U.S. patent application number 14/976720 was filed with the patent office on 2016-04-21 for micro-inverter solar panel mounting.
This patent application is currently assigned to SunPower Corporation. The applicant listed for this patent is SunPower Corporation. Invention is credited to Phillip Charles Gilchrist, John Morris.
Application Number | 20160112003 14/976720 |
Document ID | / |
Family ID | 50930641 |
Filed Date | 2016-04-21 |
United States Patent
Application |
20160112003 |
Kind Code |
A1 |
Morris; John ; et
al. |
April 21, 2016 |
Micro-Inverter Solar Panel Mounting
Abstract
Processes, systems, devices, and articles of manufacture are
provided. Each may include adapting micro-inverters initially
configured for frame-mounting to mounting on a frameless solar
panel. This securement may include using an adaptive clamp or
several adaptive clamps secured to a micro-inverter or its
components, and using compressive forces applied directly to the
solar panel to secure the adaptive clamp and the components to the
solar panel. The clamps can also include compressive spacers and
safeties for managing the compressive forces exerted on the solar
panels. Friction zones may also be used for managing slipping
between the clamp and the solar panel during or after installation.
Adjustments to the clamps may be carried out through various means
and by changing the physical size of the clamps themselves.
Inventors: |
Morris; John; (Pflugerville,
TX) ; Gilchrist; Phillip Charles; (Austin,
TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SunPower Corporation |
San Jose |
CA |
US |
|
|
Assignee: |
SunPower Corporation
San Jose
CA
|
Family ID: |
50930641 |
Appl. No.: |
14/976720 |
Filed: |
December 21, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13751376 |
Jan 28, 2013 |
9253935 |
|
|
14976720 |
|
|
|
|
61737365 |
Dec 14, 2012 |
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Current U.S.
Class: |
136/244 ;
29/525.01; 361/679.01 |
Current CPC
Class: |
Y10T 29/49117 20150115;
H02S 40/32 20141201; F16B 2/065 20130101; F16M 13/02 20130101; Y02E
10/50 20130101; H05K 7/1401 20130101; H02S 30/00 20130101; H02S
40/34 20141201 |
International
Class: |
H02S 40/32 20060101
H02S040/32; H05K 7/14 20060101 H05K007/14; F16M 13/02 20060101
F16M013/02; H02S 30/00 20060101 H02S030/00; F16B 2/06 20060101
F16B002/06 |
Claims
1.-16. (canceled)
17. A component clamping system comprising: a first solar panel,
the first solar panel comprising a front surface and a back
surface, the front surface comprising a photovoltaic collector, the
first solar panel further comprising a frameless mounting area; an
electronic component configured with one or more securements for
mounting the electronic component to a frame surrounding a second
solar panel; and a first adaptive clamp coupled to one or more
securements of the electronic component and clamped to the
frameless mounting area of the first solar panel by the application
of compressive force to the front surface of the first solar panel
and compressive force to the back surface of the first solar
panel.
18. The component clamping system of claim 17 wherein the clamp is
in the form of an "L" shape or wherein the clamp is sized and
shaped such that the photovoltaic collector on the front surface is
not covered by the clamp, or both.
19. The component clamping system of claim 17 further comprising: a
mid-cable junction mounting, the mounting coupled to the first
solar panel and secured to a cable coupled to the electronic
component.
20. The component clamping system of claim 17 wherein the clamp
includes a first spacer positioned atop the front surface and a
second spacer positioned atop the bottom surface, the spacers
configured and positioned to distribute compressive forces from the
clamp to a border of the first solar panel.
21. The component clamping system of claim 17 wherein the
electronic component is a micro-inverter.
22. The component clamping system of claim 19 wherein the mid-cable
junction mounting further comprises: a u-channel, the u-channel
positioned around a border of the first solar panel, the u-channel
serving to couple the mid-cable junction mounting to the first
solar panel.
23. A system for securing an electronic component to a solar panel,
the system comprising: an electronic component configured to be
mounted on a frameless area of a first solar panel, the electronic
component having a plurality of fastening points; a primary clamp
comprising a plurality of securement areas that each coincide with
one or more fastening point of the electronic component; and a
first compression spacer, a second compression spacer, and a third
spacer; wherein the primary clamp and the electronic component are
coupled to each other and secured to the frameless area of the
first solar panel, the frameless are of the first solar panel
having a thickness, wherein the third spacer is positioned and
configured to maintain a distance equal to or greater than the
thickness of the first solar panel.
24. The system of claim 23 wherein the first compression spacer and
the second compression spacer are positioned between the primary
clamp and the electronic component, are spaced apart from each
other, and are separated by the first solar panel.
25. The system of claim 23 wherein the electronic component is a
micro-inverter.
26. The system of claim 23 wherein the third spacers have an
internal passage and wherein the passage comprises a screw or other
connector.
27. The system of claim 23 further comprising a mid-cable junction
clamp, the mid-cable junction clamp secured the frameless area of
the first solar panel and coupled to a portion of the electronic
component.
28. The system of claim 27 wherein the mid-cable junction clamp
further comprises one or more break away sections on an exposed
securement area and a safety, the safety configured to provide a
visual or audible alarm when compressive forces exerted by the
mid-cable junction on the solar panel reach or exceed a compressive
pressure threshold.
