modules and rails. For wiring and
grounding purposes for roof-assembled panels it is beneficial to
have access below the modules so that wires can be connected and
tied. For single geometric plan purposes it is beneficial to
provide some vertical adjustability of the mounting point to
account for variability (waviness) in roof surfaces. For these
reasons the roof mounting bracket (whether it is an L shaped
bracket or different design) generally provides some vertical
adjustability (typically 1-3 inches). Moreover, roof attachments
must be made to a secure underlying surface, generally a rafter.
These rafters may not be consistently spaced. Therefore, the
mounting rails typically include some kind of adjustable groove so
that the mounting point from the rail to the roof attachment (L
bracket) can be directly over a secure mounting point--wherever
this point may be.
[0007] The conventional solar panel 10 requires many individual
operations to construct and mount in order to provide a reliable
and high performance solar electric system. Mounting on uneven roof
surfaces requires many small parts and adjustments. Making sure
there is airflow and drainage requires the panel to be raised off
the roof slightly, but aesthetic considerations require the pane]
to be close to the roof. Each module in the panel must be wired
together, extra wiring must be tucked away securely, and every
conductive component must be electrically grounded. All the
required parts and steps increase the cost of the system, which
ultimately negatively affects the payback of the system. In
addition, conventional solar modules are shipped in cardboard boxes
on palettes, requiring additional shipping costs and substantial
unpacking and cardboard disposal costs.
[0008] Accordingly, what is desired is a solar module which has
more secure electrical connectors that are integrated into a frame
of the solar modules and ensure proper connection. It is also
desirable to provide electrical connectors for solar modules that
reduce installation time and reduce electrical hook-up time. The
system and method disclosed below provides these desirable
aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a conventional solar panel assembly;
[0010] FIG. 1A is a view of a grounding screw for the solar
panel;
[0011] FIG. 1B is a view of a module attached to a rail;
[0012] FIG. 2 illustrates a perspective view of a mounting system
for a solar panel;
[0013] FIG. 2A is a diagram of a back view of the solar panel shown
in FIG. 2;
[0014] FIGS. 2B and 2C are first and second embodiments of
connector boxes;
[0015] FIG. 2D is an embodiment of a main connector block coupled
between two solar panels;
[0016] FIG. 2E shows an east-west splice that allows connection of
a module or panel to the side (typically east or west) of an
existing module;
[0017] FIG. 2F shows a north-south splice that allows connection of
a module or panel above or below (typically north or south) of an
existing module;
[0018] FIG. 3A is an embodiment of a threaded splice;
[0019] FIG. 3B illustrates an embodiment of a threaded splice with
a double screw lock;
[0020] FIG. 3C illustrates an embodiment of a slide cam lock for a
splice;
[0021] FIG. 3D illustrates a third embodiment of a splice;
[0022] FIG. 3E illustrates an embodiment of a connector mount;
[0023] FIG. 3F illustrates the connector mount holding a male
connector;
[0024] FIG. 3G illustrates the connector mount holding a female
connector;
[0025] FIG. 4A illustrates a groove on the module panel and a
surface mounting bracket for securing the module panel to the
roof;
[0026] FIG. 4B illustrates a first embodiment of a ground
mount;
[0027] FIG. 4C illustrates a second embodiment of a ground
mount;
[0028] FIGS. 4D and 4E illustrate perspective and side views of an
embodiment of a quick release clip;
[0029] FIG. 4F illustrates an exploded view of the quick release
clip;
[0030] FIG. 5A illustrates a shipping stack of solar modules with
pre-installed mounting brackets, through attachment rod and splice
storage;
[0031] FIG. 5B illustrates a first embodiment of a packing spacer
block;
[0032] FIG. 5C illustrates a second embodiment of a picking spacer
block;
[0033] FIG. 6 illustrates a wrench for a cam lock for a splice and
a connector unlock for a module;
[0034] FIG. 7 illustrates an embodiment a driver for the splices of
FIGS. 3A and 3B;
[0035] FIG. 8 illustrates an exploded view of a mounting hardware
for the solar panel system;
[0036] FIG. 9 illustrates an embodiment of a north-south (N-S)
spacer block;
[0037] FIG. 10A illustrates an embodiment of a shim block;
[0038] FIG. 10B illustrates a shim block located on a solar
panel;
[0039] FIG. 10C illustrates a shim block between solar panels to
minimize over-tightening;
[0040] FIG. 11 illustrates installing mounting hardware;
[0041] FIG. 12 illustrates positioning panels over the mounting
locations;
