U.S. patent application number 15/465352 was filed with the patent office on 2017-09-07 for systems and methods for mounting photovoltaic modules.
The applicant listed for this patent is Alion Energy, Inc.. Invention is credited to Paul ADRIANI, Kevin HENNESSY, Thomas Peter HUNT, Neil MORRIS, Anders SWAHN.
Application Number | 20170257057 15/465352 |
Document ID | / |
Family ID | 46879973 |
Filed Date | 2017-09-07 |
United States Patent
Application |
20170257057 |
Kind Code |
A1 |
SWAHN; Anders ; et
al. |
September 7, 2017 |
SYSTEMS AND METHODS FOR MOUNTING PHOTOVOLTAIC MODULES
Abstract
System and method for mounting one or more photovoltaic modules
includes one or more flexible rods, including a first end and a
second end opposite the first end, each of the one or more flexible
rods further including an inner core and a first jacket surrounding
the inner core between the first end and the second end. The first
end is configured to be attached to at least one photovoltaic
module using one or more first adhesive materials. The second end
is configured to be inserted into at least one hole of a modular
rail and attached to at least the modular rail using one or more
second adhesive materials. The one or more flexible rods are
configured to allow at least a lateral movement in a first
direction between the photovoltaic module and the modular rail and
support at least the photovoltaic module in a second direction.
Inventors: |
SWAHN; Anders; (Tiburon,
CA) ; MORRIS; Neil; (Livermore, CA) ;
HENNESSY; Kevin; (Walnut Creek, CA) ; HUNT; Thomas
Peter; (Oakland, CA) ; ADRIANI; Paul; (Palo
Alto, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Alion Energy, Inc. |
Richmond |
CA |
US |
|
|
Family ID: |
46879973 |
Appl. No.: |
15/465352 |
Filed: |
March 21, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13421740 |
Mar 15, 2012 |
9641123 |
|
|
15465352 |
|
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|
61454125 |
Mar 18, 2011 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24S 2080/015 20180501;
F24S 2025/6007 20180501; F24S 25/632 20180501; H02S 20/00 20130101;
Y02E 10/50 20130101; Y02E 10/47 20130101; F24S 2025/014 20180501;
F24S 2025/012 20180501; F24S 25/11 20180501; F24S 2080/012
20180501; F24S 2025/601 20180501; F24S 2030/17 20180501; Y10T
29/49966 20150115; H02S 20/30 20141201; Y10T 29/49959 20150115 |
International
Class: |
H02S 20/30 20060101
H02S020/30; F24J 2/52 20060101 F24J002/52 |
Claims
1-65. (canceled)
66. A system for mounting a photovoltaic module at an installation
surface, the system comprising: a flanged beam; adhesive coupling
the flanged beam to the photovoltaic module; and a mounting
structure coupled to the installation surface, wherein the flanged
beam and the mounting structure mechanically interlock with one
another to secure the photovoltaic module at the installation
surface.
67. The system of claim 66, wherein the flanged beam includes an
I-shaped cross section.
68. The system of claim 66, wherein the flanged beam includes an
upper flange, a lower flange, and at least one structure extending
between the upper flange and the lower flange.
69. The system of claim 68, wherein the adhesive couples the upper
flange to the photovoltaic module, and wherein the lower flange
mechanically interlocks with the mounting structure.
70. The system of claim 69, wherein the mounting structure
comprises a slot, and the lower flange is inserted into the slot so
as to interlock with the slot.
71. The system of claim 70, wherein the lower flange is sized to
provide a slip-fit with the slot.
72. The system of claim 70, wherein the lower flange is adhered
within the slot.
73. The system of claim 66, further comprising a fastener attaching
the flanged beam to the mounting structure.
74. The system of claim 66, wherein the flanged beam includes a
length along which the flanged beam is elongated, and wherein the
adhesive couples the flanged beam to the photovoltaic module along
an entirety of the length.
75. The system of claim 66, wherein the mounting structure is
adhered to the installation surface.
76. A method for mounting a photovoltaic module at an installation
surface, the method comprising: providing a flanged beam; coupling
the flanged beam to the photovoltaic module with adhesive; coupling
a mounting structure to the installation surface; and mechanically
interlocking the flanged beam and the mounting structure with one
another to secure the photovoltaic module at the installation
surface.
77. The method of claim 76, wherein the flanged beam includes an
I-shaped cross section.
78. The method of claim 76, wherein the flanged beam includes an
upper flange, a lower flange, and at least one structure extending
between the upper flange and the lower flange.
79. The method of claim 78, wherein the adhesive couples the upper
flange to the photovoltaic module, and wherein the lower flange
mechanically interlocks with the mounting structure.
80. The method of claim 79, wherein the mounting structure
comprises a slot, and the lower flange is inserted into the slot so
as to interlock with the slot.
81. The method of claim 80, wherein the lower flange is sized to
provide a slip-fit with the slot.
82. The method of claim 80, wherein the lower flange is adhered
within the slot.
83. The method of claim 76, further comprising attaching the
flanged beam to the mounting structure with a fastener.
84. The method of claim 76, wherein the flanged beam includes a
length along which the flanged beam is elongated, and wherein the
adhesive couples the flanged beam to the photovoltaic module along
an entirety of the length.
85. The method of claim 76, wherein the mounting structure is
adhered to the installation surface.
Description
1. CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 13/421,740, filed Mar. 15, 2012 and entitled
"Systems and Methods for Mounting Photovoltaic Modules," which
claims priority to U.S. Provisional Application No. 61/454,125,
filed Mar. 18, 2011, commonly assigned, the entire contents of each
of which are incorporated by reference herein for all purposes.
[0002] Additionally, this application is related to U.S. patent
application Ser. No. 11/091,960, commonly assigned, incorporated by
reference herein for all purposes.
2. BACKGROUND OF THE INVENTION
[0003] The present invention is directed to photovoltaic systems.
More particularly, the invention provides systems and methods for
mounting photovoltaic modules. Merely by way of example, the
invention has been applied to the mounting of photovoltaic modules
onto concrete rails. But it would be recognized that the invention
has a much broader range of applicability.
[0004] Photovoltaics convert sunlight into electricity, providing a
desirable source of clean energy. A conventional photovoltaic (PV)
module includes a semiconductor layer divided up into a series of
interconnected light-sensitive cells. In order to increase the
amount of sun light that is converted into electricity, a
photovoltaic module needs to be correctly oriented relative to the
sun. For example, the orientation will vary depending upon the
location of the PV module (e.g., its latitude and longitude). In
another example, a mounting system is utilized to provide the
orientation of the PV module.
[0005] Hence, it is highly desirable to improve techniques for the
mounting of PV modules.
3. BRIEF SUMMARY OF THE INVENTION
[0006] The present invention is directed to photovoltaic systems.
More particularly, the invention provides systems and methods for
mounting photovoltaic modules. Merely by way of example, the
invention has been applied to the mounting of photovoltaic modules
onto concrete rails. But it would be recognized that the invention
has a much broader range of applicability.
[0007] According to one embodiment, a system for mounting one or
more photovoltaic modules includes one or more flexible rods, each
of the one or more flexible rods including a first end and a second
end opposite the first end, each of the one or more flexible rods
further including an inner core and a first jacket surrounding the
inner core between the first end and the second end. The first end
is configured to be attached to at least one photovoltaic module
using one or more first adhesive materials. The second end is
configured to be inserted into at least one hole of a modular rail
and attached to at least the modular rail using one or more second
adhesive materials. The one or more flexible rods are configured to
allow at least a lateral movement in a first direction between the
photovoltaic module and the modular rail and support at least the
photovoltaic module in a second direction.
[0008] According to another embodiment, a method for mounting one
or more photovoltaic modules includes preparing one or more
flexible rods, each of the one or more flexible rods including a
first end and a second end opposite the first end, each of the one
or more flexible rods further including an inner core and a first
jacket surrounding the inner core between the first end and the
second end, forming at least one hole in a modular rail, attaching
the first end to at least one photovoltaic module using one or more
first adhesive materials, placing one or more second adhesive
materials in the at least one hole, inserting the second end into
the at least one hole, allowing at least a lateral movement in a
first direction between the photovoltaic module and the modular
rail, and supporting at least the photovoltaic module in a second
direction.
[0009] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more foldable
mourns, each of the one or more foldable mounts including a
mounting flange, a rotatable joint, and a mounting post. The
rotatable joint is attached to the mounting flange and the mounting
post. The mounting flange is configured to be rotated relative to
the mounting post using the rotatable joint. The mounting flange is
configured to be attached to at least one photovoltaic module and
the mourning post is configured to be attached to at least one
modular rail. The one or more foldable mounts are configured to
allow at least a lateral movement in a first direction between the
photovoltaic module and the modular rail and support at least the
photovoltaic module in a second direction.
[0010] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes attaching one or more
foldable mounts, each of the one or more foldable mounts including
a mounting flange, a rotatable joint, and a mounting post, to at
least a photovoltaic module using the mounting flange; rotating the
mounting flange relative to the mounting post using the rotatable
joint; attaching the mounting post to a modular rail; allowing at
least a lateral movement in a first direction between the
photovoltaic module and the modular rail; and supporting at least
the photovoltaic module in a second direction.
[0011] In yet another embodiment, a system for mounting one or more
photovoltaic modules includes one or more angled mounts, each of
the one or more angled mounts including a mounting post with a
mounting face, the mounting post extending in a first direction.
The mounting face is not perpendicular to the first direction. The
mounting face is configured to be attached to at least one
photovoltaic module using one or more first adhesive materials. The
mounting post is configured to be attached to a modular rail. The
one or more angled mounts are configured to allow at least a
lateral movement in a second direction between the photovoltaic
module and the modular rail and support at least the photovoltaic
module in the first direction.
[0012] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes providing one or more
angled mounts, each of the one or more angled mounts including a
mounting post with a mounting face, the mounting post extending in
a first direction; attaching the mounting face to at least a
photovoltaic module using one or more adhesive materials; and
attaching the mounting post to a modular rail, allowing at least a
lateral movement in a second direction between the photovoltaic
module and the modular rail, and supporting at least the
photovoltaic module in the first direction.
[0013] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more notched
mounts and one or more ribbed posts. Each of the one or more
notched mounts including a mounting flange, a rotatable joint, and
a mounting post. Each of the one or more ribbed posts including one
or more ribs alternating with one or more grooves. The rotatable
joint is attached to the mounting flange and the mounting post. The
mounting flange is configured to be rotated relative to the
mounting post using the rotatable joint. The mounting flange
includes a receiving notch, the receiving notch including an
opening at a first end configured to receive at least one of the
one or more grooves. Each of the one or more ribbed posts is
configured to be attached to at least one photovoltaic module using
one or more first adhesive materials. The mounting post is
configured to be attached to at least one modular rail. The one or
more notched mounts and the one or more ribbed posts are configured
to allow at least a lateral movement in a first direction between
the photovoltaic module and the modular rail and support at least
the photovoltaic module in a second direction.
[0014] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes attaching one or more
ribbed posts, each of the one or more ribbed posts including one or
more ribs alternating with one or more grooves, to at least a
photovoltaic module using one or more first adhesive materials;
providing one or more notched mounts, each of the one or more
notched mounts including a mounting flange, a rotatable joint, and
a mounting post; attaching the mounting post to at least a modular
rail; rotating the mounting flange relative to the mounting post
using the rotatable joint; inserting at least one or the one or
more grooves into the receiving notch; allowing at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail; and supporting at least the photovoltaic module
in a second direction.
[0015] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more flanged beams
and one or more spacers. Each of the one or more flanged beams
including a first flange and a second flange opposite the first
flange. The one or more spacers include one or more slots
respectively. The first flange is configured to be attached to at
least one photovoltaic module. The second flange is configured to
be inserted into the one or more slots. The one or more spacers are
configured to be attached to at least one modular rail using one or
more first adhesive materials. The one or more flanged beams and
the one or more spacers are configured to allow at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail and support at least the photovoltaic module in a
second direction.
[0016] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes providing one or more
flanged beams, each of the one or more flanged beams including a
first flange and a second flange opposite the first flange;
attaching the first flange to at least a photovoltaic module;
attaching one or more spacers, each including one or more slots
respectively, to a modular rail using one or more adhesive
materials; inserting the second flange into the one or more slots;
allowing at least a lateral movement in a first direction between
the photovoltaic module and the modular rail; and supporting at
least the photovoltaic module in a second direction.
[0017] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more flexible
spacers. Each of the one or more flexible spacers including a first
surface and a second surface opposite the first surface. The first
surface is configured to be attached to at least one glass panel of
a photovoltaic module using one or more first adhesive materials.
The second surface is configured to be attached to at least one or
more concrete materials of one modular rail using one or more
second adhesive materials. The one or more flexible spacers are
configured to allow at least a lateral movement in a first
direction between the photovoltaic module and the modular rail and
support at least the photovoltaic module in a second direction.
Each of the one or more flexible spacers includes one selected from
a group consisting of polyvinyl chloride (PVC), chlorinated
polyvinyl chloride (CPVC), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), polyolefins, and elastomeric polymers.
[0018] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes forming a modular rail
including one or more concrete materials; providing one or more
flexible spacers, each of the one or more flexible spacers
including a first surface and a second surface opposite the first
surface, each of the one or more flexible spacers including one
selected from a group consisting of polyvinyl chloride (PVC),
chlorinated polyvinyl chloride (CPVC), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), polyolefins, and elastomeric polymers; attaching
the first surface to at least a glass panel using one or more first
adhesive materials; attaching the second surface to at least the
one or more concrete materials of the modular rail using one or
more second adhesive materials; allowing at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail; and supporting at least the photovoltaic module
in a second direction.
[0019] Depending upon the embodiment, one or more of these benefits
may be achieved. These benefits and various additional objects,
features, and advantages of the present invention can be fully
appreciated with reference to the detailed description and
accompanying drawings that follow.
4. BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a simplified diagram showing a modular rail upon
which a PV module may be mounted.
[0021] FIG. 2 is a simplified diagram showing a MI module mounted
on the modular rail.
[0022] FIG. 3 is a simplified diagram showing another modular rail
upon which a PV module may be mounted.
[0023] FIG. 4 is a simplified diagram showing a PV module mounted
on the another modular rail.
[0024] FIG. 5 is a simplified diagram showing the modular rail
prepared liar the mounting of a PV module according to one
embodiment of the present invention.
[0025] FIG. 6 is a simplified diagram showing the IN module mounted
on the prepared modular rail according to one embodiment of the
present invention.
[0026] FIG. 7 is a simplified diagram showing a partial cut-away
view of a flexible rod used as part of the PV module mounting
system according to one embodiment of the present invention.
[0027] FIG. 8 is a simplified diagram showing a side view of a PV
module mounting system using a flexible rod according to one
embodiment of the present invention.
[0028] FIG. 9 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more flexible rods
according to one embodiment of the present invention.
[0029] FIG. 10A is a simplified diagram showing a side view of a
foldable mount as used in a PV module mounting system according to
one embodiment of the present invention.
[0030] FIG. 10B is a simplified diagram showing a side view of the
foldable mount in folded position as used in a PV module mounting
system according to one embodiment of the present invention.
[0031] FIG. 11 is a simplified diagram showing a side view of a PV
module mounting system using one or more foldable mounts according
to one embodiment of the present invention.
[0032] FIG. 12 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more foldable mounts
according to one embodiment of the present invention.
[0033] FIG. 13A is a simplified diagram showing a side view of a
foldable mount as used in a PV module mounting system according to
another embodiment of the present invention.
[0034] FIG. 13B is a simplified diagram showing a side view of the
foldable mount in folded position as used in a PV module mounting
system according to another embodiment of the present
invention.
[0035] FIG. 14 is a simplified diagram showing a side view of a PV
module mounting system using one or more foldable mounts according
to another embodiment of the present invention.
[0036] FIG. 15 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more foldable mounts
according to another embodiment of the present invention.
[0037] FIG. 16 is a simplified diagram showing a side view of a P\'
module mounting system using one or more foldable mounts according
to another embodiment of the present invention.
[0038] FIG. 17 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more foldable mounts
according to another embodiment of the present invention.
[0039] FIG. 18 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
one embodiment of the present invention.
[0040] FIG. 19 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more angled mounts
according to one embodiment of the present invention.
[0041] FIG. 30 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
another embodiment of the present invention.
[0042] FIG. 31 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more angled mounts
according to another embodiment of the present invention.
[0043] FIG. 22 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
another embodiment of the present invention.
[0044] FIG. 23 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more angled mounts
according to another embodiment of the present invention.
[0045] FIGS. 24A and 24B are simplified diagrams showing two views
of a notched mount as used in a PV module mounting system according
to certain embodiments of the present invention.
[0046] FIG. 25 is a simplified diagram showing a ribbed post as
used in a PV module mounting system according to one embodiment of
the present invention.
[0047] FIG. 26 is a simplified diagram showing a side view of a PV
module mounting system using one or more notched mounts and one or
more ribbed posts according to one embodiment of the present
invention.
[0048] FIG. 27 is a simplified diagram showing a method of mounting
a EN module to a modular rail using one or more notched mounts and
one or more ribbed posts according to one embodiment of the present
invention.
[0049] FIGS. 28A and 28B are simplified diagrams showing two views
of a PV module mounting system using one or more flanged beams and
one or more spacers according to some embodiments of the present
invention.
[0050] FIG. 29 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more flanged beams and
one or more spacers according to one embodiment of the present
invention.
[0051] FIG. 30 is a simplified diagram showing a side view of a PV
module mounting system using one or more spacers according to
another embodiment of the present invention.
[0052] FIG. 31 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more spacers according
to another embodiment of the present invention.
5. DETAILED DESCRIPTION OF THE INVENTION
[0053] The present invention is directed to photovoltaic systems.
More particularly, the invention provides systems and methods for
mounting photovoltaic modules. Merely by way of example, the
invention has been applied to the mounting of photovoltaic modules
onto concrete rails. But it would be recognized that the invention
has a much broader range of applicability.
[0054] In order to orient a photovoltaic (PV) module (e.g., a
photovoltaic panel, a solar module, a solar panel, a glass module,
a glass panel, a glass-to-glass module, and/or a glass-to-glass
panel) relative to the sun, a mounting system is required. For
example, the mounting system requires a mechanical substrate to
which the photovoltaic module is mounted. In other example, the
mechanical substrate includes a mechanical frame. In yet another
example, the mechanical substrate includes a modular concrete
rail.
[0055] FIG. 1 is a simplified diagram showing a modular rail upon
which a PV module may be mounted. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 1, the modular
rail 100 includes one or more mounting surfaces 110. For example,
the one or more mounting surfaces 110 serve as the mechanical
substrate for the mounting of one or more IN modules. In another
example, the mounting surfaces 110 are substantially coplanar.
[0056] FIG. 2 is a simplified diagram showing a PV module mounted
on the modular rail 100. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications. In one embodiment, a PV module 200 is mounted to the
one or more mounting surfaces 110 by using at least one or more
mechanical mounts. For example, the PV module 200 is a
glass-to-glass module. In another embodiment, the one or more
mounting surfaces 110 of the modular rail 100 are implemented with
a tilt angle. For example, the tilt angle varies depending upon the
geographic location (e.g. latitude or orientation) of the PV module
so that the affixed PV module 200 is oriented for optimal energy
capture from the light source (e.g., the sun).
[0057] The use of the one or more mounting surfaces 100 provides
certain advantages over conventional technology for the mounting of
PV modules. In one embodiment, the IN modules 200 are fixed along
their entire length to the one or more mounting surfaces 110 using
one or more mechanical mounts. In another embodiment, the PV
modules 200 do not have to be as strong as required by certain
conventional technology. For example, the mechanical mounting along
the one or more surfaces 110 provides a shorter span between the
contact points of the PV modules 200 and the one or more mounting
surfaces 110; therefore, the PV modules 200 are exposed to less
mechanical stress due to wind loads than the PV modules mounted
using conventional edge-mounted brackets. In another example, the
PV modules 200 is made of thinner material than the conventional
edge-mounted PV modules; therefore, the PV modules 200 is
manufactured and transported at lower cost due to their lighter
weight.
[0058] In yet another embodiment, the PV modules 200 benefit from
the "heat sink" effect due to the proximity of the PV modules 200
to the modular rails 110. For example, the PV modules 200 can stay
slightly cooler than conventional modules and can operate more
efficiently (e.g., due to the negative temperature coefficient). In
yet another embodiment, the use of mechanical mounts between the PV
modules 200 and the one or more surfaces 110 can provide the PV
modules 200 with additional air cooling that can significantly
reduce negative effects caused by the "heat sink" effect of the
modular rails 100.
[0059] FIG. 3 is a simplified diagram showing another modular rail
upon which a PV module may be mounted. FIG. 4 is a simplified
diagram showing a PV module mounted on the another modular rail.
These diagrams are merely examples, which should not unduly limit
the scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIGS. 3 and 4, a modular rail 300 includes only a single
mounting surface 310 for the PV module 200 according to one
embodiment.
[0060] In one example, the modular rail 100 and/or the modular rail
300 is constructed from concrete. In yet another example, the
modular rail 100 and/or the modular rail 300 is constructed on site
(e.g., being extruded in place using a slip-form extrusion
machine). In another example, the extrusion speed of the slip-form
extrusion machine is varied. In yet another example, the extrusion
speed should be slow enough to produce the one or more mounting
surfaces 110 and/or the mounting surface 310 with a high planarity
and little sagging to allow for uniformity of a PV module mounting
system. In yet another example, if a large planarity tolerance for
the one or more mounting surfaces 110 and/or the mounting surface
310 could be allowed, a much higher extrusion speed of slip-form
extrusion machine could be achieved, causing reduction of the
construction cost of the finished rail.
[0061] When mounting one or more PV modules 200 to the modular rail
100 and/or the modular rail 300, the mounting system must meet one
or more complex requirements. For example, the mounting system must
provide sufficient mechanical strength to prevent the PV module 200
from being blown off the modular rail 100 and/or the modular rail
300 in the presence of wind forces. In another example, the
mounting system is resistant to upward wind force on the PV module
200. In yet another example, the mounting system is resistant to
downward wind force on the PV module 200. In yet another example,
the mounting system is resistant to wind force equivalent to a
uniform load of 2400 Pa across the PV module 200. In yet another
example, the mounting system is able to last in an outdoor
environment with extremes of weather for at least 25 years. In yet
another example, the mounting system is resistant to hail of up to
2.5 cm in diameter traveling at speeds of up to 23 m/s. In yet
another example, the mounting system is resistant to heavy snow
loads on top of the PV module 200. In yet another example, the snow
loads vary from 200 Pa to 5400 Pa across the PV module. In yet
another example, the mounting system remains attached to the one or
more mounting surfaces 110 and/or the mounting surface 310 at
various temperatures. In yet another example, the mounting system
functions at air temperatures ranging from -40.degree. C. to +60'C.
In yet another example, the mounting system functions at air
temperatures ranging from -60.degree. C. to +90.degree. C. In yet
another example, the mounting system functions with PV modules 200
at temperatures of up to +85.degree. C. In yet another example, the
mounting system functions with PV modules 200 at temperatures of up
to 110.degree. C. In yet another example, the mounting system
remains attached to the one or more mounting surfaces 110 and/or
the mounting surface 310 under various moisture conditions. In yet
another example, the mounting functions after being subjected to
+85.degree. C. air at 85% relative humidity for 1000 hours. In yet
another example, the mounting system is resistant to ultraviolet
(UV) light. In yet another example, the mounting system is not
highly flammable. In yet another example, the mounting system is
resistant to one or more of salt air, carbonic acid rain, sulfuric
acid rain, oily contamination, oxidation, galvanic corrosion,
agricultural airborne ammonia, and the like.
[0062] In yet another example, the mounting system does not have
exposed conductive surfaces to eliminate the need for electrical
bonding and/or pounding. In yet another example, the mounting
system remains attached to the one or more mounting surfaces 110
and/or the mounting surface 310 with the varying textures. In yet
another example, the varying textures include differences in a
surface height from 1 nm to 10 mm. In yet another example, the
mounting system remains attached to the one or more mounting
surfaces 110 and/or the mounting surface 310 during different
stages of curing of the concrete material. In yet another example,
the one or more mounting surfaces 110 and or the mounting surface
310 cure within 5 days. In yet another example, the one or more
mounting surfaces 110 and/hr the mounting surface 310 cure within
30 days. In yet another example, the mounting system must be able
to attach well to the one or more mounting surfaces 110 and/or the
mounting surface 310 that may vary in planarity (e.g., due to
sagging) by as much as 20 mm across the area to which the PV module
200 is mounted.
[0063] In yet another example, the mounting system must be able to
attach well to the glass surface of the PV module 200. In yet
another example, the mounting system must be flexible enough to be
able to reduce the stress on the PV module 200 caused by the
heating of the PV module 200 while the modular rail 100 and/or the
modular rail 300 to which it is mounted remains colder. In yet
another example, the mounting system is flexible enough to allow up
to 2 mm of differential movement between the PV module 200 and the
modular rail 100 and/or the modular rail 300. In yet another
example, the mounting system is flexible enough to support the PV
module 200 without damage when a temperature differential between
the PV module 200 and the modular rail 100 and/or the modular rail
300 is as high as 100.degree. C. In yet another example, the
mounting system allows lateral movement (e.g., in a direction
substantially parallel to the face of the PV module 200) between
the PV module 200 and the modular rail 100 and/or the modular rail
300 to which it is mounted. In yet another example, the mounting
system must be able to support the weight of the PV module 200 in a
substantially vertical direction. In yet another example, the
weight of the PV module 200 varies between 5 kg and 50 kg. In yet
another example, if the mounting system includes one or more
adhesive materials that are applied in the field, the one or more
adhesive materials must have a rapid curing time under the weather
conditions (e.g., temperature, moisture, wind load) at the time of
application of the one or more adhesive materials in the field. In
yet another example, the one or more adhesive materials cure within
5 days. In yet another example, the one or more adhesive materials
cure within 30 days. In yet another example, any portion of the
mounting system attached to the PV module 200 in the factory needs
to have a low profile so as not to significantly reduce the number
of PV modules 200 that is packed in a single shipping crate.
[0064] FIG. 5 is a simplified diagram showing the modular rail 300
prepared for the mounting of a PV module according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. In FIG. 5, the modular rail 300 is
shown with its mounting surface 310 prepared for the mounting of a
PV module. For example, the mounting surface 310 has one or more
holes 510 located at intervals along the length of the mounting
surface 310. In another example, the one or more holes 510 have a
substantially uniform size. In yet another example, the one or more
holes 510 have a substantially uniform depth. In yet another
example, the one or more holes 510 vary in size from 5 mm to 100
mm. In yet another example, the one or more holes 510 vary in depth
from 5 mm to 500 mm. In yet another example, the one or more holes
510 vary in depth from 5 ram to 100 mm. In yet another example, the
one or more holes 510 are arranged using a predetermined pattern
and spacing.
[0065] FIG. 6 is a simplified diagram showing the IN module 200
mounted on the prepared modular rail 300 according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 6, the PV module
200 is mounted on the mounting surface 310 above the one or more
holes 510 according to some embodiments.
[0066] As discussed above and further emphasized here, FIGS. 5 and
6 are merely examples, which should not unduly limit the scope of
the claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. For example, the
modular rail 100 is substituted for the modular rail 300. In
another example, the one or more holes 510 are located at regular
intervals along the length of the one or more mounting surfaces
110.