29. A solar panel clamp system comprising: a u-channel, the
u-channel having a securement area sized and configured to be
positioned around a frameless border of a first solar panel, the
u-channel configured and sized to couple a component to the first
solar panel, the u channel comprising a compressible material, the
u-channel comprising one or more break away sections on the
securement area and a safety, the safety configured to provide a
visual or audible alarm when compressive forces exerted by a
component secured to the first solar panel by the u-channel reach
or exceed a compressive pressure threshold of the first solar
panel.
30. The solar panel clamp system of claim 29 wherein the visual
alarm is a flash or color change and wherein the audible alarm is a
click or squeal.
31. The solar panel clamp system of claim 29 wherein the u-channel
includes a friction strip positioned to engage the frameless border
of the first solar panel border.
32. A solar panel system having a frameless mounting area
comprising: a photovoltaic component; a first clamp, a second
clamp, and a third clamp, wherein each of the clamps is secured to
a different portion of the photovoltaic component; wherein the
first clamp exerts compressive forces on a front surface of a first
solar panel and the component exerts opposing compressive forces on
a back surface of the first solar panel, these compressive forces
serving to secure the clamp and the photovoltaic component to a
first frameless portion of the solar panel, and wherein the second
clamp is secured to a different portion of the photovoltaic
component and wherein the second clamp is compressively secured to
a second frameless portion of the first solar panel using a means
for exerting securing forces.
33. The solar panel system of claim 32 wherein the photovoltaic
component is a micro-inverter and the different portion of the
photovoltaic component is a cable.
34. The solar panel system of claim 32 wherein the means for
exerting securing forces comprises: a ratchet and pawl or a cam or
a spring
Description
[0001] The present application claims priority to U.S. provisional
application No. 61/737,365, filed on Dec. 14, 2012, which is herein
incorporated by reference in its entirety.
BACKGROUND
[0002] The present invention relates to securing electronic
components to solar arrays and more specifically, to processes,
machines, and articles of manufacture for mounting micro-inverters
to solar arrays without the necessity to secure the micro-inverter
or one or more of its components to a frame surrounding the solar
array.
[0003] Solar array panels are installed in sets to gather and
convert electromagnetic light waves into direct electrical current.
The direct current may be further converted to alternating current
or otherwise conditioned using inverters. A single inverter may
serve an entire set of solar panels converting or conditioning the
power received from the set of solar array panels.
[0004] More recently, individual inverters have been paired with
individual solar panels to convert or condition the direct current
generated by individual panels. The fragile nature of solar panels,
and the photovoltaic collectors positioned on their face, has
promoted numerous protection mechanisms, including the use of
transparent covering materials and full-frame cases, to protect the
solar panels, and to promote their longevity.
BRIEF SUMMARY
[0005] Processes, machines, devices and articles of manufacture are
provided for mounting or otherwise securing inverters,
micro-inverters, or other electronic components to a solar panel
with limited or no assistance from a frame surrounding or
supporting the solar panel. These embodiments may include using
clamps that use friction, compressive forces, or both to secure an
inverter, micro-inverter, or other electronic component to a solar
panel. These clamps may be positioned along an edge of the solar
panel and may not interfere with or may mildly interfere with the
light gathering efficiency of the solar panel or the individual
photovoltaic collectors on the face of the panel. The clamps may be
configured to use reactionary forces generated between the clamps
and the electronic component to secure the clamp and the electronic
component to a frameless portion of a solar panel.
[0006] Embodiments may include clamps such as: brackets, mountings,
clips, or the like, that are sized or configured to convert
frame-mounted electronics for a solar panel into a frameless
mounting configuration. These clamps may include compression zones
or areas that exert securing forces against the solar panel as well
as safeties that provide alerts when compressive forces may be
reaching tolerance thresholds of the solar panel materials. The
clamps may also include friction zones or areas that retard travel,
slipping or other movement between the mounted components and a
solar panel during installation, as well as after installation, of
the components to the solar panel.
[0007] Process embodiments can include configuring one or more
clamps to bridge and allow an inverter or other component
originally manufactured to be frame-mounted on a solar panel frame,
to be mounted on a solar panel without a frame, or at least to be
mounted on a portion of the solar panel without the use or
necessity of a frame. This process may include measuring the
existing micro-inverter and solar panel layouts and any fastening
points they may already have or are intended to have, and
constructing one or more clamps that can secure to both the
assembly or its components (with or without using the fastening
points) and the solar panel, and also serve to accommodate the
differences between both. These differences may include size
differences, securement point differences, and material tolerance
differences.
[0008] These clamps may include a friction area for providing
friction securement forces as well as a compression area for
providing compression securement forces, and may also include a
safety to provide alerts, mechanical protections, or otherwise
serve to decrease or prevent the application of compressive forces
greater than compressive force tolerances of a solar panel or a
specific securement area on the solar panel. The compression zone
and friction area may have or provide for uniform pressure and
friction applied by them to the solar panel and may have or provide
for non-uniform pressure and friction applied by them to the solar
panel. The uniform or non-uniform pressure and friction may be
applied at various spacings, both uniform and non-uniform, in the
areas of the solar panel acted on by the clamps.