[0042] FIG. 13 illustrates inserting splices into the frame;
[0043] FIG. 14 illustrates an array assembly being coupled
together;
[0044] FIGS. 15A-B shows the splice entering the opening in the
panel (n-s) direction;
[0045] FIG. 15C shows the spice flat up upon entry;
[0046] FIG. 15D shows, after entry, the splice is rotated and the
round on the splice jams in the flat;
[0047] FIG. 16 illustrates an example of an electrical schematic
for proper wiring;
[0048] FIG. 17 illustrates an inter-module grounding splice;
[0049] FIGS. 18A and 18B illustrate an electrical connector
integrated into the frame of the solar module;
[0050] FIGS. 18C1-18C5 are a perspective view, top view, right
view, front view and front view, respectively, of the electrical
connector shown in FIGS. 18A and 18B;
[0051] FIGS. 19 and 20 illustrate another embodiment of the
connector holder and connector of an electrical connector;
[0052] FIG. 21A-E are a perspective view, a right view, a front
view, a left view and a end view, respectively, of another
embodiment of a female electrical connector;
[0053] FIGS. 22A-E are a perspective view, a right view, a front
view, a left view and a end view, respectively, of another
embodiment of a male electrical connector that can be used with the
female connector of FIGS. 21A-21E;
[0054] FIGS. 23A and 23B are a side view and a sectional view along
line A-A, respectively, of the female connector of FIGS. 21A-E in
an retracted position; and
[0055] FIGS. 24A and 24B are a side view and a sectional view along
line A-A, respectively, of the female connector of FIGS. 21A-E in
an install position.
DETAILED DESCRIPTION OF ONE OR MORE EMBODIMENTS
[0056] The system and method are particularly applicable to an
embodiment of a solar module electrical connector that has the
features described below and it is in this context that the system
and method are described. It will be appreciated, however, that the
system and method has greater utility since the system covers solar
module electrical connector made with different materials or with
different features that are within the scope of the system and
method.
[0057] FIG. 2 illustrates a perspective view of a mounting system
for a solar panel 100. As is seen, there are three modules
102A-102C shown that are coupled together that include several
features that allow for a modularized and integrated system for the
solar panel 100. Firstly, there is a splice that mechanically
connects one module to another and provides the electrical
grounding connection between the solar modules. The mechanical
strength of the splice and attachment technique to the module frame
allows each module frame to function in the same rigid way as the
underlying frame rail in a conventional solar panel assembly. In
addition, there are cable connector grooves between modules that
minimize the amount of wiring activities that are required for
connecting the modules together. Finally, the system includes only
requiring one electrical grounding connection to the entire panel;
module to module and module to rail grounding connections are not
needed. In addition the mounting system provides many elements that
significantly ease the assembly of the solar panels as well as
allowing for the efficient packing of the solar modules prior to
installation. To describe the features of the system in more detail
refer now to the following description in conjunction with the
accompanying figures.
[0058] FIG. 2A is a diagram of a back view of the solar panel 100.
As has been above-mentioned the solar panel 100 includes a
plurality of modules 102A-102C. However, one of ordinary skill in
the art readily recognizes that the panel 100 could include any
number of modules in both the X and Y directions and could be in
any configuration and its use would be within the spirit and scope
of the system. As is seen each module 102 includes a junction box
103. Each junction box 103 is coupled to wiring segments 1.08 which
includes a connector mount. Wiring segments 108 are utilized to
electrically connect the modules 102 together and also to connect
the modules 1.02 to a combiner junction box 121. Accordingly, the
combiner junction box 121 provides a connection for high voltage
wiring and a grounding path. The combiner junction box 121 provides
for wiring transitions which are done either manually or
automatically. The combiner junction box 121 is utilized to
electrically couple a plurality of solar panels. An set of
electrical connectors 1000 that are integrated into a frame member
1002 (such as an end frame member) are also shown and will be
described in more detail below with reference to FIGS. 18-20.
[0059] FIG. 2B is a first embodiment of a conventional combiner
junction box 121'. As is seen, the conventional junction box 121'
would have to be adapted to the solar module based upon the wiring
165. This would add considerable time and cost when installing the
box 121'.