[0067] FIG. 7 is a simplified diagram showing a partial cut-away
view of a flexible rod used as part of the PV module mounting
system according to one embodiment of the present invention. This
diagram is merely an example, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 7, a flexible rod (e.g., a flexible joining material)
700 includes an inner core 710. For example, the inner core 710
includes one or more fibers. In another example, the one or more
fibers are substantially parallel. In yet another example, the one
or more fibers are braided. In yet another example, the one or more
fibers are each selected from a group consisting of Aramid
(Kevlar), polyester, ultrahigh molecular weight polyethylene
(UHMWPE), nylon, viscose rayon, cotton, and the like. In yet
another example, the one or more fibers do not include any brittle
materials (e.g., certain ceramics, certain metals, and/or certain
plastics). In yet another example, the one or more fibers do not
include any stiffer fiber materials (e.g., certain carbon
materials, certain fiberglass materials, and/or Polybenzobisoxazole
(PBO)).
[0068] In some embodiments, the inner core 710 is surrounded by an
inner jacket 720. For example, the inner jacket 720 runs the entire
length of the flexible rod 700. In another example, the inner
jacket 720 completely surrounds the inner core 710 except at each
of the ends of the flexible rod 700. In yet another example, the
inner jacket 720 is cross-braided. In yet another example, the
inner jacket 720 includes one or more materials selected from a
group consisting of Aramid (Kevlar), polyester, ultrahigh molecular
weight polyethylene (UHMWPE), nylon, viscose rayon, cotton, and the
like. In yet another example, the inner jacket 720 includes an
ultraviolet (UV) light stable material. In yet another example, the
inner jacket 720 protects the one or more fibers in the inner core
710 from moisture and/or UV light. In yet another example, the
inner jacket 720 extends the practical lifetime of the flexible rod
700. In yet another example, the inner jacket 720 adds stiffness to
the flexible rod 700. In yet another example, the inner jacket 720
increases the weight that the flexible rod 700 can support.
[0069] In some embodiments, the inner jacket 720 is surrounded by
an outer jacket 730. For example, the outer jacket 730 runs the
entire length of the flexible rod 700. In another example, the
outer jacket 730 completely surrounds the inner jacket 720 except
at each of the ends of the flexible rod 700. In yet another
example, the outer jacket 730 is cross-braided. In yet another
example, the outer jacket 730 includes one or more materials
selected from a group consisting of Aramid (Kevlar), polyester,
ultrahigh molecular weight polyethylene (UHMWPE), nylon, viscose
rayon, cotton, and the like. In yet another example, the outer
jacket 730 is omitted. In yet another example, the outer jacket 730
adds stiffness to the flexible rod 700. In yet another example, the
outer jacket 730 increases the weight that the flexible rod 700 can
support. In yet another example, a tightness of the outer jacket
730 is adjusted to control the amount of weight that the flexible
rod 700 can support. In yet another example, the outer jacket 730
provides abrasion and/or chafing resistance to the flexible rod
700.
[0070] According to some embodiments, a size and/or materials
included in the flexible rod 700 are chosen to meet one or more
desirable properties. For example, the size and/or materials are
selected to provide suitable pull strength to withstand the wind
loads to which the PV module will be subjected. In another example,
the size and/or materials are selected to provide sufficient
stiffness so that the flexible rod 700 supports its share of the
weight of the PV module 200. In yet another example, the size
and/or materials are selected to provide the lateral flexibility
due to lateral movement between the PV module 200 and the modular
rail to which it is mounted. In yet another example, the size
and/or materials are selected to provide the lateral flexibility
and lateral strength needed to withstand the large amount of
bending movement that occurs many times and/or for many cycles as
the mounting system is subjected to thermal and/or wind loads. In
yet another example, the size and/or materials are selected to
withstand a large amount of sheer movement and sheer stresses that
occurs many times and/or for many cycles as the mounting system is
subjected to thermal and/or wind loads.
[0071] FIG. 8 is a simplified diagram showing a side view of a PV
module mounting system using a flexible rod according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 8, the PV module
mounting system includes a flexible rod 810 attached between a
modular rail 820 and a PV module 830. For example, the flexible rod
810 is the flexible rod 700. In another example, the modular rail
820 is the modular rail 100 and/or the modular rail 300. In yet
another example, the PV module 830 is the PV module 200.
[0072] In yet another example, the flexible rod 810 is attached to
the PV module 830. In yet another example, the flexible rod 810 is
attached to the PV module 830 using one or more adhesive materials
840. In yet another example, the one or more adhesive materials 840
are fast curing. In yet another example, the one or more adhesive
materials 840 form a flexible bond between the flexible rod 810 and
the PV module 830. In yet another example, the one or more adhesive
materials 840 are each selected from a group consisting silicone,
organo-silane modified ethylene-vinyl acetate (EVA), organo-silane
modified thermoplastic polyolefin (TPO), epoxy, organo-silane
modified epoxy, polyurethane, polyacrylic, organo-silane modified
polyurethane, organo-silane modified acrylic, polydimethylsiloxane
(PDMS), poly(methyl-phenylsiloxane) (PMPS), ether-type
polyurethane, ester-type polyurethane, poly(methyl methacrylate)
(PMMA), and the like. In yet another example, the PV module 830 is
first primed with an organo-silane-containing primer and the one or
more adhesive materials further include one or more general-purpose
adhesive materials.
[0073] In yet another example, the flexible rod 810 is placed into
a hole 850 in the modular rail 820. In yet another example, the
hole 850 is one of the one or more holes 510. In yet another
example, the flexible rod 810 is held in place in the hole 850
using one or more adhesive materials 860. In yet another example,
the one or more adhesive materials 850 are fast curing. In yet
another example, the one or more adhesive materials 850 form a
rigid bond between the flexible rod 810 and the modular rail 820.
In yet another example, the one or more adhesive materials 860 are
each selected from a group consisting of silicone, ethylene-vinyl
acetate (EVA), thermoplastic polyolefin (TPO), epoxy, polyurethane,
polydimethylsiloxane (PDMS), poly(methyl-phenylsiloxane) (PMPS),
ether-type polyurethane, ester-type polyurethane, poly(methyl
methacrylate) (PMMA), and the like. In yet another example, the
modular rail 820 is first primed. In yet another example, the one
or more adhesive materials 860 are different from the one or more
adhesive materials 840. In yet another example, excess of the one
or more adhesive materials 860 is displaced from the top of the
hole 850. In yet another example, the excess of the one or more
adhesive materials 860 displaced from the top of the hole 850 acts
as a self-leveling mechanism that accounts for variations in the
planarity of the one or more mounting surfaces of the modular rail
820, the length of the flexible rod 810, and/or the depth of the
hole 850.
[0074] In yet another example, a diameter of the flexible rod 810
is selected to provide sufficient pull strength of the mounting
system based on the wind loads to which the PV module 830 is
subjected. In yet another example, the diameter of the flexible rod
810 is selected to provide sufficient surface area between the
flexible rod 810 and the PV module 830 and/or surface area between
the flexible rod 810 and the modular mil 820 to provide sufficient
attachment strength between the flexible rod 810 and the PV module
830 and between the flexible rod 810 and the modular rail 820 to
withstand the wind loads to which the PV module 830 is subjected.
In yet another example, the flexible rod 810 varies in diameter
from 10 mm to 100 mm. In yet another example, the flexible rod 810
varies in length from 25 mm to 250 mm.
[0075] As discussed above and further emphasized here, FIG. 8 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. For example, each PV
module 830 is mounted to the modular rail 820 using more than one
hole 850 and flexible rod 810. In another example, four holes 850
and four corresponding flexible rods 810 are used. In yet another
example, six or more holes 850 and six or more corresponding
flexible rods 810 are used.
[0076] FIG. 9 is a simplified diagram showing a method of mounting
a PV module to a modular rail using one or more flexible rods
according to one embodiment of the present invention. This diagram
is merely an example, which should not unduly limit the scope of
the claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. As shown in FIG. 9,
the method 900 includes a process 910 for preparing one or more
flexible rods, a process 920 for attaching one or more flexible
rods to a PV module, a process 930 for forming a modular rail, a
process 940 for forming one or more holes in the modular rail, a
process 950 for placing one or more adhesive materials in the one
or more holes, and a process 960 for inserting one or more flexible
rods into the one or more holes. According to certain embodiments,
the method 900 of mounting a PV module to a modular rail using one
or more flexible rods is performed using variations among the
processes 910-960 as would be recognized by one of ordinary skill
in the art.
[0077] At the process 910, one or more flexible rods are prepared.
For example, each of the one or more flexible rods is the flexible
rod 700. In another example, each of the one or more flexible rods
are cut from a longer piece of flexible rod material. In yet
another example, the flexible rod material is taken from a spool.
In yet another example, each of the one or more flexible rods is
between 25 mm and 250 mm in length. In yet another example, each of
the one or more flexible rods are substantially the same length. In
yet another example, each of the one or more flexible rods is a
different length.
[0078] At the process 920, the one or more flexible rods are
attached to a PV module. For example, the PV module is the PV
module 830. In another example, the PV module is the PV module 200.
In yet another example, the one or more flexible rods are attached
to the PV module using one or more adhesive materials. In yet
another example, the one or more adhesive materials are the one or
more adhesive materials 840. In yet another example, the one or
more adhesive materials form a flexible bond between each of the
one or more flexible rods and the PV module. In yet another
example, the one or more flexible rods are attached to the PV
module using a predetermined pattern and spacing. In yet another
example, the surface of the PV module 830 is chemically modified
using an atmospheric corona discharge and/or an atmospheric plasma
discharge. In yet another example, the process 920 is performed in
the factory. In yet another example, the process 920 is performed
in the field.
[0079] At the process 930, the modular rail is formed. For example,
the modular rail is the modular rail 820, the modular rail 100,
and/or the modular rail 200. In another example, the modular rail
is formed in-situ in the field using a slip-four extrusion machine.
In yet another example, the extrusion speed of the slip-form
extrusion machine is varied. In yet another example, the extrusion
speed should be slow enough to produce one or more mounting
surfaces which are substantially planar. In yet another example,
the extrusion speed should be slow enough to produce the one or
more mounting surfaces with a high planarity and little sagging to
allow for uniformity in the PV module mounting system. In yet
another example, if a large planarity variability in the one or
more mounting surfaces could be allowed, a much higher extrusion
speed of slip-form extrusion machine could be achieved, causing
reduction of the construction cost of the finished rail. In yet
another example, the modular rail is preformed in the factory and
transported to the installation site.
[0080] At the process 940, one or more holes are formed in to the
modular rail. For example, the one or more holes are the one or
more holes 510. In another example, each of the one or more holes
is the hole 850. In yet another example, the one or more holes are
arranged using the predetermined pattern and spacing for the one or
more flexible rods attached to the PV module. In yet another
example, the one or more holes are formed by using a hole punch
tool. In yet another example, the hole punch tool is used with the
slip-form extrusion machine. In yet another example, the one or
more holes are formed before the modular rail has been allowed to
cure. In yet another example, the one or more holes are formed by
drilling a previously formed and cured modular rail.
[0081] At the process 950, one or more adhesive materials are
placed into the one or more holes. For example, the one or more
adhesive materials are the one or more adhesive materials 860. In
another example, the one or more adhesive materials are fast
curing. In yet another example, the one or more adhesive materials
partially fill the one or more holes. In yet another example, the
one or more adhesive materials substantially fill the one or more
holes. In yet another example, the one or more adhesive materials
are placed in the one or more holes manually. In yet another
example, the one or more adhesive materials are placed in the one
or more holes using an automated robotic arm with one or more
adhesive dispensers.
[0082] At the process 960, the one or more flexible rods are
inserted into the one or more holes. For example, the one or more
flexible rods are aligned with the one or more holes and then
inserted into the one or more holes. In another example, the one or
more adhesive materials in the one or more holes form rigid bonds
between the one or more flexible rods and the modular rail. In yet
another example, excess of the one or more adhesive materials is
displaced from the top of one or more of the one or more holes. In
yet another example, the excess of the one or more adhesive
materials displaced from the top of one or more of the one or more
holes acts as a self-leveling mechanism that accounts for
variations in the planarity of the one or more mounting surfaces of
the modular rail, the length of the one or more flexible rods,
and/or the depth of the one or more holes.
[0083] FIG. 10A is a simplified diagram showing a side view of a
foldable mount as used in a PV module mounting system according to
one embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 10A, the foldable
mount 1000 includes a mounting flange 1010, a rotatable joint 1020,
and an insertable end (e.g., a mounting post) 1030. For example,
the rotatable joint 1020 allows the mounting flange 1010 and the
insertable end 1030 to be rotated relative to each other. In
another example, the rotatable joint 1020 includes a hinge. In yet
another example, the rotatable joint 1020 includes a
ball-and-socket joint. In yet another example, the insertable end
1030 is tapered to provide a point 1040 distal to the rotatable
joint 1020. In yet another example, the insertable end 1030 varies
in length from 0.25 cm to 50 cm. In yet another example, the
insertable end 1030 is shaped like a wedge. In yet another example,
the insertable end 1030 is shaped like a cone. In yet another
example, the insertable end 1030 is shaped like an arrow head. In
yet another example, the insertable end 1030 is shaped like a spear
head. In yet another example, the insertable end 1030 includes one
or more barbs. In yet another example, the insertable end 1030
includes one or more ribs
[0084] In yet another example, the foldable mount 1000 includes one
or more materials. In yet another example, the insertable end 1030
is flexible. In yet another example, the insertable end 1030 is
sufficiently stiff to support part of the weight of a PV module. In
yet another example, the one or more materials are selected from a
group consisting of polyvinyl chloride (PVC), chlorinated polyvinyl
chloride (CPVC), high-density polyethylene (HDPE), low-density
polyethylene (LDPE), polypropylene (PP), poly(ethylene
terephthalate) (PET), polycarbonate (PC), polyamide (PA),
poly(methyl methacrylate) (PMMA), polyoxymethylene (POM),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), poly(ethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, nonengineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, the foldable mount 1000 is coated with a non-conductive
coating.