[0009] Clamp embodiments may comprise plastics, such as a resin,
rubbers, metals and metal alloys, and may have various
configurations, including rectangular shapes and "L" shapes. The
clamps may generate compressive forces or other securement forces
onto a solar panel by being secured to fastening points of a
micro-inverter or a component of a micro-inverter assembly, and by
providing for a space between itself and the micro-inverter or
assembly in which the solar panel may fit. As this space changes,
e.g. becomes closer, compressive securement forces can be generated
to secure the micro-inverter or assembly component directly to a
portion of the solar panel and without the necessity of a
frame.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 shows a perspective view of a frameless solar panel
for use in embodiments.
[0011] FIG. 2 shows an enlarged perspective view of a portion of a
frameless solar panel having a primary clamp fastened to a
micro-inverter and together serving to secure themselves to the
solar panel in accord with embodiments.
[0012] FIG. 3 shows a perspective view of a mid-cable junction
clamp and mid-cable junction secured to an edge of a frameless
solar panel in accord with embodiments.
[0013] FIG. 4 shows an exploded perspective view of a
micro-inverter assembly, a primary metallic clamp, a mid-cable
junction clamp, a tertiary clamp, and a portion of a frameless
solar panel, in accord with embodiments.
[0014] FIG. 5 shows a perspective sectional front view of the
frameless solar panel with the micro-inverter assembly of FIG. 4
mounted in accord with embodiments.
[0015] FIG. 6 shows a perspective sectional back view of the
frameless solar panel with the micro-inverter assembly of FIG. 4
mounted in accord with embodiments.
[0016] FIG. 7 shows an exploded perspective view of a
micro-inverter assembly, a primary polymer clamp, a mid-cable
junction clamp, a tertiary clamp, and a portion of a frameless
solar panel, in accord with embodiments.
[0017] FIG. 8 shows a perspective sectional front view of the
frameless solar panel and micro-inverter assembly of FIG. 7 in
accord with embodiments.
[0018] FIG. 9 shows a perspective sectional back view of the
frameless solar panel and micro-inverter assembly of FIG. 7 in
accord with embodiments.
[0019] FIG. 10a shows a perspective view of a primary polymer
mounting clamp in accord with embodiments.
[0020] FIG. 10b shows a side-view of a deflection zone as may be
employed by a clamp in embodiments.
[0021] FIGS. 11a-11g shows top, bottom, and side views of the
primary clamp from FIG. 10a.
[0022] FIGS. 12a-12b shows top and side views of a primary metallic
clamp in accord with embodiments.
[0023] FIG. 13 shows a process in accord with embodiments.
[0024] FIG. 14 shows a process in accord with embodiments.
[0025] FIG. 15a-15c show means for generating or exerting securing
forces in accord with embodiments.
DETAILED DESCRIPTION
[0026] Processes, apparatus, systems and articles of manufacture
are provided. These may include various processes, apparatus, and
articles of manufacture for mounting micro-inverters to solar
panels. Edges or other portions of these solar panels may be
frameless. These edges, or other portions of the solar panels, may
receive a clamp for securing a micro-inverter or other associated
cabling or junction box, to the solar panel. In certain
embodiments, one or more edges of the solar panel may lack a frame
for mounting electronics directly to the frame and indirectly to
the solar panel. These frameless mounting areas may be used by
clamps or other securements to secure micro-inverters and their
associated components and cabling to the solar panel.
[0027] In embodiments, existing configurations of frame-mounted
micro-inverters and associated components and cabling may be used
with adaptive clamps configured to pair with the micro-inverter and
its associated components and cabling, and adaptively secure them
to a solar panel without, necessarily, the use of a frame for which
the existing frame-mounted micro-inverter and associated components
and cabling were configured for.
[0028] In preferred embodiments the micro-inverter and some or all
of its components will be mounted on the back, shade-side of the
solar panel. However, certain components may be mounted on each
side of the solar panel in certain configurations. These multi-side
mounting systems may be preferred to reduce torsional forces on the
solar panel. In other words, in certain installations, a
micro-inverter may be mounted on the back of the solar panel while
some connected components, and perhaps the cabling as well, may be
mounted on the front of the solar panel.
[0029] In embodiments, a micro-inverter and its associated cabling,
and components, such as a junction box, already configured for
mounting to a framed solar panel, may be mounted to a frameless
solar panel using a primary L shape clamp in a corner of a
frameless solar panel, a mid-cable junction clamp along an edge of
the solar panel, and a tertiary clamp near an opposite end of the
solar panel. These clamps may be made of metal, plastic, polymers,
rubber, resin, and combinations thereof, and may create securing
forces through friction or compression or adhesion and various
combinations thereof, between, for example, the clamp and the
micro-inverter or other component. The frictional forces may be
created using rubber, EPDM, or other material with surface friction
properties. The compressive forces may be created by using moveable
fasteners, such as screws, springs, ratchets, pawls, and levels.
Adhesional forces may also be created using adhesives or other
bonding agents to bond the micro-inverter and its components and
cabling to a clamp and also for bonding the clamps to a solar
panel. Thus, in embodiments, frictional, compressive, and
adhesional forces may all work together to secure a micro-inverter
and its components and cabling to a solar panel.