[0060] A custom combiner junction box 121'' is shown in FIG. 2C.
The custom combiner junction box 121'' has several advantages over
the conventional combiner junction box 121. Referring back to FIG.
2A, firstly, as is seen the connections for wiring segments 108 can
be coupled directly into the connections 175 of the junction box
103'. FIG. 2D illustrates the combiner junction box 121'' coupled
between two solar panels. Furthermore the custom combiner junction
box 121'' is directly coupled to the outside of the solar panel and
permanently fastens to the side of the panel with a bolt, The bolt
also provides a grounding path to a system ground conductor.
[0061] Accordingly, the solar panel 100 requires significantly
fewer parts to assemble and is more easily constructed than the
conventional solar panel 10 of FIG. 1.
[0062] Optimally a cable holder 136 can also be used in this solar
panel. Referring back to FIG. 2A, a cable holder 136 is coupled to
a side portion of a module to hold cables that may be stored in the
panel. Typically the cable holder 136 is a cable clip that holds
the stored cable in place. Also, the cable holder 136 can be molded
into the cable itself.
[0063] Referring now to FIG. 2E, as is seen there is an east-west
(e-w) splice 104 shown internal to two modules 102A and 102B that
connect the modules 102A and 102B. The splice 104 provides several
useful features for the panel 100, including mechanical rigidity
between molecules, a grounding path between modules, an alignment
method between modules, and a securing method between modules.
[0064] Also north-south splices between rows can be effectively
utilized. FIG. 2F shows a north-south splice 104 that allows
connector of a module or panel above (typically north) or below an
existing module. This splice 104E provides alignment between rows,
rigidity between rows and provides a grounding connection. Use of
this north-south splice 104E reduces mounting points on the
mounting surface.
[0065] In one embodiment, the splice is a removable connecting
piece that is in a module. Additionally, the splice is generally
hidden when installed, by virtue of mounting inside the module
frame hollow section or side groove. The splice allows for a very
close fit between modules, thereby improving space utilization.
Also, the splice has conductive capability (including the
non-conductive main part with conductive wires or surface). It
should also be understood, that although the splice in this
embodiment is internal to the solar modules, one of ordinary skill
in the art readily recognizes that the splice could be external and
its use could be within the spirit and scope of the system. The
following will describe different embodiments of a splice.
[0066] FIG. 3A is a first embodiment of a threaded splice 200, The
splice 200 as is seen include first and second threads 202a and
202b at opposite ends thereof. This splice drives modules together,
provides structural rigidity and provides grounding between
modules. Through the use of the opposing threads 202a, 202b a
single motion can be utilized to drive modules together and apart.
The splice 200 utilizes a driver to tighten and untighten the
splice between modules. In this embodiment a screw driver head is
utilized on the end portions 206a and 206b of the threads 202a and
202b. Other driver heads could be utilized such as Phillips, etc.
and that use would be within the spirit and scope of the system.
Furthermore there is a cam lock 208 which locks the splice in place
when properly positioned within the solar panel. An implementation
of such a driver will described in detail later in the
specification.
[0067] FIG. 3B illustrates a second embodiment of a threaded splice
300 that includes double screw lock 302. In this embodiment, a
screw lock 302 drives the solar modules together. The screw lock
302 provides structural rigidity and also provides electrical
grounding between modules. In this embodiment, the left and right
hand thread 308a, 308b allow for a variety of distances between
modules. The spacing between modules is dictated by the center left
and right hand thread 308a and 308b. The splice 300 is coupled to
the solar module using a custom wrench. The use of such wrench will
be described in detail hereinafter,
[0068] FIG. 3C illustrates an embodiment of a slide cam lock for a
splice. The slide cam lock 350 ensures alignment of modules through
extrusion using the locking mechanism 352a and 352b. The blocks
move into position to secure the splice.
[0069] FIG. 3D illustrates a third embodiment of a splice 104. The
splice 104 is tapered to allow for easy initial assembly line up
and a final tight fit between the modules 102A and 102B. In a
preferred embodiment it is precisely located in the panel 100 in a
centerline fashion. In a preferred embodiment the splice 104 is a
tapered conductive metal to provide a grounding path between
modules, and includes a sharp edge to improve grounding to each
module. The splice 104 is also grooved for easy screw insertion
from the top or the side of the module 102. The splice 104
precisely aligns the modules 102 and allows the assembler to
compress the connector sockets 108, thereby completing an
electrical connection between the two adjacent modules. The
electrical connection between the two adjacent modules by the
splice 304 eliminates the need to run a grounding wire between each
module. As is seen only one other grounding wire is required for an
entire panel assembly as long as all solar modules are connected
with a splice. The splice provides sufficient rigidity between
modules so that the entire panel can be transported and lifted to a
roof, or installed directly on a roof or other surface in a secure
and long lasting fashion.