[0085] FIG. 10B is a simplified diagram showing a side view of the
foldable mount 1000 in folded position as used in a PV module
mounting system according to one embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 10B, the rotatable joint 1020 is
rotated so that the mounting flange 1010 and the insertable end
1030 are substantially parallel. In another example, when the
foldable mount 1000 is in folded position, it provides as small a
cross-sectional footprint as possible. In yet another example, the
small cross-sectional footprint allows for maximum density when
packing multiple foldable mourns 1000.
[0086] FIG. 11 is a simplified diagram showing a side view of a PV
module mounting system using one or more foldable mounts 1000
according to one embodiment of the present invention. This diagram
is merely an example, which should not unduly limit the scope of
the claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. As shown in FIG. 11, a
PV module 1110 is mounted to a modular rail 1120 using one or more
foldable mounts 1000. For example, each of the one or more foldable
mounts 1000 is attached to the PV module 1110 using a respective
mounting flange 1010. For example, the mounting flange 1010 of each
of the one or more foldable mounts 1000 is attached to the PV
module 1110 using one or more adhesive materials. In yet another
example, the one or more adhesive materials are fast curing. In yet
another example, the one or more adhesive materials form a flexible
bond between the mounting flange 1010 of each of the one or more
foldable mounts 1000 and the PV module 1110. In yet another
example, the one or more adhesive materials are each selected from
a group consisting of silicone, organo-silane modified
ethylene-vinyl acetate (EVA), organo-silane modified thermoplastic
polyolefin (TPO), epoxy, organo-silane modified epoxy,
polyurethane, polyacrylic, organo-silane modified polyurethane,
organo-silane modified acrylic, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the PV module 1110 is first primed
with an organo-silane-containing primer and the one or more
adhesive materials further include one or more general-purpose
adhesive materials. In yet another example, the mounting flange
1010 of each of the one or more foldable mounts 1000 is attached to
the PV module 1110 using bolts, screws, and/or other mechanical
fasteners. In yet another example, one or more gasket materials are
used between the mounting flange 1010 of each of the one or more
foldable mounts 1000 and the PV module 1110. In yet another
example, each of the one or more gasket materials is selected from
a list consisting of ethylene propylene diene monomer (EPDM),
UV-resistant rubber, and the like.
[0087] In yet another example, the modular rail 1120 is the modular
rail 100 and/or the modular rail 200. In yet another example, the
insertable end 1030 of each of the one or more foldable mounts 1000
is inserted into the modular rail 1120. In yet another example, the
insertable end 1030 of each of the one or more foldable mounts 1000
is inserted into the modular rail 1120 to a depth between 5 mm and
500 mm.
[0088] According to some embodiments, the angle of the PV module
1110 relative to the sun is controlled through use of the one or
more foldable mounts 1000. For example, each of the one or more
foldable mounts 1000 is rotated at the respective rotatable joint
1020 to account for variations in the height of the modular rail
1120 and/or the desired angle of the PV module 1110 relative to the
sun. In another example, the depth to which the insertable end 1030
of each of the one or more foldable mounts 1000 is inserted into
the modular rail 1120 is adjusted to account for variations in the
height of the modular rail 1120 and/or the desired angle of the PV
module 1110 relative to the sun. In yet another example, a length
and a size of the insertable end 1030 of each of the one or more
foldable mounts 1000 is selected to provide sufficient pull
strength for the mounting system based on the wind loads to which
the PV module 1110 is subjected.
[0089] As discussed above and further emphasized here, FIG. 11 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of foldable mounts 1000 is varied. For example, the PV
module 1110 is mounted to the modular rail 1120 using only one
foldable mount 1100. In another example, four foldable mounts 1000
are used. In yet another example, six or more foldable mounts 1000
are used. In some embodiments, a different style of modular rail
1120 is used. For example, an insertable end 1030 is inserted into
one of the one or more mounting surfaces 110 of the modular rail
100 and another insertable end 1030 is inserted into another one of
the one or more routing surfaces 110 of the modular rail 100 as
shown in FIG. 1.
[0090] FIG. 12 is a simplified diagram showing a method of mounting
a PV module 1110 to a modular rail 1120 using one or more foldable
mounts 1000 according to one embodiment of the present invention.
This diagram is merely an example, which should not unduly limit
the scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 12, the method 1200 includes a process 1210 for
attaching one or more foldable mounts to a PV module, a process
1220 for rotating the one or more foldable mounts for transport, a
process 1230 for transporting the PV module to the installation
site, a process 1240 for forming a modular rail, a process 1250 for
rotating the one or more foldable mounts for use, and a process
1260 for inserting the one or more foldable mounts into the modular
rail. According to certain embodiments, the method 1200 of mounting
a PV module to a modular rail using one or more foldable mounts is
performed using variations among the processes 1210-1260 as would
be recognized by one of ordinary skill in the art. According to
some embodiments, one or more of the processes 1220 and/or 1230 are
optional.
[0091] At the process 1210, one or more foldable mounts 1000 are
attached to a PV module 1110. For example, the PV module 1110 is
the PV module 200. In another example, the one or more foldable
mounts 1000 are attached to the PV module 1110 using the respective
mounting flange 1010 of each of the one or more foldable mounts
1000. In yet another example, the one or more foldable mounts 1000
are attached to the PV module 1110 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials form a flexible bond between the mounting flange 1010 of
each of the one or more foldable mounts 1000 and the PV module
1110. In yet another example, the mounting flange 1010 of each of
the one or more foldable mounts 1000 is attached to the ITV module
1110 using bolts, screws, and/or other mechanical fasteners. In yet
another example, one or more gasket materials is placed on the PV
module 1110 before each of the one or more foldable mounts 1000 is
attached. In yet another example, the one or more foldable mounts
1000 are attached to the PV module 1110 using a predetermined
pattern and spacing. In yet another example, the PV module 1110 is
primed before each of the one or more foldable mounts 1000 is
attached. In yet another example, the surface of the PV module 1110
is roughened before the one or more foldable mounts 1000 is
attached. In yet another example, the surface of the PV module 1110
is chemically modified using an atmospheric corona discharge and/or
an atmospheric plasma discharge. In yet another example, the
process 1210 is performed in the factory. In yet another example,
the process 1210 is performed in the field.
[0092] At the optional process 1220, the one or more foldable
mounts 1000 are rotated for transport. For example, the one or more
foldable mounts 1000 are rotated using the respective rotatable
joint 1010 as shown in FIG. 10B. In another example, during the
process 1220, each insertable end 1030 of each of the one or more
foldable mounts 1000 is rotated to provide as small a
cross-sectional footprint as possible relative to the PV module
1110. In yet another example, each insertable end 1020 of each of
the one or more foldable mounts 1000 is rotated so that each each
insertable end 1020 of each of the one or more foldable mounts 1000
is substantially parallel to the PV module 1110.
[0093] At the optional process 1230, the PV module 1110 is
transported to the installation site. For example, the PV module
1110 is placed in a crate and/or a rack for transportation. In
another example, more than one PV module 1110 is placed in the same
crate and/or rack for transportation, taking advantage of the small
cross-sectional footprint made possible by the rotation of each of
the foldable mounts 1000.
[0094] At the process 1240, the modular rail 1120 is formed. For
example, the modular rail 1020 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 1120 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the per module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-form extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 1120 is preformed in the factory and
transported to the installation site.
[0095] At the process 1250, the one or more foldable mounts 1000
are rotated for use. For example, the angle of the PV module 1110
relative to the sun is controlled through use of the rotatable
joint 1020 of each of the one or more foldable mounts 1000. For
example, each of the one or more foldable mounts 1000 is rotated at
the respective rotatable joint 1020 to account for variations in
the height of the modular rail 1120 and/or the desired angle of the
PV module 1110 relative to the sun.
[0096] At the process 1260, the one or more foldable mounts 1000
are inserted into the modular rail 1120. For example, the
insertable end 1030 of each of the one or more foldable mounts 1000
is inserted into the modular rail 1120. In another example, the
process 1260 occurs before the modular rail 1120 is substantially
cured. In yet another example, the process 1260 is controlled so
that the depth to which the insertable end 1030 of each of the one
or more foldable mounts 1000 is inserted into the modular rail 1120
is adjusted to account for variations in the height of the modular
rail 1120 and/or the desired angle of the PV module 1110 relative
to the sun. In yet another example, the process 1260 is controlled
so that the insertable end 1030 of each of the one or more foldable
mounts 1000 is inserted a suitable distance into the modular rail
1120 so that after the modular rail 1120 substantially cures, the
one or more foldable mounts 1000 provide sufficient pull strength
to account for the wind loads to which the PV module 1110 is
subjected.
[0097] FIG. 13A is a simplified diagram showing a side view of a
foldable mount as used in a PV module mounting system according to
another embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 13A, the foldable
mount 1300 includes a mounting flange 1310, a rotatable joint 1320,
and an mounting rod 1330. For example, the rotatable joint 1320
allows the mounting flange 1310 and the mounting rod 1330 to be
rotated relative to each other. In another example, the rotatable
joint 1320 includes a hinge. In yet another example, the rotatable
joint 1320 includes a ball-and-socket joint. In yet another
example, the foldable mount 1330 varies length from 0.25 cm to 50
cm. In yet another example, the foldable mount 1300 includes one or
more materials. In yet another example, the foldable mount 1300 is
flexible. In yet another example, the mounting rod 1330 is
sufficiently stiff to support part of the weight of a PV module. In
yet another example, the one or more materials are selected from a
group consisting of polyvinyl chloride (PVC), chlorinated polyvinyl
chloride (CPVC), high-density polyethylene (HDPE), low-density
polyethylene (LDPE), polypropylene (PP), poly(ethylene
terephthalate) (PET), polycarbonate (PC), polyamide (PA),
poly(methyl methacrylate) (PMMA), polyoxymethylene (POM),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), poly(ethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, the foldable mount 1300 is coated with a non-conductive
coating.
[0098] FIG. 13B is a simplified diagram showing a side view of the
foldable mount 1300 in folded position as used in a PV module
mounting system according to another embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 13B, the rotatable joint 1320 is
rotated so that the mounting flange 1310 and the mounting rod 1330
are substantially parallel. In another example, when the foldable
mount 1300 is in folded position, it provides as small a
cross-sectional footprint as possible. In yet another example, the
small cross-sectional footprint allows for maximum density when
packing multiple foldable mounts 1300.
[0099] FIG. 14 is a simplified diagram showing a side view of a PV
module mounting system using one or more foldable mounts 1300
according to another embodiment of the present invention. This
diagram is merely an example, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 14, a PV module 1410 is mounted to a modular rail
1420 using one or more foldable mounts 1300. For example, each of
the one or more foldable mounts 1300 is attached to the PV module
1410 using a respective mounting flange 1310. For example, the
mounting flange 1310 of each of the one or more foldable mounts
1300 is attached to the PV module 1410 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials are fast curing. In yet another example, the one or more
adhesive materials form a flexible bond between the mounting flange
1310 of each of the one or more foldable mounts 1300 and the PV
module 1330. In yet another example, the one or more adhesive
materials are each selected from a group consisting of silicone,
organo-silane modified ethylene-vinyl acetate (EVA), organo-silane
modified thermoplastic polyolefin (TPO), epoxy, organo-silane
modified epoxy, polyurethane, polyacrylic, organo-silane modified
polyurethane, organo-silane modified acrylic, polydimethylsiloxane
(PDMS), poly(methyl-phenylsiloxane) (PMPS), ether-type
polyurethane, ester-type polyurethane, poly(methyl methacrylate)
(PMMA), and the like. In yet another example, the PV module 1410 is
first primed with an organo-silane-containing primer and the one or
more adhesive materials further include one or more general-purpose
adhesive materials. In yet another example, the mounting flange
1310 of each of the one or more foldable mounts 1300 is attached to
the IN module 1410 using bolts, screws, and/or other mechanical
fasteners. In yet another example, one or more gasket materials are
used between the mounting flange 1310 of each of the one or more
foldable mounts 1300 and the PV module 1110. In yet another
example, each of the one or more gasket materials is selected from
a list consisting of ethylene propylene diene monomer (EPDM),
UV-resistant rubber, and the like.
[0100] In yet another example, the modular rail 1420 is the modular
rail 100 and/or the modular rail 300. In yet another example, the
modular rail 1420 includes one or more holes 1430. In yet another
example, the one or more holes 1430 substantially line up with the
one or more foldable mounts 1300. In yet another example, the
mounting rod 1330 of each of the one or more foldable mounts 1300
is placed into a respective hole 1430 in the modular rail 1420. In
yet another example, the mounting rod 1330 of each of the one or
more foldable mounts 1300 is held in place in the respective hole
1430 using one or more adhesive materials 1440. In yet another
example, the one or more adhesive materials 1440 are fast curing.
In yet another example, the one or more adhesive materials 1440
form a rigid bond between the mounting rod 1330 of each of the one
or more foldable mounts 1300 and the modular rail 1420. In yet
another example, the one or more adhesive materials 1440 are each
selected from a group consisting of silicone, ethylene-vinyl
acetate (EVA), thermoplastic polyolefin (TPO), epoxy, polyurethane,
polydimethylsiloxane (PDMS), poly(methyl-phenylsiloxane) (PMPS),
ether-type polyurethane, ester-type polyurethane, poly(methyl
methacrylate) (PMM), and the like. In yet another example, the
modular rail 1420 is first primed. In yet another example, the one
or more adhesive materials 1440 are different from the one or more
adhesive materials used to attach the muting flange 1310 of each of
the one or more foldable mounts 1300 to the PV module 1410. In yet
another example, excess of the one or more adhesive materials 1440
is displaced from the top of the one or more holes 1430. In yet
another example, the excess of the one or more adhesive materials
1440 displaced from the top of the one or more holes 1430 acts as a
self-leveling mechanism that accounts for variations in the
planarity of the one or more mounting surfaces of the modular rail
1420, the length of the mounting rod 1330 of each of the one or
more foldable mounts 1300, and/or the depth of the one or more
holes 1430.