[0030] The clamps may extend along edges of frameless solar panels
and may be sized to fit over the front face and the rear face of
the solar panel, and then be secured further around the solar
panel. The solar panel in embodiments may be comprised of, for
example, glass, ceramic, or other brittle material. In preferred
embodiments, penetration of the solar panel need not be performed
by the clamp to secure the micro-inverter assembly to a solar
panel. However, drilling through or otherwise penetrating the solar
panel may be employed in methods, devices, and system embodiments
as part of securement, or for other reasons as well. For example,
cotter pins may extend through the clamps and the solar panel for
initial orientation during installation and may be used for final
securement also. In preferred embodiments, any penetrations through
the solar panel will avoid the solar photovoltaic collectors on the
face of the solar panel. In preferred embodiments, no penetrations
are made in the solar panels, however in certain embodiments
penetrations may be made or may exist in the panel and may be used
for securement.
[0031] In embodiments, a micro-inverter main assembly may be
secured in a corner of a solar panel, as noted above, or along
other portions of the panel as well. This may include edges of the
panel, and areas away from the edges of the panel too. In
embodiments, cabling may be mounted on the same side of the solar
panel as the micro-inverter main assembly and along an edge of the
solar panel while, preferably, limiting or not extending cabling or
components or clamps into the light receiving areas of the solar
panel photovoltaic collectors.
[0032] In embodiments, clamps used for mounting cabling or junction
boxes to the solar panel may be similar to those used for mounting
a micro-inverter itself. These cabling and junction box clamps may
be edge mounted along a solar panel, and may preferably be
positioned on the same side of the solar panel as the
micro-inverter. Other configurations are also possible.
[0033] As a non-limiting example, cabling or junction boxes may be
mounted on the opposite side of the solar panel from the
micro-inverter and the cabling and micro-inverter may be mounted on
various portions of the panel--not only the edges or corners of the
panel. FIG. 6 shows how the junction box 551, and micro-inverter
420, may be mounted on the same side of the solar panel--the back
of the panel--and the cabling may be mounted along an edge and
extendable over the side and past the side of the solar panel.
[0034] The clamps preferably may employ compression zones and
friction zones to secure themselves to the solar panel. The
compression zones may include the use of rubber, silicone, felt,
plastomers, or other flexible and compressive materials, preferably
with an elasticity greater than the material comprising the solar
panel. The elastic material may preferably be configured such that
an installer can readily recognize when adequate compressive forces
are being exerted to secure the clamp, while remaining under the
tolerances of the solar panel materials to which the clamp is
applying securement forces. This configuration can include
deflection zones that compress to touch the panel under certain
compressive forces as well as safeties that click or otherwise
provide audible or visual warnings that certain compressive forces
have been reached.
[0035] The friction zones may also employ rubber, silicone, and
other materials. These materials may be selected because of the
frictional resistance forces they can exert to prevent sliding and
movement when compressive forces are low, as during assembly, or
when material tolerances prevent larger compressive forces from
being exerted on the solar panel.
[0036] In embodiments, the mounting process preferably may include
first securing the clamps to the micro-inverter or other component
to be mounted, sliding the clamp over the solar panel, and then
applying any additional compressive forces to hold the clamp and
micro-inverter or its components or cabling in place. In so doing,
retrofits of existing micro-inverters may be accommodated and
accomplished. In other embodiments, the mounting process may be
carried out in a different order, such as mounting the clamps to
the solar panel first, then securing the micro-inverter or other
component or cabling to the clamp.
[0037] As is shown in subsequent figures, the clamp maybe secured
to the solar panel through pairs of fasteners. Thus, in
embodiments, a primary clamp may be secured to a micro-inverter,
the combined clamp and micro-inverter may be slid over an edge of
the solar panel until the components reach their final deployed
position, and the fasteners may be tightened further to clamp the
micro-inverter to the solar panel. The primary clamp may be
metallic as well as polymeric and may be specially configured to
remain clear of solar photovoltaic collectors on the face of the
solar panel.
[0038] The mounting provided herein may result in the
micro-inverter being flush with a surface of the solar-panel or
being spaced away from the solar panel. Moreover, the clamp and
mounting locations may be adjusted to accommodate various solar
panel designs and installation configurations, including
installation configurations confronted in the field.
[0039] FIG. 1 shows a perspective view of a frameless solar panel
100 as may be employed in embodiments. As can be seen, photovoltaic
collectors 111 and a panel edge 110 are shown. As can also be seen,
the solar panel 100 lacks a frame along at least three of its
edges. Thus, in embodiments, a solar panel without a frame or other
external metallic mounting system may, nevertheless, receive
micro-inverters or supporting components or cabling, even
micro-inverters or components configured to be frame-mounted,
despite the absence of a frame or other metallic external mounting
apparatus for these panels.
[0040] FIG. 2 shows an enlarged perspective view of a corner of a
frameless solar panel 200. FIG. 2 also shows panel photovoltaic
collectors 211, panel edge 210, micro-inverter 220, fastening
points 221, securement area 222, compression zone 224, and primary
L clamp face 223. As can be seen in FIG. 2, the clamp face 223 is
L-shaped and includes four securement areas 222 along its edge. The
clamp also includes a compression spacer behind L clamp face (and
therefore not visible in this view). The micro-inverter 220 is also
visible through the solar panel 200. As can also be seen, the
L-shaped clamp face 223 is sized and shaped to fit within the panel
edge 210 on the light receiving side of the panel and the
securement areas 222 coincide with fastening points 221 on the
micro-inverter 220. This panel edge lacks the panel light
collectors 211. Thus, in preferred embodiments, the clamp used for
securing the micro-inverter or other components to the frameless
solar panel 200 may not cover the active light collectors of the
solar panel 200. However, in other embodiments, the clamp used for
securing the micro-inverter or other components to the frameless
solar panel may cover the active light collectors of the solar
panel, such as where the panel comprises light collectors nearer or
at its edge.