[0070] In an embodiment, each splice would utilize a screw for
attachment to secure the two modules together. Other mechanisms for
securing the two modules together include but are not limited to a
cam type compression device, a press fit or toothed barb device, a
spring clip attachment, a through pin and an expandable section at
each end. For a three module solar panel, as illustrated in
exploded view, a total of four splices and eight self-threading
screws are utilized to provide the solar panel. Accordingly, a
minimal number of parts are required for the assembly of the panel.
The splice also includes a plurality of raised features, which
couple the modules together. The first raised feature 132 acts as a
stop for the splice. The second raised feature 134 acts as a
grounding path for the splice.
[0071] Referring back to FIG. 2A, a plurality of connector mounts
108 are provided in each of the modules 102. These connector mounts
108 provide the following advantages:
[0072] The connector mounts 108 can be labeled (+/-) and then sized
to only accept the proper cable connection, thereby minimizing
wiring problems. The connector mounts 108 are located on the
modules (on the left/right or E-W sides, and/or on the top/bottom
or N/S sides) to prevent improper wiring based on cable lengths and
connector socket size/configuration. The connector mounts 108 are
on frame sides to allow for easy and reliable module
interconnection. The connector mounts 108 on frame sides allow for
pre-installed home run return wire paths. The connector mounts 108
on frame sides allow for interconnection of strings. The connector
mounts 108 on frame sides allow for concealed wire connections
after modules are mounted. Finally, the overall design improves
wire management and grounding.
[0073] FIG. 3E illustrates an embodiment of a connector mount 400.
The connector mount 400 could be utilized with either a male
connector 402 or female connector shown in FIGS. 3F and 3G
respectfully for securing the electrical contacts. The connector
mount 400 retains and engages the electrical contact when the solar
panel is driven by a splice to close the electrical circuit. The
junction mount 400 can also be molded onto the connector itself,
The connector mount 400 also retains the electrical contacts when
modules are separated to open the electrical circuit. The connector
mount 400 is either factory installable or field installable. Also
the connector mount 400 can be molded into connector itself.
[0074] FIG. 4A illustrates a groove 142 on the metal plate 138 of
the module. The groove allows for securing the panel (composed of
one or more modules) to a structure, such as a roof, with the
mounting bracket. The grooves 142 on the sides of each of the metal
plate are aligned when the modules are connected with splices,
thereby creating a continuous groove along the entire panel to
allow for the connection of the solar panel to a roof or the like.
In so doing the solar panel can be rigidly mounted on a structure
in a single plane. The continuous groove allows attachment to an
available secure point (typically a rafter) at any horizontal
location. Typically the grooved portion will comprise an extrusion
on a metal plate 138 shown in FIG. 4 that is part of the module
thereby creating a full and roughly continuous extension in the
panel. This groove 142 can be installed on both the sides
(east-west) and top/bottom (north-south) of the modules, allowing
the module to be installed in a variety of different
orientations.
[0075] A bracket 140 attaches securely to the roof and then
attaches to the grooved metal plate 138 with a bolt. This bracket
140 may include provisions to mount the panel at a variable height
to account for variations in surfaces. Alternatively, this bracket
140 may be mounted to the roof with a threaded bolt or other
variable height mounting point. The solar panels can be mounted on
a horizontal, vertical or sloped structure or surface utilizing the
mounting bracket,
[0076] In another embodiment a ground mount is attached to the
metal plate for attachment to a flat surface or structure. FIG. 4B
illustrates a first embodiment of a ground mount 500. The ground
mount 500 uses the existing slider channel to mount to flat
surfaces. A set screw is inserted in aperture 502 to prevent
movement from a determined location and holes 504 allow for the
attachments of the solar module to a flat surface or structure. The
slider channel allows for near infinite mounting locations on the
frame axis.