[0101] In yet another example, a cross-sectional area of the
mounting rod 1330 of each of the one or more foldable mounts 1300
is selected to provide sufficient pull strength of the mounting
system based on the wind loads to which the PV module 1410 is
subjected. In yet another example, the cross-sectional area of the
mounting rod 1330 of each of the one or more foldable mounts 1300
is selected to provide sufficient surface area between the mounting
rod 1330 of each of the one or more foldable mounts 1300 and the
modular rail 1420 to provide sufficient attachment strength between
the mounting rod 1330 of each of the one or more foldable mounts
1300 to withstand the wind loads to which the PV module 1410 is
subjected. In yet another example, the mounting rod 1330 of each of
the one or more foldable mounts 1300 varies in cross-sectional area
from 25 mm.sup.2 to 30,000 mm.sup.2. In yet another example, the
mounting rod 1330 of each of the one or more-foldable mounts 1300
varies in length from 25 mm to 250 mm.
[0102] As discussed above and further emphasized here, FIG. 14 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of holes 1430 and corresponding foldable mounts 1300 is
varied. For example, the PV module 1410 is mounted to the modular
rail 1420 using only one hole 1430 and one foldable mount 1300. In
another example, four holes 1430 and four corresponding foldable
mounts 1300 are used. In yet another example, six or more holes
1430 and six or more corresponding foldable mounts 1300 are used.
In some embodiments, a different style of modular rail 1420 is
used. For example, the mounting rod 1330 of each of the one or more
foldable mounts 1300 is inserted into one of the one or more
mounting surfaces 110 of the modular rail 100 as shown in FIG. 1.
In another example, a mounting rod 1300 is inserted into one of the
one or more mounting surfaces 110 and another mounting rod 1300 is
inserted into another one of the one or more mounting surfaces
110.
[0103] FIG. 15 is a simplified diagram showing a method of mounting
a PV module 1410 to a modular rail 1420 using one or more foldable
mounts 1300 according to another embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 15, the method 1500 includes a
process 1510 for attaching one or more foldable mounts to a PV
module, a process 1520 for rotating the one or more foldable mounts
for transport, a process 1530 for transporting the PV module to the
installation site, a process 1540 for forming a modular rail, a
process 1550 for forming one or more holes in the modular rail, a
process 1560 for placing one or more adhesive materials in the one
or more holes, a process 1570 for rotating the one or more foldable
mounts for use, and a process 1580 for inserting one or more
foldable mounts into the one or more holes. According to certain
embodiments, the method 1500 of mounting a PV module to a modular
rail using one or more foldable mounts is performed using
variations among the processes 1510-1580 as would be recognized by
one of ordinary skill in the art. According to some embodiments,
one or more of the processes 1520 and/or 1530 are optional.
[0104] At the process 1510, one or more foldable mounts 1300 are
attached to a PV module 1410. For example, the PV module 1410 is
the PV module 200. In another example, the one or more foldable
mounts 1300 are attached to the PV module 1410 using the respective
mounting flange 1310 of each of the one or more foldable mounts
1300. In yet another example, the one or more foldable mounts 1300
are attached to the PV module 1410 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials form a flexible bond between the mounting flange 1310 of
each of the one or more foldable mounts 1300 and the PV module
1410. In yet another example, the mounting flange 1310 of each of
the one or more foldable mounts 1300 is attached to the PV module
1410 using bolts, screws, and/or other mechanical fasteners. In yet
another example, one or more gaskets materials is placed on the PV
module 1410 before each of the one or more foldable mounts 1300 is
attached. In yet another example, the one or more foldable mounts
1300 are attached to the PV module 1410 using a predetermined
pattern and spacing. In yet another example, the PV module 1410 is
primed before each of the one or more foldable mounts 1300 is
attached. In yet another example, the surface of the PV module 1410
is roughened before the one or more foldable mounts 1300 is
attached. In yet another example, the surface of the PV module 1410
is chemically modified using an atmospheric corona discharge and/or
an atmospheric plasma discharge. In yet another example, the
process 1510 is performed in the factory. In yet another example,
the process 1510 is performed in the field.
[0105] At the optional process 1520, the one or more foldable
mounts 1300 are rotated for transport. For example, the one or more
foldable mounts 1300 are rotated using the respective rotatable
joint 1310 as shown in FIG. 13B. In another example, during the
process 1520, each mounting rod 1330 of each of the one or more
foldable mounts 1300 is rotated to provide as small a
cross-sectional footprint as possible relative to the PV module
1410. In yet another example, each mounting rod 1320 of each of the
one or more foldable mounts 1300 is rotated so that each mounting
rod 1320 of each of the one or more foldable mounts 1300 is
substantially parallel to the PV module.
[0106] At the optional process 1530, the PV module 1410 is
transported to the installation site. For example, the PV module
1410 is placed in a crate and/or a rack for transportation. In
another example, more than one PV module 1410 is placed in the same
crate and/or rack for transportation, taking advantage of the small
cross-sectional footprint made possible by the rotation of each of
the foldable mounts 1300.
[0107] At the process 1540, the modular rail 1420 is formed. For
example, the modular rail 1420 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 1420 is
formed in-situ in the field using a slip-fours extrusion machine.
In yet another example, the extrusion speed of the slip-form
extrusion machine is varied. In yet another example, the extrusion
speed should be slow enough to produce one or more mounting
surfaces which are substantially planar. In yet another example,
the extrusion speed should be slow enough to produce the one or
more mounting surfaces with a high planarity and little sagging to
allow for uniformity in the PV module mounting system. In yet
another example, if a large planarity variability in the one or
more mounting surfaces could be allowed, a much higher extrusion
speed of slip-form extrusion machine could be achieved, causing
reduction of the construction cost of the finished rail. In yet
another example, the modular rail 1420 is preformed in the factory
and transported to the installation site.
[0108] At the process 1550, one or more holes 1430 are formed in to
the modular rail 1420. For example, the one or more holes 1430 are
the one or more holes 510. In yet another example, the one or more
holes 1430 are arranged using the predetermined pattern and spacing
for the one or more foldable mounts 1300 attached to the PV module
1410. In yet another example, the one or more holes 1430 are formed
by using a hole punch tool. In yet another example, the hole punch
tool is used with the slip-form extrusion machine. In yet another
example, the one or more holes 1430 are formed before the modular
rail 1420 has been allowed to cure. In yet another example, the one
or more holes 1430 are formed by drilling a previously formed and
cured modular rail 1420.
[0109] At the process 1560, one or more adhesive materials 1440 are
placed into the one or more holes 1430. For example, the one or
more adhesive materials 1440 are fast curing. In another example,
the one or more adhesive materials 1440 partially fill the one or
more holes 1430. In yet another example, the one or more adhesive
materials 1440 substantially fill the one or more holes 1430. In
yet another example, the one or more adhesive materials 1440 are
placed in the one or more holes 1430 manually. In yet another
example, the one or more adhesive materials 1440 are placed in the
one or more holes 1430 using an automated robotic arm with one or
more adhesive dispensers.
[0110] At the process 1570, the one or more foldable mounts 1300
are rotated for use. For example, the angle of the PV module 1410
relative to the sun is controlled through use of the rotatable
joint 1320 of each of the one or more foldable mounts 1300. For
example, each of the one or more foldable mounts 1300 is rotated at
the respective rotatable joint 1320 to account for variations in
the height of the modular rail 1420 and/or the desired angle of the
PV module 1410 relative to the sun.
[0111] At the process 1580, the one or more foldable mounts 1300
are inserted into the one or more holes 1430. For example, the
mounting rod 1330 of each of the one or more foldable mounts 1300
is are aligned with a respective one of the one or more holes 1430
and then inserted into the respective hole 1430. In another
example, the one or more adhesive materials 1440 in the one or more
holes 1430 form a rigid bond between the mounting rod 1330 of each
of the one or more foldable mounts 1300 and the modular rail 1420.
In yet another example, excess of the one or more adhesive
materials 1440 is displaced from the top of one or more of the one
or more holes 1430. In yet another example, the excess of the one
or more adhesive materials 1440 displaced from the top of one or
more of the one or more holes 1430 acts as a self-leveling
mechanism that accounts for variations in the planarity of the one
or more mounting surfaces of the modular rail 1420, the length of
the mounting rod 1330 of each of the one or more foldable mounts
1300, and/or the depth of the one or more holes 1430.
[0112] FIG. 16 is a simplified diagram showing a side view of a PV
module mounting system using one or more foldable mounts 1300
according to another embodiment of the present invention. This
diagram is merely an example, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 16, a PV module 1610 is mounted to a modular rail
1620 using one or more foldable mounts 1300. For example, each of
the one or more foldable mounts 1300 is attached to the PV module
1610 using a respective mounting flange 1310. For example, the
mounting flange 1310 of each of the one or more foldable mounts
1300 is attached to the PV module 1610 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials are fast curing. In yet another example, the one or more
adhesive materials form a flexible bond between the mounting flange
1310 of each of the one or more foldable mounts 1300 and the PV
module 1610. In yet another example, the one or more adhesive
materials are each selected from a group consisting of silicone,
organo-silane modified ethylene-vinyl acetate (EVA), organo-silane
modified thermoplastic polyolefin (TPO), epoxy, organo-silane
modified epoxy, polyurethane, polyacrylic, organo-silane modified
polyurethane, organo-silane modified acrylic, polydimethylsiloxane
(PDMS), poly(methyl-phenylsiloxane) (PMPS), ether-type
polyurethane, ester-type polyurethane, poly(methyl methacrylate)
(PMMA), and the like. In yet another example, the PV module 1610 is
first primed with an organo-silane-containing primer and the one or
more adhesive materials further include one or more general-purpose
adhesive materials. In yet another example, the mounting flange
1310 of each of the one or more foldable mounts 1300 is attached to
the PV module 1610 using bolts, screws, and/or other mechanical
fasteners. In yet another example, one or more gasket materials are
used between the mounting flange 1310 of each of the one or more
foldable mounts 1300 and the PV module 1110. In yet another
example, each of the one or more gasket materials is selected from
a list consisting of ethylene propylene diene monomer (EPDM),
UV-resistant rubber, and the like.
[0113] In yet another example, the modular rail 1620 is the modular
rail 100 and/or the modular rail 300. In yet another example, the
mounting rod 1330 of each of the one or more foldable mounts 1300
is attached to the modular rail 1620 using one or more adhesive
materials 1630. In yet another example, the one or more adhesive
materials 1630 are fast curing. In yet another example, the one or
more adhesive materials 1630 form a rigid bond between the mounting
rod 1330 of each of the one or more foldable mounts 1300 and the
modular rail 1620. In yet another example, the one or more adhesive
materials 1630 are each selected from a group consisting of
silicone, ethylene-vinyl acetate (EVA), thermoplastic polyolefin
(TPO), epoxy, polyurethane, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the modular rail 1620 is first
primed. In yet another example, the one or more adhesive materials
1630 are different from the one or more adhesive materials uses to
attach the mounting flange 1310 of each of the one or more foldable
mounts 1300 to the PV module 1610.
[0114] In yet another example, a cross-sectional area of the
mounting rod 1330 of each of the one or more foldable mounts 1300
is selected to provide sufficient pull strength of the mounting
system based on the wind loads to which the PV module 1610 is
subjected. In yet another example, the cross-sectional area of the
mounting rod 1330 of each of the one or more foldable mounts 1300
is selected to provide sufficient surface area between the mounting
rod 1330 of each of the one or more foldable mounts 1300 and the
modular rail 1620 to provide sufficient attachment strength between
the mounting rod 1330 of each of the one or more foldable mounts
1300 to withstand the wind loads to which the PV module 1610 is
subjected. In yet another example, the mounting rod 1330 of each of
the one or more foldable mounts 1300 varies in cross-sectional area
from 25 mm.sup.2 to 30,000 mm.sup.2. In yet another example, the
mounting rod 1330 of each of the one or more foldable mounts 1300
varies in length from 25 mm to 250 mm.
[0115] As discussed above and further emphasized here, FIG. 16 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of foldable mounts 1300 is varied. For example, the PV
module 1610 is mounted to the modular rail 1620 using only one
foldable mount 1300. In another example, four foldable mounts 1300
are used. In yet another example, six or more foldable mounts 1300
are used. In some embodiments, a different style of modular rail
1620 is used. For example, the mounting rod 1330 of each of the one
or more foldable mounts 1300 is inserted into one of the one or
more mounting surfaces 110 of the modular rail 100 as shown in FIG.
1. In another example, a mounting rod 1300 is inserted into one of
the one or more mounting surfaces 110 and another mounting rod 1300
is inserted into another one of the one or more mounting surfaces
110.
[0116] FIG. 17 is a simplified diagram showing a method of mounting
a PV module 1610 to a modular rail 1620 using one or more foldable
mounts 1300 according to another embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 17, the method 1700 includes a
process 1710 for attaching one or more foldable mounts to a PV
module, a process 1720 for rotating the one or more foldable mounts
for transport, a process 1730 for transporting the PV module to the
installation site, a process 1740 for forming a modular rail, a
process 1750 for rotating the one or more foldable mounts for use,
and a process 1760 for attaching one or more foldable mounts to the
modular rail. According to certain embodiments, the method 1700 of
method of mounting a PV module to a modular rail using one or more
foldable mounts is performed using variations among the processes
1710-1760 as would be recognized by one of ordinary skill in the
art. According to some embodiments, one or more of the processes
1720 and/or 1730 are optional.