[0041] The clamp face 223 includes securing areas 222, each with
two screws and biasing springs. The position of the securing areas
222 as well as the screws and their sizing may coincide with
existing fastening points of the micro-inverter 220. During
installation, to properly manage securing forces exerted by the
clamp as the screws 225 are turned, an audible or visual
compression safety may also be used to signal when a certain
compressive force has been reached and is being exerted. This
safety may be sized and designed such that notice will be provided
to an installer when compressive forces being exerted by the screws
225 begins to reach the compressive force tolerance of the
materials comprising the panel edge 210. In other words, as an
installer is applying compressive forces through the screws 225 in
the securing area 222, and is receiving compressive feedback,
through springs in that area as well, an additional audible or
visual compression safety may be present to sound a click, squeal,
flash, color change, or other audible or visual alarm that proper
compressive forces are being exerted or that limits for the panel,
or panel edge, are being approached. This safety may be located in
the securement area as well as in other areas of the clamp, such as
in the compression spacer behind the L-shaped clamp face 223.
[0042] FIG. 3 shows a perspective view of the mid-cable junction
clamp 323 used for mounting a micro-inverter mid-cable junction
onto an edge of the frameless solar panel 300. Also visible in FIG.
3 is the panel thickness 330, the clamping force 322 exerted by the
face of the mid-cable junction clamp 323 on the solar panel,
exposed orientation lip 326, compression zone 324, friction zone or
friction strip 325, and securing area 321.
[0043] In embodiments, the clamping force being exerted by the
clamp face on the panel may be exerted by internal springs as well
as by screws, pins, a gear and ratchet system, a cam and lever, or
other mechanical securing devices used by an installer during
installation. These various systems may also provide for adjustment
such that various forces may be exerted by a clamp on the solar
panel. The size of the securing area 321 is preferably sized to
keep stresses on the edge of the frameless solar panel 300 exerted
by the clamp to be well within the solar panel's compressive stress
limits.
[0044] The clamp 323 may include an exposed lip 326, which can
serve to assist during alignment and orientation of assembly as
well as serve to control the size of the securement area. The
securement area 321 may not receive opposing compressive forces
from below the area in which the lip 326 is present because an
equal opposing force is not created there by the clamp. The
friction strip 325, which is present in the securement area of the
clamp, may be oriented in different directions as well, and there
may be other friction strips as well to provide resistance to
slipping forces along multiple axes.
[0045] In operation, the mid-cable clamp 323 may be secured to the
mid-cable junction 331 and may preferably have an adjustable
receiving space larger than the panel thickness 330. This receiving
space may be adjusted using various means for exerting securing
forces described herein, including a cam and lever, a ratchet, and
pins, examples of which are provided in FIGS. 15a-15c. In use, the
receiving space may slide over the panel 300 prior to securing the
clamp to the panel. Compressive forces may then be exerted through
various methodologies to compress the receiving space over and to
the solar panel. As noted, the structures for creating the
compressive forces can include, but are not limited to, an internal
ratchet or pawl or cam system, as well as springs, and externally
accessible screws.
[0046] In embodiments, the mid-cable junction clamp may also first
be attached to the solar panel prior to the micro-inverter
mid-cable junction 331 being attached to the clamp. In embodiments,
the mid-cable clamp 323 may also first be secured to the
micro-inverter mid-cable junction 331 and then the entire assembly
may be secured by three clamps (a primary clamp, a mid-cable clamp,
and a tertiary clamp) to the frameless solar panel 300. The
mid-cable clamp 323 may also be held in place by frictional forces
created by a friction strip or friction zone 325 as the compressive
forces are applied and the securement is made.
[0047] The mid-cable junction clamp 323 shown in FIG. 3 may
comprise a polymer material, but other materials may be used as
well. In embodiments, composite materials including polymers,
metals and metal alloys may be used, and these may be combined with
other materials as well. Thus, the base of the mid-cable junction
clamp may be a metal alloy, where it is secured to the mid-cable
junction and the top of the mid-cable junction clamp may be a
polymer and a rubber, where the mid-cable junction clamp receives
and secures the solar panel 300.
[0048] The size of the securement area 321 and the exposed lip 326
may be selected to manage the amount of compressive forces placed
on a panel 300 as well as to reduce the amount of unwanted pin
point loads that may be developed at or near the edges of the
securement area 321. In other words, the securement area 321 may be
selected during design to allow for a large enough total overall
compressive force to be applied for securement of the clamp and the
cable to the panel 300 but to also satisfy a PSI compressive force
tolerance of the panel 300 for the cable being secured.