[0077] FIG. 4C illustrates a second embodiment of a ground mount
600 which includes a stud 602, The stud 602 allows for vertical
attachments to a racking structure and the set screw prevents
movement from a determined location. This ground mount 600 also
uses the existing slider channel. Similarly, the slider channel
allows for near infinite mounting locations on frame axis
[0078] Another type of mounting assembly is a quick release clip
that is utilized as a mount for a roof or other surfaces and
attached to the groove of the module. FIGS. 4D and 4E illustrate a
side and perspective view of an embodiment of a quick release clip
700 coupled to a groove 680 of an extrusion 682, The quick release
clip 700 replaces bolt and nut assemblies associated with a
mounting assembly on a roof or other surface. The quick release
clip 700 allows for quick release of modules from a surface without
a tool. FIG. 4F illustrates an exploded view of slip release clip
700. The clip 700 includes a support member 701, a first flat
washer 702, a bevel washer 703, a coil spring 704, a lock washer
705, a second flat washer 706. The clip 700 also includes an
assembly mounting post 707, a cam lever 708, a pin 709 and a
L-bracket 710. The clip 700 is assembled such that elements 701-705
are assembled on the post 707. The cam lever is inserted on top of
the post 707 via the pin 709. The post 707 is inserted in the
groove 711 of the bracket 710. The coil spring 704 separates the
elements 701-703 on one side of the L-bracket 710 and 705-706 on
the other side of the L-bracket 71.0 such that the cam lever 708
can move the mounting post 707 in and out of the extrusion. By
adding and subtracting washers, coarse adjustment for positioning
the quick release clip 700 on a surface is provided. Fine
adjustment for positioning the quick release clip 700 is controlled
by the position of the cam lever 708.
[0079] Secure Stacking of Modules
[0080] Finally, solar modules can be securely stacked and shipped
with pre-installed mounting brackets, reducing shipping, packing
and unpacking costs.
[0081] FIG. 5A illustrates how multiple modules 1.02 are securely
stacked for shipment on a single palette 742. A plurality of
packing spacers 740 is utilized when stacking panels. A packing
strap 730 is provided to hold the plurality of modules 102
together,
[0082] FIG. 5B illustrates an embodiment of a packing spacer block
750. The packing spacer block 752 ensures proper clearances for
shipping of stacked modules. A gap (in one embodiment a 0.642''
gap) retains the packaging strap 802 (FIG. 5a) during shipment of
stacked modules. The spacer block 750 also ensures proper clearance
and alignment during module installation. A chamfered edge
facilitates module alignment during installation. FIG. 5C
illustrates a second embodiment of a packing spacer block 770 which
includes a channel 780 for holding wiring.
[0083] Installation
[0084] The following is an example of installation of a solar panel
system in accordance with an embodiment. To install the solar panel
system requires a mechanical tool kit and an electrical tool kit.
The mechanical tool kit comprises a plurality of tools such as a
ratchet, a driver, a wrench, a socket and a wire cutter all of
which are of a standard size. The mechanical tool kit also includes
a plurality of custom tools. Those tools include a connector tool,
a wrench for the splices and a screw driver for tightening the
splices.
[0085] The electrical tool kit comprises a custom multipurpose
wrench, a wire cutter, a wire stripping tool and a plug maker tool.
To describe the features of the custom tools in more detail refer
now to the following:
[0086] FIG. 6 illustrates the custom multipurpose wrench 800. The
wrench 800 includes a body portion. The body portion 801 at one end
includes an opening 802 for setting a cam lock for a splice. The
body portion 801 also includes at an opposite end a second opening
806 for unlocking a connector for a module. The body portion
further includes a third opening 804 between the first and second
openings 802 and 806 for driving a double screw lock splice,
[0087] FIG. 7 illustrates an embodiment of a driver 900 for the
splices of FIGS. 3A and 3B. The driver engages a driver end 902 of
a splice to drive modules together. The driver drives the splice
through insertion of the driver 900 through a module frame
through-hole. In one embodiment a hex end 904 of the driver 900 can
be attached to an off the shelf hand ratchet. The driver 900 joins
and separates modules through the module frame through hole.
Different versions of drivers such as Phillips, etc., can be
attached to different drive heads.