[0117] At the process 1710, one or more foldable mounts 1300 are
attached to a PV module 1610. For example, the PV module 1610 is
the PV module 200. In another example, the one or more foldable
mounts 1300 are attached to the PV module 1610 using the respective
mounting flange 1310 of each of the one or more foldable mounts
1300. In yet another example, the one or more foldable mounts 1300
are attached to the PV module 1610 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials form a flexible bond between the mounting flange 1310 of
each of the one or more foldable mounts 1300 and the PV module
1610. In yet another example, the mounting flange 1310 of each of
the one or more foldable mounts 1300 is attached to the PV module
1610 using bolts, screws, and/or other mechanical fasteners. In yet
another example, one or more gasket materials is placed on the PV
module 1610 before the mounting flange 1310 of each of the one or
more foldable mounts 1300 is attached. In yet another example, the
one or more foldable mounts 1300 are attached to the PV module 1610
using a predetermined pattern and spacing. In yet another example,
the PV module 1610 is primed before each of the one or more
foldable mounts 1300 is attached. In yet another example, the
surface of the PV module 1610 is roughened before the one or more
foldable mounts 1300 is attached. In yet another example, the
surface of the PV module 1610 is chemically modified using an
atmospheric corona discharge and/or an atmospheric plasma
discharge. In yet another example, the process 1710 is performed in
the factory. In yet another example, the process 1710 is performed
in the field.
[0118] At the optional process 1720, the one or more foldable
mounts 1300 are rotated for transport. For example, the one or more
foldable mounts 1300 are; rotated using the respective rotatable
joint 1310 as shown in FIG. 13B. In another example, during the
process 1720, each mounting rod 1330 of each of the one or more
foldable mounts 1300 is rotated to provide as small a
cross-sectional footprint as possible relative to the PV module
1610. In yet another example, each mounting rod 1320 of each of the
foldable mounts 1300 is rotated so that each each mounting rod 1320
of each of the one or more foldable mounts 1300 is substantially
parallel to the PV module.
[0119] At the optional process 1730, the PV module 1610 is
transported to the installation site. For example, the PV module
1610 is placed in a crate and/or a rack for transportation. In
another example, more than one PV module 1610 is placed in the same
crate and/or rack for transportation, taking advantage of the small
cross-sectional footprint made possible by the rotation of each of
the foldable mounts 1300.
[0120] At the process 1740, the modular rail 1620 is formed. For
example, the modular rail 1620 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 1620 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-form extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 1620 is preformed in the factory and
transported to the installation site.
[0121] At the process 1750, the one or more foldable mounts 1300
are rotated for use. For example, the angle of the PV module 1610
relative to the sun is controlled through use of the rotatable
joint 1320 of each of the one or more foldable mounts 1300. For
example, each of the one or more foldable mounts 1300 is rotated at
the respective rotatable joint 1320 to account for variations in
the height of the modular rail 1620 and/or the desired angle of the
PV module 1610 relative to the sun.
[0122] At the process 1760, the one or more foldable mounts 1300
are attached to the modular rail 1620. For example, the mounting
rod 1330 of each of the one or more foldable mounts 1300 is
attached to the modular rail 1620 using one or more adhesive
materials 1630. In another example, the one or more adhesive
materials 1630 form a rigid bond between the mounting rod 1330 of
each of the one or more foldable mounts 1300 and the modular rail
1620. In yet another example, the mounting surface of the modular
rail 1620 is roughened before the one or more foldable mounts 1300
is attached.
[0123] FIG. 18 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
one embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 18, a PV module
1810 is mounted to a modular rail 1820 using one or more angled
mounts 1830. For example, each of the one or more angled mounts
1830 is attached to the PV module 1810 using a respective mounting
face 1840. In another example, each of the one or more angled
mounts 1830 varies in length from 0.25 cm to 50 cm. In yet another
example, each mounting face 1840 of each of the one or more angled
mounts 1830 is attached to the PV module 1810 using one or more
adhesive materials 1850. In yet another example, the one or more
adhesive materials 1850 are fast curing. In yet another example,
the one or more adhesive materials 1850 form a flexible bond
between the mounting face 1840 of each of the one or more angled
mounts 1830 and the PV module 1810. In yet another example, the one
or more adhesive materials 1850 are each selected from a group
consisting of silicone, organo-silane modified ethylene-vinyl
acetate (EVA), organo-silane modified thermoplastic polyolefin
(TPO), epoxy, organo-silane modified epoxy, polyurethane,
polyacrylic, organo-silane modified polyurethane, organo-silane
modified acrylic, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PIMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the PV module 1810 is first primed
with an organo-silane-containing primer and the one or more
adhesive materials 1850 further include one or more general-purpose
adhesive materials.
[0124] In yet another example, each of the one or more angled
mounts 1830 (e.g., a mounting post end distal to the mounting face
1840) is shaped like a wedge. In yet another example, each of the
one or more angled mounts 1830 is shaped like a cone. In yet
another example, each of the one or more angled mounts 1830 is
shaped like an arrow head. In yet another example, each of the one
or more angled mounts 1830 is shaped like a spear head. In yet
another example, each of the one or more angled mounts 1830
includes one or more barbs. In yet another example, each of the one
or more angled mounts 1830 includes one or more ribs, hi yet
another example, each of the one or more angled mounts 1830
includes one or more materials. In yet another example, each of the
one or more angled mounts 1830 is flexible. In yet another example,
each of the one or more angled mounts 1830 is sufficiently stiff to
support part of the weight of a PV module. In yet another example,
the one or more materials are selected from a group consisting of
polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC),
high-density polyethylene (HDPE), low-density polyethylene (LDPE),
polypropylene (PP), poly(ethylene terephthalate) (PET),
polycarbonate (PC), polyamide (PA), poly(methyl methacrylate)
(PMMA), polyoxymethylene (POM), polyphenylene oxide (PPO),
polyphenylene sulfide (PPS), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), polyethylene terephthalate) (Rynite), polyphenylene
ether (PPE) modified by polystyrene (PS) or polyamide (PA) (Xyron),
acrylonitrile butadiene styrene (ABS), polyphenylene oxide (PPO)
blended with polystyrene (PS) (Noryl), engineering polymers,
non-engineering plastics, polyolefins, elastomeric polymers,
hot-dipped zinc-coated steel, anodized aluminum, powder-coated
metal, painted metal, polymeric over molded metal, polymer over
extruded metal, and the like. In yet another example, each of the
one or more angled mounts 1830 is coated with a non-conductive
coating.
[0125] In yet another example, the modular rail 1820 is the modular
rail 100 and/or the modular rail 300. In yet another example, each
of the one or more angled mounts 1830 is inserted into the modular
rail 1820. In yet another example, each of the one or more angled
mounts 1830 is inserted into the modular rail 1820 to a depth
between 5 mm and 500 mm.
[0126] According to some embodiments, the angle of the PV module
1810 relative to the sun is controlled through use of the one or
more angled mounts 1830. For example, the angled face 1840 of each
of the one or more angled mounts 1830 is angled relative to a
direction of the rest of the respective one or more angled mounts
1830 to control the mounting angle of the PV module 1810. In
another example, the angled face 1840 of each of the one or more
angled mounts 1830 is not perpendicular to the direction of the
rest of the respective one or more angled mounts. In yet another
example, the depth to which the one or more angled mounts 1830 is
inserted into the modular rail 1820 is adjusted to account for
variations in the height of the modular rail 1820 and/or the
desired angle of the IN module 1810 relative to the sun. In yet
another example, a length and a size of the one or more angled
mounts 1830 is selected to provide sufficient pull strength for the
mounting system based on the wind loads to which the PV module 1810
is subjected.
[0127] As discussed above and further emphasized here, FIG. 18 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of angled mounts 1830 is varied. For example, the PV
module 1810 is mounted to the modular rail 1820 using only one
angled mount 1830. In another example, four angled mounts 1830 are
used. In yet another example, six or more angled mounts 1830 are
used. In some embodiments, a different style of modular rail 1820
is used. For example, the insertable end 1830 of each of the one or
more angled mounts 1830 is inserted into the mounting surface 310
of the modular rail 300 as shown in FIG. 3.
[0128] FIG. 19 is a simplified diagram showing a method of mounting
a PV module 1810 to a modular rail 1820 using one or more angled
mounts 1830 according to one embodiment of the present invention.
This diagram is merely an example, which should not unduly limit
the scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 19, the method 1900 includes a process 1910 for
attaching one or more angled mounts to a PV module, a process 1920
for forming a modular rail, and a process 1930 for inserting the
one or more foldable mounts into the modular rail. According to
certain embodiments, the method 1900 of mounting a PV module to a
modular rail using one or more angled mounts is performed using
variations among the processes 1910-1930 as would be recognized by
one of ordinary skill in the art.
[0129] At the process 1910, one or more angled mounts 1830 are
attached to a PV module 1810. For example, the PV module 1810 is
the PV module 200. In another example, the one or more angled
mounts 1830 are attached to the PV module 1810 using the respective
mounting face 1840 of the one or more angled mounts 1830. In yet
another example, the one or more angled mounts 1830 are attached to
the PV module 1810 using one or more adhesive materials 1840. In
yet another example, the one or more adhesive materials 1840 form a
flexible bond between the mounting face 1840 of each of the one or
more angled mounts 1830 and the PV module 1810. In yet another
example, each of the one or more angled mounts 1830 is selected to
have a same angle between the mounting face 1840 and the respective
one or more angled mounts 1830. In yet another example, the same
angle is selected to control the angle between the PV module 1810
and the sun. In yet another example, the one or more angled mounts
1830 are attached to the PV module 1810 using a predetermined
pattern and spacing. In yet another example, the PV module 1810 is
primed before each of the one or more angled mounts 1830 is
attached. In yet another example, the surface of the PV module 1810
is roughened before the one or more foldable mounts 1830 is
attached. In yet another example, the surface of the PV module 1810
is chemically modified using an atmospheric corona discharge and/or
an atmospheric plasma discharge. In yet another example, the
process 1910 is performed in the factory. In yet another example,
the process 1910 is performed in the field.
[0130] At the process 1920, the modular rail 1820 is formed. For
example, the modular rail 1820 is the modular rail 100, and or the
modular rail 300. In another example, the modular rail 1820 is
thrilled in-situ in the field using a slip-form extrusion machine.
In yet another example, the extrusion speed of the slip-form
extrusion machine is varied. In yet another example, the extrusion
speed should be slow enough to produce one or more mounting
surfaces which are substantially planar. In yet another example,
the extrusion speed should be slow enough to produce the one or
more mounting surfaces with a high planarity and little sagging to
allow for uniformity in the PV module mounting system. In yet
another example, if a large planarity variability in the one or
more mounting surfaces could be allowed, a much higher extrusion
speed of slip-form extrusion machine could be achieved, causing
reduction of the construction cost of the finished rail. In yet
another example, the modular rail 1820 is preformed in the factory
and transported to the installation site.
[0131] At the process 1930, the one or more angled mounts 1830 are
inserted into the modular rail 1820. For example, the process 1930
occurs before the modular rail 1820 is substantially cured. In yet
another example, the process 1930 is controlled so that the depth
to which the one or more angled mounts 1830 is inserted into the
modular rail 1820 is adjusted to account for variations in the
height of the modular rail 1820 and/or the desired angle of the PV
module 1810 relative to the sun. In yet another example, the
process 1930 is controlled so that the one or more angled mounts
1830 is inserted a suitable distance into the modular rail 1820 so
that after the modular rail 1820 substantially cures, the one or
more angled mounts 1830 provide sufficient pull strength to account
for the wind loads to which the PV module 1810 is subjected.
[0132] FIG. 20 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
another embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 20, a PV module
2010 is mounted to a modular rail 2020 using one or more angled
mounts 2030. For example, each of the one or more angled mounts
2030 is attached to the PV module 2010 using a respective mounting
face 2040. In another example, each of the one or more angled
mounts 2030 varies in length from 0.25 cm to 50 cm. In yet another
example, each mounting face 2040 of each of the one or more angled
mounts 2030 is attached to the PV module 2010 using one or more
adhesive materials 2050. In yet another example, the one or more
adhesive materials 2050 are fast curing. In yet another example,
the one or more adhesive materials 2050 form a flexible bond
between the mounting face 2040 of each of the one or more angled
mounts 2030 and the PV module 2010. In yet another example, the one
or more adhesive materials 2050 are each selected from a group
consisting of silicone, organo-silane modified ethylene-vinyl
acetate (EVA), organo-silane modified thermoplastic polyolefin
(TPO), epoxy, organo-silane modified epoxy, polyurethane,
polyacrylic, organo-silane modified polyurethane, organo-silane
modified acrylic, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the PV module 2010 is primed with an
organo-silane-containing primer and the one or more adhesive
materials 2050 further include one or more general-purpose adhesive
materials.
[0133] In yet another example, each of the one or more angled
mounts 2030 includes one or more materials. In yet another example,
each of the one or more angled mounts 2030 is flexible. In yet
another example, each of the one or more angled mounts 2030 is
sufficiently stiff to support part of the weight of a PV module. In
yet another example, the one or more materials are selected from a
group consisting of polyvinyl chloride (PVC), chlorinated polyvinyl
chloride (CPVC), high-density polyethylene (HDPE), low-density
polyethylene (LDPE), polypropylene (PP), polyethylene
terephthalate) (PET), polycarbonate (PC), polyamide (PA),
poly(methyl methacrylate) (PMMA), polyoxymethylene (POM),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), polyethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, each of the one or more angled mounts 2030 is coated with
a non-conductive coating.