[0049] Break away sections may be present in the securement area to
allow for adjustment of the size or shape of the securement area
321. These break away sections may comprise scored lines spaced at
various distances apart in the securement area 321. By breaking
away a scored section of the securement area 321, the amount of
total securement force may remain the same and the PSI exerted on
the solar panel may increase.
[0050] FIG. 4 shows an exploded view of a section of a frameless
solar panel 400 and various components that may be secured to the
solar panel 400. Visible in FIG. 4 are the frameless solar panel
400, the micro-inverter 420, stainless steel hardware (screws and
spacers) 442, a connector 444, a tertiary cable clip 443, a
mid-cable junction clamp securing area 421, a mid-cable junction
clamp 423, a mid-cable junction 431, Ethylene Propylene Diene
Monomer (EPDM) spacers 441, a metal L top clamp 425, and topside
EPDM spacer/friction strip 445. The stainless steel hardware 442
shown includes screws as well as spacer collars. These collars may
be configured such that they provide an audible warning or visible
warning, such as, but not limited to, a click or color change when
compressive forces being applied by the screw approach a
compressive force threshold of the solar panel. Also, in
embodiments, the spacer collars may provide a mechanical stop to
prevent over compression. Likewise, the clamp may also provide
mechanical stops in embodiments as well.
[0051] As can be seen in FIG. 4, the stainless steel hardware 442
from the metal clamp 425 of the micro inverter 420, is positioned
just outside the edge of the frameless solar panel 400. During
assembly, the tertiary cable clamp 443 and the mid-cable junction
clamp 423 may be slid over an edge of the frameless solar panel 400
prior to securing the components and cabling to the clamps 443 and
423. In so doing, proper compressive forces and tensions may be
applied to secure the clamps to the solar panel. This process may
be different or even reversed as well, with the clamps first being
secured to some or all of the micro-inverter assembly components
before securing the clamps to the solar panel. In this or other
embodiments a gap of, for example, 5 mm when the panel thickness is
3 mm, may be left in the bracket before it is slid over the solar
panel edge and then securement forces may be applied to remove the
gap and secure the clamps to the solar panel. In embodiments, the
EPDM spacers may occupy a portion of this gap and may be, for
example, 2 mm in thickness. These spacers may serve to provide
frictional temporary forces to hold the clamps in place during
securement. Other thicknesses and gaps may be used as well in
embodiments.
[0052] FIG. 5 shows a micro-inverter assembly coupled to the
frameless solar panel 400 using various clamps in accord with
embodiments. As can be seen, the face of the frameless solar panel
400 has portions of the cable clamp 443, the mid-cable junction
clamp 423, and the metal bracket frameless panel clamp 425, on its
upper face, while the inverter assembly components are positioned
on the opposite, lower face. Visible in FIG. 5 are the frameless
solar panel 400, the tertiary cable clamp 443, the mid-cable
junction 431, the mid-cable junction clamp 423, the metal bracket
frameless panel clamp 425, friction strip 446, securement access
535, and the micro-inverter 420. As is also noticeable in FIG. 5,
when the micro-inverter assembly is secured to the frameless solar
panel, a final connector may be routed to and beneath the solar
panel. In other embodiments, as is shown in FIG. 5, a connector may
also extend beyond the solar panel to connect the micro-inverter
assembly to an outside system or circuit. The position of the
connector may depend upon the final installation logistics and
orientation of the solar panel in the field installation. The
friction strip 446 may serve to prevent slippage of the clamp 423
in the lateral direction shown by arrows 501. The friction strip
may also serve to prevent slippage in the perpendicular direction
shown by arrows 502. The securement access may provide an opening
through which a means for generating or exerting securing forces,
such as a cam or pawl, ratchet, threaded screw, or spring system
can be activated or put in place to provide compressive forces for
the mid-cable junction clamp 423.
[0053] FIG. 6 shows the reverse side of the solar panel of FIG. 5,
with the inverter assembly attached. In addition to the components
identified in FIG. 5, FIG. 6 also shows a junction box 551. This
junction box 551 may be positioned in various locations on a solar
panel and may be a primary point of electrical and mechanical
connection between the micro-inverter assembly and the actual
photovoltaic collectors of the solar panel 400.
[0054] FIG. 7 shows an exploded view of a micro-inverter assembly
and frameless solar panel much like that from FIG. 4. A notable
difference is that the clamps are each made of a resin material
rather than a steel or other metal alloy material, as is shown in
FIG. 4. As can be seen in FIG. 7, the L-shaped clamp top has a
higher profile that the metal clamp of FIG. 4 and has various
support ridges along its length, unlike the metal clamp shown in
FIG. 4. These ridges may provide resistance to torsional forces
applied to the clamp and may provide reinforcement in other
orientations as well. The ridges or reinforcements may also run
along the length of the clamp in addition to being perpendicular to
the length, or instead of this orientation. The orientation of the
ridges may be aligned in different positions as well.
[0055] FIG. 7 includes a frameless solar panel 700, stainless steel
hardware 742, clamp 723, clamp 725, EPDM spacer 741, micro-inverter
720, mid-cable junction 731, cable clip 743, and connector 744. As
above, the connector 744 along with the mid-cable junction 731, and
the micro-inverter 720, comprise the micro-inverter assembly. In
embodiments, the micro inverter assembly may include the same,
fewer, or more components as well. As with earlier discussions,
compressive forces may also be managed while applying securing
pressures in the clamp 723. Management of compressive forces may be
managed via sensing systems, as discussed elsewhere herein, or by,
as additional examples, breakaway areas specifically designed to
fail prior to reaching tolerances of the frameless solar panel.