[0088] The solar panel system may be mounted over a fire resistant
roof covering rated for the application. The minimum mechanical
means to be used for securing of the pane] to the roof are
particular to the roof type, e.g. composition, slate, barrel tile,
cement tile, wood shake, foam core, tar and gravel, metal seam, and
slate. The minimum mechanical means (attachment points) are shown
in the offered in the diagrams below. Note that the specific number
of attachment points should be appropriate to the roof type, local
building code, and wind, snow, and seismic loading conditions. The
mounting hardware is shown in FIG. 8, The hardware 950 comprises a
bolt 952, a first lock nut 954, L-bracket 956, a second lock nut
950, flashing 960, a standoff plate 962 and a lag bolt 964. Spacer
blocks and shim blocks are also used in assembling the solar
panels.
[0089] FIG. 9 illustrates an embodiment of a north-south (N-S)
spacer block 966. The N-S spacer block ensures proper spacing
between modules. The spacer block 960 is a general spacer block and
can be removed after installation. The N-S spacer block 964 can
also be used as conduit to hold loose wire.
[0090] FIG. 10A illustrates an embodiment of a shim block 960. The
shim block 960 ensures that proper clearances between modules. FIG.
10B illustrates a shim block 960 on a panel 102. FIG. 10C
illustrates a shim block 960 between two solar panels 1.02a, 102b
for minimizing over-tightening.
[0091] By utilizing the above tools and hardware the solar panel
system can then be installed with ease.
[0092] Mechanical Installation
[0093] Below is a description of the installation of the solar
panel system in accordance with an embodiment.
[0094] Step 1. The mounting hardware (FIG. 11) Is installed--A flat
standoff late is mounted directly to a rafter using a hex lag bolt.
Flashing and the L bracket are mounted to the flat standoff
plate.
[0095] Step 2. The panels are positioned over the mounting location
(FIG. 12). Attachment points should be installed so that the top
and bottom of the module fit precisely between the attachment
points. A bolt is inserted into both the top and bottom frame
extrusion and is fasted to the slotted L bracket by a flanged lock
nut.
[0096] Step 3. The splices are inserted (FIG. 13) into the frame.
In an embodiment two splices are inserted into the frame on the
long edge of the module using a custom tool. The first splice will
connect the top frame of the module and the bottom will connect to
bottom frame of the module. When tightened together, the two
splices will draw two modules together and will act as a structural
member as well as a grounding bond.
[0097] Step 4. An array assembly is coupled using the splice (FIG.
14). The solar panels will be drawn together using either the
custom wrench between the modules or by using the custom driver.
The custom driver is inserted through the frame through hole using
a ratchet driver. Both the top and bottom splice should be secured
at the same rate. The assembly sliding motion will ensure that the
pair of connectors on the side of the module snap in securely to
the neighboring panel. The shim block on the long edge of the
module will prevent over insertion.
[0098] Step 5, Next, the splices are fully tightened, using the
custom driver and ratchet. Utilizing a shim block will prevent
over-tightening.
[0099] Step 6. Thereafter, the bolts are fully tightened. The
custom wrench is utilized to fully tighten the bolts on the L
bracket assembly and attachment points.
[0100] Step 7. Finally, the above steps are repeated to assemble
the desired number of modules in the string.
[0101] North-South Assembly
[0102] After the modules are assembled in a string into a solar
panel, one or more solar panels needed to be assembled in a
north-south (N-S) direction,
[0103] FIGS. 15A-D show that N-S assembly. FIG. 15A-B shows the
splice entering can opening in a panel (N-S) direction. The flat on
the splice faces up. There is also a flat in the opening where the
splice can engage when the flat on the spice is up,
[0104] FIG. 15C shows the splice flat up upon entry into the panel.
FIG. 15D shows, after entry, the splice is rotated and the round
surface on the splice jams in the flat on the splice. By utilizing
the splice in this manner, solar panels can be assembled in the
north-south direction.
[0105] Electrical Installation
[0106] The modules can be interconnected in series or in parallel
by connecting the positive and negative leads from the module
junction box as desired. For easiest electrical installation,
modules should be connected in series to form strings. Strings can
then be easily wired in series or parallel,
[0107] An example electrical schematic for proper wiring is shown
in FIG. 16. Note the inter-module, inter-string, and panel array to
conductor box and inverter wiring,
[0108] Grounding
[0109] For the solar panel system, inter-module grounding is
achieved via splices and inter-string grounding is achieved via
bare copper wire connected between grounding lugs,
[0110] Inter-module Grounding--To ensure proper grounding between
modules, the splice must be fully threaded into each panel until
the splice is butted against the grounding nut interior to the
frame. Splices can be used for grounding between modules for
connections along the long edge of the modules. Splices connected
along the short edges of the modules are mechanical only, and do
not provide grounding. FIG. 17 illustrates two inter-module
grounding splices.