[0134] In yet another example, the modular rail 2020 is the modular
rail 100 and/or the modular rail 300. In yet another example, the
modular rail 2020 includes one or more holes 2060. In yet another
example, the one or more holes 2060 substantially line up with the
one or more angled mounts 2030. In yet another example, each of the
one or more angled mounts 2030 is placed into a respective hole
2060 in the modular rail 2020. In yet another example, each of the
one or more angled mounts 2030 is held in place in the respective
hole 2060 using one or more adhesive materials 2070. In yet another
example, the one or more adhesive materials 2078 are fast curing.
In yet another example, the one or more adhesive materials 2070
form a rigid bond between each of the one or more angled mounts
2030 and the modular rail 2020. In yet another example, the one or
more adhesive materials 2070 are each selected from a group
consisting of silicone, ethylene-vinyl acetate (EVA), thermoplastic
polyolefin (TPO), epoxy, polyurethane, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the modular rail 2020 is first
primed. In yet another example, the one or more adhesive materials
2070 are different from the one or more adhesive materials 2050. In
yet another example, excess of the one or more adhesive materials
2070 is displaced from the top of the one or more holes 2060. In
yet another example, the excess of the one or more adhesive
materials 2070 displaced from the top of the one or more holes 2060
acts as a self-leveling mechanism that accounts for variations in
the planarity of the one or more mounting surfaces of the modular
rail 2020, the length of each of the one or more angled mounts
2030, and/or the depth of the one or more holes 2060.
[0135] In yet another example, a cross-sectional area of each of
the one or more angled mounts 2030 is selected to provide
sufficient pull strength of the mounting system based on the wind
loads to which the PV module 2010 is subjected. In yet another
example, the cross-sectional area of each of the one or more angled
mounts 2030 is selected to provide sufficient surface area between
each of the one or more angled mounts 2030 and the PV module 2010
and/or the modular rail 2020 to provide sufficient attachment
strength between each of the one or more angled mounts 2030 to
withstand the wind loads to which the PV module 2010 is subjected.
In yet another example, each of the one or more angled mounts 2030
varies in cross-sectional area from 25 mm.sup.2 to 30,000 mm.sup.2.
In yet another example, each of the one or more angled mounts 2030
varies in length from 25 ram to 250 mm.
[0136] As discussed above and further emphasized here, FIG. 20 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of holes 2060 and corresponding angled mounts 2030 is
varied. For example, the PV module 2010 is mounted to the modular
rail 2020 using only one hole 2060 and one angled mount 2030. In
another example, four holes 2060 and four corresponding angled
mounts 2030 are used. In yet another example, six or more holes
2060 and six or more corresponding angled mounts 2030 are used. In
some embodiments, a different style of modular rail 2020 is used.
For example, each of the one or more angled mounts 2030 is inserted
into one of the one or more mounting surfaces 110 of the modular
rail 100 as shown in FIG. 1. In another example, an angled mount
2030 is inserted into one of the one or more mounting surfaces 110
and another angled mount 2030 is inserted into another one of the
one or more mounting surfaces 110.
[0137] FIG. 21 is a simplified diagram showing a method of mounting
a PV module 2010 to a modular rail 2020 using one or more angled
mounts 2030 according to another embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 21, the method 2100 includes a
process 2110 for attaching one or more angled mounts to a PV
module, a process 2120 for forming a modular rail, a process 2130
for forming one or more holes in the modular rail, a process 2140
for placing one or more adhesive materials in the one or more
holes, and a process 2150 for inserting one or more angled mounts
into the one or more holes. According to certain embodiments, the
method 2100 of method of mounting a PV module to a modular rail
using one or more angled mounts is performed using variations among
the processes 2110-2150 as would be recognized by one of ordinary
skill in the art.
[0138] At the process 2110, one or more angled mounts 2030 are
attached to a PV module 2010. For example, the PV module 2010 is
the PV module 200. In another example, the one or more angled
mounts 2030 are attached to the PV module 2010 using the respective
mounting face 2040 of the one or more angled mounts 2030. In yet
another example, the one or more angled mounts 2030 are attached to
the PV module 2010 using one or more adhesive materials 2040. In
yet another example, the one or more adhesive materials 2040 form a
flexible bond between the mounting face 2040 of each of the one or
more angled mounts 2030 and the PV module 2010. In yet another
example, each of the one or more angled mounts 2030 is selected to
have a same angle between the mounting face 2040 and the respective
one or more angled mounts 2030. In yet another example, the same
angle is selected to control the angle between the PV module 2010
and the sun. In yet another example, the one or more angled mounts
2030 are attached to the PV module 2010 using a predetermined
pattern and spacing. In yet another example, the PV module 2010 is
primed before each of the one or more angled mounts 2030 is
attached. In yet another example, the surface of the PV module 2010
is roughened before the one or more foldable mounts 2030 is
attached. In yet another example, the surface of the PV module 1210
is chemically modified using an atmospheric corona discharge and/or
ara atmospheric plasma discharge. In yet another example, the
process 2110 is performed in the factory. In yet another example,
the process 2110 is performed in the field.
[0139] At the process 2120, the modular rail 2020 is formed. For
example, the modular rail 2020 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 2020 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-form extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 2020 is preformed in the factory and
transported to the installation site.
[0140] At the process 2130, one or more holes 2060 are formed in to
the modular rail 2020. For example, the one or more holes 2060 are
the one or more holes 510. In another example, the one or more
holes 2060 are arranged using the predetermined pattern and spacing
for the one or more angled mounts 2060 attached to the IN module
2010. In yet another example, the one or more holes 2060 are formed
by using a hole punch tool. In yet another example, the hole punch
tool is used with the slip-form extrusion machine. In yet another
example, the one or more holes 2060 are formed before the modular
rail 2020 has been allowed to cure. In yet another example, the one
or more holes 2060 are formed by drilling a previously formed and
cured modular rail 2020.
[0141] At the process 2140, one or more adhesive materials 2070 are
placed into the one or more holes 2060. For example, the one or
more adhesive materials 2070 are fast curing. In another example,
the one or more adhesive materials 2070 partially fill the one or
More holes 2060. In yet another example, the one or more adhesive
materials 2070 substantially fill the one or more holes 2060. In
yet another example, the one or more adhesive materials 2070 are
placed in the one or more holes 2060 manually. In yet another
example, the one or more adhesive materials 2070 are placed in the
one or more holes 2060 using an automated robotic arm with one or
more adhesive dispensers.
[0142] At the process 2150, the one or more angled mounts 2030 are
inserted into the one or more holes 2060. For example, the mounting
rod 1330 of each of the one or more angled mounts 2030 is are
aligned with a respective one of the one or more holes 2060 and
then inserted into the respective hole 2060. In another example,
the one or more adhesive materials 2070 in the one or more holes
2060 form a rigid bond between the mounting rod 1330 of each of the
one or more angled mounts 2030 and the modular rail 2020. In yet
another example, excess of the one or more adhesive materials 2070
is displaced from the top of one or more of the one or more holes
2060. In yet another example, the excess of the one or more
adhesive materials 2070 displaced from the top of one or more of
the one or more holes 2060 acts as a self-leveling mechanism that
accounts for variations in the planarity of the one or more
mounting surfaces of the modular rail 2020, the length of the
mounting rod 1330 of each of the one or more angled mounts 2030,
and/or the depth of the one or more holes 2060.
[0143] FIG. 22 is a simplified diagram showing a side view of a PV
module mounting system using one or more angled mounts according to
another embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 22, a PV module
2210 is mounted to a modular rail 2220 using one or more angled
mounts 2230. For example, each of the one or more angled mounts
2230 is the angled mount 2030. In another example, each of the one
or more angled mounts 2230 is attached to the PV module 2210 using
a respective mounting face 2240. In yet another example, each of
the one or more angled mounts 2230 varies in length from 0.25 cm to
50 cm. In yet another example, the mounting face 2240 of each of
the one or more angled mounts 2230 is attached to the PV module
2210 using one or more adhesive materials 2250. In yet another
example, the one or more adhesive materials 2250 are fast curing.
In yet another example, the one or more adhesive materials 2250
form a flexible bond between the mounting face 2240 of each of the
one or more angled mounts 2230 and the PV module 2210. In yet
another example, the one or more adhesive materials 2250 are each
selected from a group consisting of silicone, organo-silane
modified ethylene-vinyl acetate (EVA), organo-silane modified
thermoplastic polyolefin (TPO), epoxy, organo-silane modified
epoxy, polyurethane, polyacrylic, organo-silane modified
polyurethane, organo-silane modified acrylic, polydimethylsiloxane
(PDMS), poly(methyl-phenylsiloxane) (PMPS), ether-type
polyurethane, ester-type polyurethane, poly(methyl methacrylate)
(PMMA), and the like. In yet another example, the PV module 2210 is
first primed with an organo-silane-containing primer and the one or
more adhesive materials 2250 further include one or more
general-purpose adhesive materials.
[0144] In yet another example, each of the one or more angled
mounts 2230 includes one or more materials. In yet another example,
each of the one or more angled mounts 2230 is flexible. In yet
another example, each of the one or more angled mounts 2230 is
sufficiently stiff to support part of the weight of a PV module. In
yet another example, the one or more materials are selected from a
group consisting of polyvinyl chloride (PVC), chlorinated polyvinyl
chloride (CPVC), high-density polyethylene (HDPE), low-density
polyethylene (LDPE), polypropylene (PP), polyethylene
terephthalate) (PET), polycarbonate (PC), polyamide (PA),
poly(methyl methacrylate) (PMMA), polyoxymethylene (POM),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), polyethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, each of the one or more angled mounts 2230 is coated with
a non-conductive coating.
[0145] In yet another example, the modular rail 2220 is the modular
rail 100 and/or the modular rail 300. In yet another example, each
of the one or more angled mounts 2230 is attached to the modular
rail 2220 using one or more adhesive materials 2260. In yet another
example, the one or more adhesive materials 2260 are fast curing.
In yet another example, the one or more adhesive materials 2260
form a rigid bond between each of the one or more angled mounts
2230 and the modular rail 2220. In yet another example, the one or
more adhesive materials 2260 are each selected from a group
consisting of silicone, ethylene-vinyl acetate (EVA), thermoplastic
polyolefin (TPO), epoxy, polyurethane, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the modular rail 2220 is first
primed. In yet another example, the one or more adhesive materials
2260 are different from the one or more adhesive materials
2250.
[0146] In yet another example, a cross-sectional area of each of
the one or more angled mounts 2230 is selected to provide
sufficient pull strength of the mounting system based on the wind
loads to which the PV module 2210 is subjected. In yet another
example, the cross-sectional area of each of the one or more angled
mounts 2230 is selected to provide sufficient surface area between
the each of the one or more angled mounts 2230 and the PV module
2210 and/or the modular rail 2220 to provide sufficient attachment
strength to withstand the wind loads to which the PV module 2210 is
subjected. In yet another example, each of the one or more angled
mounts 2230 varies in cross-sectional area from 25 mm.sup.2 to
30,000 mm.sup.2. In yet another example, each of the one or more
angled mounts 2230 varies in length from 25 mm to 250 mm.
[0147] According to some embodiments, the angle of the PV module
2210 relative to the sun is controlled through use of the one or
more angled mounts 2230. For example, the angled face 2240 of each
of the one or more angled mounts 2230 is angled relative to the
rest of the respective one or more angled mounts to control the
mounting angle of the PV module 2210. In yet another example, a
size of the one or more angled mounts 2230 is selected to provide
sufficient pull strength for the mounting system based on the wind
loads to which the PV module 2210 is subjected.
[0148] As discussed above and further emphasized here, FIG. 22 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of angled mounts 2230 is varied. For example, the PV
module 2210 is mounted to the modular rail 2220 using only one
angled mount 2230. In another example, four angled mounts 2230 are
used. In yet another example, six or more angled mounts 2230 are
used. In some embodiments, a different style of modular rail 2220
is used. For example, each of the one or more angled mounts 2230 is
inserted into the mounting surface 310 of the modular rail 300 as
shown in FIG. 3.
[0149] FIG. 23 is a simplified diagram showing a method of mounting
a PV module 2210 to a modular rail 2220 using one or more angled
mounts 2230 according to another embodiment of the present
invention. This diagram is merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIG. 23, the method 2300 includes a
process 2310 for attaching one or more angled mounts to a PV
module, a process 2320 for forming a modular rail, and a process
2330 for attaching one or more angled mounts to the modular rail.
According to certain embodiments, the method 2300 of method of
mounting a PV module to a modular rail using one or more angled
mounts is performed using variations among the processes 2310-2330
as would be recognized by one of ordinary skill in the art.
[0150] At the process 2310, one or more angled mounts 2230 are
attached to a PV module 2210. For example, the PV module 2210 is
the PV module 200. In another example, the one or more angled
mounts 2230 are attached to the PV module 2210 using the respective
mounting face 2240 of the one or more angled mounts 2230. In yet
another example, the one or more angled mounts 2230 are attached to
the PV module 2210 using one or more adhesive materials 2240. In
yet another example, the one or more adhesive materials 2240 form a
flexible bond between the mounting face 2240 of each of the one or
more angled mounts 2230 and the PV module 2210. In yet another
example, each of the one or more angled mounts 2230 is selected to
have a same angle between the mounting face 2240 and the respective
one or more angled mounts 2230. In yet another example, the same
angle is selected to control the angle between the PV module 2210
and the sun. In yet another example, the one or more angled mounts
2230 are attached to the PV module 2210 using a predetermined
pattern and spacing. In yet another example, the PV module 2210 is
primed before each of the one or more angled mounts 2230 is
attached. In yet another example, the surface of the PV module 2210
is roughened before the one or more angled mounts 2230 is attached.
In yet another example, the surface of the PV module 1210 is
chemically modified using an atmospheric corona discharge and/or an
atmospheric plasma discharge. In yet another example, the process
2310 is performed in the factory. In yet another example, the
process 2310 is performed in the field.
[0151] At the process 2320, the modular rail 2220 is formed. For
example, the modular rail 2220 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 2220 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-harm extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 2220 is preformed in the factory and
transported to the installation site.