These breakaways or other components can take on various
configurations and include the scores shown on FIG. 12a. The clamps
may also include mechanical stops to prevent over compression.
These stops may be included with the hardware 742 and may comprise
a polymer, such as rubber, to provide a flexible and resilient
stop.
[0056] FIG. 8 shows a micro-inverter assembly attached to a bottom
edge of the frameless solar panel 700. As can be seen, the top
surface of the solar panel 700 has primary clamp 725, mid-cable
clamp 723, and tertiary clamp 743 extending over and onto the top
surface. On the reverse surface, the micro-inverter 720, mid-cable
junction 731, and the remaining portions of the cable are
positioned and secured.
[0057] FIG. 9 is similar to FIG. 6 in mounting details and
discussion. FIG. 9 shows a connector 744, a micro-inverter 720, a
junction box 951, a mid-cable junction 731 having a compression bar
945, a mid-cable junction clamp 723, a tertiary cable clamp 743,
and an additional connector 744. Also visible in FIG. 9 is the edge
of the frameless solar panel.
[0058] FIG. 10a shows a perspective view of a top L clamp 1023 as
may be employed in embodiments. Visible in FIG. 10a are the secured
areas 1022, L overhang 1010, and a securing area 1021. Consistent
with the above, as screws or other secure devices are placed
through the securing area, clamping force will be applied across
the entire body of the clamp.
[0059] FIG. 10b shows a deflection zone as may be employed in
various embodiments. These deflection zones may be used in clamps
to monitor the compressive forces exerted by the clamp. The posts
173 may move towards a surface 1070 to show that the limit of
deflection 1072 has been reached or is approaching. In other words,
the force needed to move the posts 1073 to a surface 1070 indicates
that a certain force has been applied to the clamp and is being
applied by the clamp to a panel to which the clamp is secured.
[0060] FIG. 11 shows top side and bottom side views of polymer L
clamp as may be employed in embodiments. The top side of the clamp
is shown at 1023a, the other side is shown at 1023b, and a bottom
view is shown at 1023c. As can be seen in 1023c, the polymer is
reinforced with ribs along its length for structural support. These
ribs are shown at 1011, section B-B. Section AA, at 1013, shows how
a recess may be formed along the length of the clamp. A cushion,
such as an EPDM spacer, may be placed along the length as well. The
top side EPDM spacer 445, of FIG. 4, is such an example. The
sectional view C-C shows how the screw channel 1110 may have a wall
1111. This wall may serve as a safety. This wall may be designed
with a compression zone that can withstand a certain compression
tolerance and may then send an audible or visual signal when this
compression tolerance is reached or exceeded. The signal may
include a visible deflection, a change in color, a cracking or
popping or clicking sound, and other variations of audible or
visual indicators. The indicator signal may be created through the
use of variable materials in the walls or by using a variable
cross-sectional thickness in the wall with a sacrificial area, or
through other configurations and methods as well.
[0061] FIG. 12 shows a top and side view of the metal clamp as may
be employed in embodiments. The top side is visible at 1223 and the
side view is visible at 1223b. The securing area 1221 is shown
along with the clamping force 1222. The securing area 1221 may be
applying uniform compressive forces when used for securement and
may provide nonuniform forces as well. As can be seen in FIG. 12,
the L clamp has a substantially uniform width across the entire
length of the L clamp. In embodiments, the clamp may have different
widths and lengths and may be configured to secure to certain
specific solar panels. The L clamp may also have scores 1225 across
the clamp that may be used to change the length of the clamp by
creating bend points for easily fatiguing the metal and snapping
unwanted lengths of the clamp away from it during in-situ field
installation. In other words, should the clamp be sized to fit
several sizes of panel, the clamp may be reduced in size for a
certain panel by removing a portion of the clamp prior to
installation. As can be seen, the scores 1225 may have various
orientations.
[0062] FIG. 13 provides a method as may be employed in embodiments.
These actions of the method may be performed with others, and in
this or various other orders. They may also be performed as
described or with more are fewer steps or considerations as well as
with more or different considerations. As shown in FIG. 13, 1300, a
solar panel may be provided with a frameless mounting surface or
surfaces. As shown at 1310, a micro-inverter assembly may be
secured to a frameless mounting surface of the solar panel. The
micro-inverter assembly may be previously configured to mount on a
frame surrounding the solar panel. Thus, in embodiments an adaptive
clamp may be designed or adapted after design to use the existing
securement points of the micro-inverter assembly when securing the
assembly to a frameless solar panel. This adaptation or design may
include adding safeties to the clamp to provide warning or signals
when compressive tolerances of the solar panel are being reached.
This adaptation or design may also include providing securements
that are permanent and can be secured and unsecured. The
securements that can be secured and unsecured include those shown
in FIGS. 15a-15c, as well as others. The permanent securements can
include adhesives such as glues and epoxies. When permanent
securements are used it is preferred that the coefficients of
thermal expansion for the adhesive, the securement, and the solar
panel be matched or fall within their range of tolerances such as
to avoid placing failure stresses generated by thermal expansion
and contraction on the solar panel. To further account for thermal
expansion and contraction securement points can be spaced apart
from one another along the lengths of the assembly and the solar
panel.