[0111] Inter-string Grounding--On the end of a string of modules,
attach a grounding lug to the frame of one module using the
grounding screw. Ensure that in fastening the grounding screw, the
black anodized surface of the module frame has been scratched to
remove the non-conductive black coating of the aluminum frame.
Then, between two modules located on separate strings, connect the
grounding lugs with at a bare copper wire.
[0112] Panel to Conductor Box Grounding--On the end of a string of
modules, attach a grounding lug to the frame of one module using
the grounding screw. Then, the grounding lug L is connected to a
combiner box with copper wire or use the combiner box itself to
provide the grounding.
[0113] Now, the electrical connectors for the solar module that may
be integrated into the frame of the solar module (shown in FIG. 2A)
will be described in more detail.
[0114] FIGS. 18A and 18B illustrate an electrical connector
integrated into the frame of the solar module. In particular, FIG.
18A illustrates the set electrical connectors 1000 integrated into
a frame member 1002 wherein the set of electrical connector may
further comprise one or more pockets 1004 (two are shown in the
embodiment in FIG. 18A) into which an electrical connector 1006 and
a connector holder 1010 (shown in FIG. 18B) may releasably or
permanently affixed. Each electrical connector 1006 may have an
electrical lead 1008 attached to it. Each pocket 1004 in the frame
member 1002 is sized so that the electrical connector 1006 and the
connector holder 1010 may be moved laterally, vertically and/or
angularly within the pocket and still maintain the electrical
connection with the next solar module. As shown in FIG. 18B, the
electrical connector 1006 and holder 1010 pass through the frame
member 1002 and releasably or permanently affix the electrical
connector to the frame member 1002 so that electrical connection
between two adjacent solar modules can be made. In each solar
module, there may be a male connector 1006a and a female connector
1006b (as shown in FIG. 18B) and the male and female connectors
1106a, 1006b of one solar module electrically mate with the
corresponding female and male connectors on an adjacent solar
module or with a junction box 121, 121', 121'' as shown in FIGS.
2A-2D. Each of the male and female connectors have electrical
connectors inside them that are electrically connected together
when the male and female connectors are connected to each other.
Each holder 1010 for the male and female connectors are similar and
allow the particular electrical connector to be positioned so that
the connectors can be mated with the adjacent solar modules and/or
the junction box.
[0115] FIGS. 18C1-18C5 illustrate various views of the electrical
connector shown in FIGS. 18A and 18B. As shown in FIGS. 18C1 and
18C2, each connector has a notation 1020, such as example+sign that
is in the surface of the connector to ensure that the electrical
connectors are connected correctly when the solar modules are
installed. For example, each solar module may have a positive
voltage connector and a negative voltage connector (for AC power)
and the notations 1020 ensure that the connectors for adjacent
solar modules are connected to each other properly so that the
solar modules are electrically connected properly. These figures
also show the male connector 1006a with a first embodiment of the
connector holder 1010 installed.
[0116] FIG. 19 illustrate an embodiment of the connector holder
1010. As shown, the holder 1010 may be made of a resilient
material, such as a plastic or a metal material, etc. . . . and may
further comprise a body portion 1010a, a first and second wing
portions 1010b, 1010c which is resilient and are biased away from
the body portion 1010a. In operation, as the connector holder 1010
and connector 1006 are inserted into the pocket in the frame member
1002, the first and second wing portions 1010b, 1010c are forced
towards the body portion 1010a and then spring back out to hold the
connector 1006 in the pocket of the frame member. The holder 1010
may further comprises a first and axial portions 1010d, 1010e, that
may be biased closed, located at the bottom of the body portion
1010a as shown in FIG. 19 that allow the axial position of the
connector 1006a (into or out of the holder) to be adjusted wherein
the axial portions, when closed, hold the electrical lead 1008. As
shown in FIG. 20, the holder 1010 may further comprise a holder
pocket portion 1010f that provides room to permit the axial
location of the connector 1006 (in and out of the holder) to be
adjusted. As shown in FIG. 20, two holders 1010 and connectors
1006a are shown in which the connector 1006a is in a retracted
position in one holder/connector assembly shown on the left side of
FIG. 20 and is in an extended position in the other
holder/connector assembly shown on the right side of FIG. 20. As
described above, the axial position of the connector 1006a may be
adjusted by compressing the axial portions 1010d, 1010e and then
adjusting the position of the connector 1006a. Once the proper
axial position of the connector 1006 is achieved (when installing
the solar modules), the axial portions 1010d, 1010e can be released
and the connector is held in its desirable axial position. Now,
another embodiment of a female and male electrical connector are
described.