[0063] FIG. 14 also provides a method in accord with embodiments.
As noted above, the actions described in FIG. 14 may be performed
in this order, in other orders, and with more, fewer or the same
number of steps, processes, or considerations. Shown in FIG. 14, as
1400, is that one or more frameless solar panels may be provided
wherein the solar panels include panel collectors and have an edge
or other mounting area that comprises glass or ceramic composition
or non-metallic composition. As shown in 1410, an adaptive clamp
may be used to secure a micro-inverter to a face, such as the shade
side, of the solar panel by securing the adaptive clamp to the
mounting area of the panel. As shown in 1420, compressive forces
may be adjusted on this first adaptive clamp in order to secure the
adaptive clamp to the mounting area. As shown in 1430, a second
adaptive clamp may be secured to the solar panel, wherein the
second clamp may be used to secure a micro-inverter cable to the
solar panel. As to 1440, testing may be performed on the assembly
and the securement. This may include testing the securing forces of
the adaptive clamps on the solar panel as well as testing the
compressive forces being placed on the solar panel. This testing
can be targeted to provide for securement forces that are large
enough to prevent unwanted disassembly between the micro-inverter
and the solar panel while at the same time serving to retard
cracking or other damage to the solar panel at installation, as
well as during lifetime use. Step 1450 of FIG. 14 provides for
mounting the solar panel at a target location and step 1460 shows
connecting the micro-inverter for control and for drawing energy
from the solar panel.
[0064] FIG. 15 shows various means that may be used to apply
securement forces by an adaptive clamp to secure a micro-inverter
assembly, or a component of it, to a solar panel without the
necessity of a frame. FIG. 15a shows a ratchet and pawl system 1500
that serves to extend an arm 1542 towards a surface 1540 in order
to apply securement forces to the surface. This ratchet and pawl
system may also be geared to move the arm 1542 downward instead.
Shown in FIG. 15a are the arm 1542, surface 1540, ratchet stop
1530, pawl 1510, central axis 1525, arrow of possible rotation
1552, and arrows of possible linear movement 1520 and 1542. The
surface 1540 may be a surface of a solar panel or other surface to
which securement forces from a clamp may be applied for securement
purposes. In embodiments, this surface may be an edge of a solar
panel where there is little or no interference with photovoltaics
on the solar panel.
[0065] FIG. 15b shows a cam 1544 and lever 1543 that may be used to
generate and apply securement forces for a clamp employed in
embodiments. The lever 1543 and cam 1544 may move in the direction
of arrow 1580 and may apply upward forces on the block 1581, which
may in turn apply securement forces to surface 1540. The cam and
lever may also apply forces to surface 1545 of the clamp.
[0066] FIG. 15c shows how a threaded post 1561 may be used to apply
securement forces to a surface 1540 of a solar panel. This threaded
post may be oriented and positioned such that as the post is
rotated and extends outwardly from a threaded receiver 1560 of a
block 1570, securement forces may be placed in the direction of
arrows 1571. The clamp surface 1545 and extension distance 1550 are
also labeled in FIG. 15c. Each of the above securement compression
means may be used in various combinations in embodiments. This
includes using a single type of means described herein as well as
using various and mixed types of means described herein.
[0067] As discussed above various changes and redesigns are
possible in the various embodiments and teachings provided herein.
For example, various resins or polymers may be used for the clamps
described herein. An example of such a resin may include the Asahi
Kasei Chemicals Corporation Xyron.RTM. 540Z modified Polyphenylene
Ether. Similarly, the clamp material may comprise aluminum AL
5052--H32 type, having a thickness of 1.5 mm and a temper hardness
of H32, other thicknesses and hardnesses may be used in embodiments
as well. In preferred embodiments torque tightening values may fall
in a range of 5.9 to 6.6 ft-lbs of torque (about 8-9 N-m) to reduce
the likely hood of breakage of the panel. Also, torque values in
embodiments should not exceed 7.37 ft-lbs of torque (10 N-m) to
avoid breakage of the panels.
[0068] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a," "an" and
"the" are intended to include plural forms as well, unless the
context clearly indicates otherwise. Likewise "clamp" as used
throughout may also mean and can also be understood to mean
"adaptive clamp" and vice-versa. It will be further understood that
the terms "comprises" and/or "comprising," when used in this
specification, specific the presence of stated features, integers,
steps, operations, elements, and/or components, but do not preclude
the presence or addition of one or more other features, integers,
steps, operation, elements, components, and/or groups thereof.
[0069] The corresponding structures, material, acts, and
equivalents of all means or steps plus function elements in the
claims below are intended to include any structure, material or act
for performing the function in combination with other claimed
elements are specifically claimed. The description of the present
invention has been presented for purposes of illustration and
description, but is not intended to be exhaustive or limited to the
invention in the form disclosed. Many modifications and variations
will be apparent to those of ordinary skill without departing from
the scope and spirit of the invention. The embodiment was chosen
and described in order to best explain the principles of the
invention and the practical application, and to enable others of
ordinary skill in the art to understand the invention for
embodiments with various modifications as are suited to the
particular use contemplated.
* * * * *