[0117] FIG. 21A-E are a perspective view, a right view, a front
view, a left view and a end view, respectively, of another
embodiment of a female electrical connector 1006b that may be
connected to the male connector to establish an electrical
connection between adjacent solar modules. This embodiment of the
female connector has the electrical lead 1008 and the connector
holder. In the embodiment, the connector holder 1028 is integrated
into the electrical connector and has a first and second portions
1028a, 1028b that have a spring effect to secure the electrical
connector to the frame using a first and second latching portions
1028e, 1028f as shown in FIG. 21A that are located at an end of
each first and second portions 1028a, 1028b. In one implementation,
each portion 1028a, 1028b may have a u shape. The electrical
connector 1006b also has a mating portion 1030 that can be mated
with a corresponding mating portion of the male connector as shown
in FIGS. 22A-22E. The electrical connector 1006b also has one or
more electrical contacts 1032 that electrically connect to
corresponding electrical contacts of the male connector as shown in
FIGS. 22A-22E.
[0118] FIGS. 22A-E are a perspective view, a right view, a front
view, a left view and a end view, respectively, of another
embodiment of a male electrical connector 1006a that can be used
with the female connector 1006b of FIGS. 21A-21E to establish an
electrical connection between adjacent solar modules. This
embodiment of the male connector has the electrical lead 1008 and
the connector holder. In the embodiment, the connector holder 1028
is integrated into the electrical connector and has a first and
second portions 1028a, 1028b that have a spring effect to secure
the electrical connector to the frame using a first and second
latching portions 1028r, 1028f as shown in FIG. 21A that are
located at an end of each first and second portions 1028a, 1028b.
In one implementation, each portion 1028a, 1028b may have a u
shape. The electrical connector 1006b also has the mating portion
1030 and the one or more electrical contacts 1032 that electrically
connect to corresponding electrical contacts of the female
connector.
[0119] In one implementation, the female shown in FIGS. 21A-E may
be used with a retractable electrical connector as will now be
described in FIGS. 23A-B and 24A-B. In particular, the electrical
connector has the capability to retract into the frame of the solar
module so that, during shipping and movement of the solar module,
any protrusion is eliminated from the panel. When the one or more
electrical connector(s) are in the retracted position, the
electrical connectors cannot be damaged by hitting or getting
caught on something outside of the panel during transit. Later,
when ready for installation, the connector can be moved into an
install position where it protrudes from the panel for
interconnection with an adjacent panel. Now, an implementation of
the retractable electrical connector is described in more
detail.
[0120] FIGS. 23A and 23B are a side view and a sectional view along
line A-A, respectively, of the female connector of FIGS. 21A-E in
an retracted position and FIGS. 24A and 24B are a side view and a
sectional view along line A-A, respectively, of the female
connector of FIGS. 21A-E in an install position. The female
electrical connector has the same elements as described above. In
the retracted position, the first and second latching portions
1028e, 1028f are attached to a back portion of the frame 1002.
Then, when the female connector is moved into the install position
(by pushing in the first and second portions 1028a, 1028b) so that
the female electrical connector is moved out and then the first and
second latching portions 1028e, 1028f connect to the outer portion
of the frame 1002 as shown in FIGS. 24A-B.
[0121] Although the system has been described in accordance with
the embodiments shown, one of ordinary skill in the art will
readily recognize that there could be variations to the embodiments
and those variations would be within the spirit and scope of the
system. For example, although the splice is preferably made of a
conductive material such as aluminum, it could be made utilizing a
non-conductive material which has a conductive capability added to
its surface and its use would be within the spirit and scope of the
system. Accordingly, many modifications may be made by one of
ordinary skill in the art without departing from the spirit and
scope of the appended claims.
* * * * *