[0152] At the process 2330, the one or more angled mounts 2230 are
attached to the modular rail 2220. For example, each of the one or
more angled mounts 2230 is attached to the modular rail 2220 using
one or more adhesive materials 2260. In another example, the one or
more adhesive materials 2260 form a rigid bond between each of the
one or more angled mounts 2230 and the modular rail 2220. In yet
another example, the mounting surface of the modular rail 2220 is
roughened before the one or more angled mounts 2230 is
attached.
[0153] FIGS. 24A and 24B are simplified diagrams showing two views
of a notched mount as used in a PV module mounting system according
to certain embodiments of the present invention. These diagrams are
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. As shown in FIGS. 24A
and 24B, the notched mount 2400 includes a mounting flange 2410.
For example, the mounting flange 2410 includes a receiving notch
2420. In another example, the mounting flange 2410 is attached to
an insertable end (e.g., a mounting post) 2430. In yet another
example, the insertable end 2430 varies in length from 0.25 cm to
50 cm. In yet another example, the mounting flange 2410 is attached
to the insertable end 2430 using a rotatable joint 2440. In yet
another example, the mounting flange 2410 is thinner at an end 2450
distal to the rotatable joint 2440. In yet another example, the
receiving notch 2420 includes an opening 2460 at the end 2450. In
yet another example, the opening 2460 is flared. In yet another
example, the opening 2460 is wider at the end 2450. In yet another
example, the receiving notch 2420 includes a neck 2470. In yet
another example, the neck 2470 forms a narrowing point in the
receiving notch 2420. In yet another example, the receiving notch
2420 includes a post retaining end 2480.
[0154] In yet another example, the rotatable joint 2440 allows the
mounting flange 2410 and the insertable end 2430 to be rotated
relative to each other. In another example, the rotatable joint
2440 includes a hinge. In yet another example, the rotatable joint
2440 includes a ball-and-socket joint. In yet another example, the
insertable end 2430 is tapered to provide a point 2490 distal to
the rotatable joint 2440. In yet another example, the insertable
end 2430 is shaped like a wedge. In yet another example, the
insertable end 2430 is shaped like a cone. In yet another example,
the insertable end 2430 is shaped like an arrow head. In yet
another example, the insertable end 2430 is shaped like a spear
head. In yet another example, the insertable end 3430 includes one
or more barbs. In yet another example, the insertable end 2430
includes one or more ribs. In yet another example, the notched
mount 2400 includes one or more materials. In yet another example,
the insertable end 2430 is flexible. In yet another example, the
insertable end 2430 is sufficiently stiff to support part of the
weight of a PV module. In yet another example, the one or more
materials are selected from a group consisting of polyvinyl
chloride (PVC), chlorinated polyvinyl chloride (CPVC), high-density
polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene
(PP), poly(ethylene terephthalate) (PET), polycarbonate (PC),
polyamide (PA), poly(methyl methacrylate) (PMM), polyoxymethylene
(POM), polyphenylene oxide (PPMM, polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), poly(ethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyimide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, the notched mount 2400 is coated with a non-conductive
coating.
[0155] As discussed above and further emphasized here, FIGS. 24A
and 24B are merely an example, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. In some
embodiments, the rotatable joint 2440 is omitted. For example, the
insertable end 2430 is fixedly attached to the mounting flange
2410.
[0156] FIG. 25 is a simplified diagram showing a ribbed post as
used in a PV module mounting system according to one embodiment of
the present invention. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 25, the ribbed post 2500 includes
one or more ribs 2510. For example, the one or more ribs 2510
create one or more grooves 2520 in the ribbed post 2500. In another
example, the one or more grooves 2520 are areas along the ribbed
post 2500 that are smaller than the areas along the ribbed post
2500 where the one or more ribs 2510 are located. In yet another
example, the ribbed post 2500 includes one or more materials each
selected from a group consisting of polyvinyl chloride (PVC),
chlorinated polyvinyl chloride (CPVC), high-density polyethylene
(HDPE), low-density polyethylene (LDPE), polypropylene (PP),
polyethylene terephthalate) (PET), polycarbonate (PC), polyamide
(PA), poly(methyl methacrylate) (PMMA), polyoxymethylene (POM),
polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), polyethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, ribbed post 2500 is coated with a non-conductive coating.
In yet another example, a length of the ribbed post 2500 is
selected to provide as small a cross-sectional footprint. In yet
another example, the ribbed post 2500 varies in length from 0.25 cm
to 15 cm.
[0157] As discussed above and further emphasized here, FIG. 25 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of ribs 2510 and corresponding grooves 2520 is varied.
For example, a ribbed post 2500 includes only one rib 2510 and one
corresponding groove 2520. In another example, a ribbed post 2500
includes two ribs 2510 and two corresponding grooves 2520. In yet
another example, the ribbed post 2500 includes more than three ribs
2510 and corresponding grooves 2520.
[0158] FIG. 26 is a simplified diagram showing a side view of a PV
module mounting system using one or more notched mounts 2400 and
one or more ribbed posts 2500 according to one embodiment of the
present invention. This diagram is merely an example, which should
not unduly limit the scope of the claims. One of ordinary skill in
the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 26, a PV module 2610 is mounted to
a modular rail 2620 using one or more notched mounts 2400 and one
or more ribbed posts 2500. For example, each of the one or more
ribbed posts 2500 is attached to the PV module 2610. In another
example, an end of each of the one or more ribbed posts 2500 is
attached to the PV module 2610 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials are fast curing. In yet another example, the one or more
adhesive materials form a flexible bond between the end of each of
the one or more ribbed posts 2500 and the PV module 2610. In yet
another example, the one or more adhesive materials are each
selected from a group consisting of silicone, organo-silane
modified ethylene-vinyl acetate (EVA), organo-silane modified
thermoplastic polyolefin (TPO), epoxy, organo-silane modified
epoxy, polyurethane, polyacrylic, organo-silane modified
polyurethane, organo-silane modified acrylic, polydimethylsiloxane
(PDMS), poly(methyl-phenylsiloxane) (PIMPS), ether-type
polyurethane, ester-type polyurethane, poly(methyl methacrylate)
(PMMA), and the like. In yet another example, the PV module 2610 is
primed with an organo-silane-containing primer and the one or more
adhesive materials further include one or more general-purpose
adhesive materials.
[0159] In yet another example, the modular rail 2620 is the modular
rail 100 and/or the modular rail 300. In yet another example, the
insertable end 2430 of each of the one or more notched mounts 2400
is inserted into the modular rail 2620. In yet another example, the
insertable end 2430 of each of the one or more notched mounts 2400
is inserted into the modular rail 2620 to a depth between 5 mm and
500 mm.
[0160] In yet another example, each of the one or more ribbed posts
2500 is inserted into a corresponding receiving notch 2420 of one
of the one or more notched mounts 2400. In yet another example,
each of the one or more ribbed posts 2500 is inserted into a
corresponding receiving notch 2420 of one of the one or more
notched mounts 2400 at a position corresponding to one of the one
or more grooves 2520 on each of the one or more ribbed posts 2500.
In yet another example, each of the narrowed ends 2450 aids in
aligning each of the one or more receiving notches 2420 with a
corresponding one of the one or more grooves 2520. In yet another
example, each of the flared openings 2460 aids in aligning the
receiving notch 2420 with a corresponding one of the one or more
grooves 2520. In yet another example, each of ribbed posts 2500 is
held in place at the corresponding post retaining end 2480 by the
corresponding neck 2470. In yet another example, each of ribbed
posts 2500 is clicked into position at the corresponding post
retaining end 2480. In yet another example, each of the grooves
2520 is approximately the same size and shape as each of the post
retaining ends 2480. In yet another example, each of ribbed posts
2500 is held in place at the corresponding post retaining end 2480
by one or more adhesive materials. In yet another example, the one
or more adhesive materials are each selected from a group
consisting of epoxy, polyurethane, polyacrylic, silicone,
ethylene-vinyl acetate (EVA), thermoplastic polyolefin (TPO),
ether-type polyurethane, ester-type polyurethane, poly(methyl
methacrylate) (PMMA), polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (IMPS), and the like. In yet another
example, the one or more adhesive materials are fast curing.
[0161] According to some embodiments, the angle of the PV module
2610 relative to the sun is controlled through use of the one or
more notched mounts 2400. For example, each of the one or more
notched mounts 2400 is rotated at the respective rotatable joint
2110 to account for variations in the height of the modular rail
2620 and/or the desired angle of the PV module 2610 relative to the
sun. In another example, the depth to which the insertable end 2430
of each of the one or more notched mounts 2400 is inserted into the
modular rail 2620 is adjusted to account for variations in the
height of the modular rail 2620 and/or the desired angle of the PV
module 2610 relative to the sun. In yet another example, the
respective groove 2520 on each of the one or more notched posts
2500 is selected to account for variations in the height of the
modular rail 2620, the depth to which the insertable end 2430 of
each of the one or more notched mounts 2400 is inserted into the
modular rail 2620, and/or the desired angle of the PV module 2610
relative to the sun. In yet another example, a length and a size of
the insertable end 2430 of each of the one or more notched mounts
2400 is selected to provide sufficient pull strength for the
mounting system based on the wind loads to which the PV module 2610
is subjected. In yet another example, a size of each of the one or
more ribbed posts 2500 is selected to provide sufficient pull
strength for the mounting system based on the wind loads to which
the PV module 2610 is subjected.
[0162] As discussed above and further emphasized here, FIG. 26 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of notched mounts 2400 and corresponding ribbed posts
2500 is varied. For example, the PV module 2610 is mounted to the
modular rail 2620 using only one notched mount 2400 and one ribbed
posts 2500. In another example, four notched mounts 2400 and four
corresponding ribbed posts 2500 are used. In yet another example,
six or more notched mounts 2400 and six or more corresponding
ribbed posts 2500 are used. In some embodiments, a different style
of modular rail 2620 is used. For example, the insertable end 2430
of each of the one or more notched mounts 2400 is inserted into the
mounting surface 310 of the modular rail 300 as shown in FIG.
3.
[0163] FIG. 27 is a simplified diagram showing a method of mounting
a PV module 2610 to a modular rail 2620 using one or more notched
mounts 2400 and one or more ribbed posts 2500 according to one
embodiment of the present invention. This diagram is merely an
example, which should not unduly limit the scope of the claims. One
of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 27, the method
2700 includes a process 2710 for attaching one or more ribbed posts
to a PV module, a process 2720 for forming a modular rail, a
process 2730 for inserting one or more notched mounts into the
modular rail, and a process 2740 for inserting the one or more
ribbed posts into the one or more notched mounts. According to
certain embodiments, the method 2700 of mounting a PV module to a
modular rail using one or more notched mounts and one or more
ribbed posts is performed using variations among the processes
2710-2740 as would be recognized by one of ordinary skill in the
art.
[0164] At the process 2710, one or more ribbed posts 2500 are
attached to a PV module 2610. For example, the PV module 2610 is
the PV module 200. In another example, the one or more ribbed posts
2500 are attached to the PV module 2610 using one or more adhesive
materials. In yet another example, the one or more adhesive
materials form a flexible bond between each of the one or more
ribbed posts 2500 and the PV module 2610. In yet another example,
the one or more ribbed posts 2500 are arranged in a predetermined
pattern. In yet another example, the PV module 2610 is primed
before each of the one or more ribbed posts 2500 is attached. In
yet another example, the surface of the PV module 2610 is roughened
before the one or more ribbed posts 2500 is attached. In yet
another example, the surface of the PV module 2610 is chemically
modified using an atmospheric corona discharge and/or an
atmospheric plasma discharge. In yet another example, the process
2710 is performed in the factory. In yet another example, the
process 2710 is performed in the field.
[0165] At the process 2720, the modular rail 1820 is formed. For
example, the modular rail 2620 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 2620 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system, hi yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-forma extrusion machine could be achieved, causing
reduction of the construction cost of the finished rail, hi yet
another example, the modular rail 2620 is preformed in the factory
and transported to the installation site.
[0166] At the process 2730, the one or more notched mounts 2500 are
inserted into the modular rail 2620. For example, the process 2730
occurs before the modular rail 2620 is substantially cured. In
another example, the process 2730 is controlled so that the depth
to which each insertable end 2430 of each of the one or more
notched mounts 2500 is inserted into the modular rail 2620 is
adjusted to account for variations in the height of the modular
rail 2620 and/or the desired angle of the PV module 2610 relative
to the sun. In yet another example, the process 2730 is controlled
so that the insertable end 2430 of each of the one or more notched
mounts 2500 is inserted a suitable distance into the modular rail
2620 so that after the modular rail 2620 substantially cures, the
one or more notched mounts 2400 provide sufficient pull strength to
account for the wind loads to which the PV module 2610 is
subjected.
[0167] At the process 2740, the one or more ribbed posts 2500 are
inserted into the one or more notched mounts 2400. For example, an
angle of each mounting flange 2410 of each of the one or more
notched posts 2400 is adjusted using the corresponding rotatable
joint 2440 to account for variations in the height of the modular
rail 2620 and/or the desired angle of the PV module 2610 relative
to the sun. In another example each of the one or more ribbed posts
2500 is inserted into a corresponding receiving notch 2420 of one
of the one or more notched mounts 2400. In yet another example,
each of the one or more ribbed posts 2500 is inserted into a
corresponding receiving notch 2420 of one of the one or more
notched mounts 2400 at a position corresponding to one of the one
or more grooves 2520 on each of the one or more ribbed posts 2500.
In yet another example, each of the narrowed ends 2450 aids in
aligning each of the one or more receiving notches 2420 with a
corresponding one of the one or more grooves 2520. In yet another
example, each of the flared openings 2460 aids in aligning each of
the one or more receiving notches 2420 with a corresponding one of
the one or more grooves 2520. In yet another example, each of
ribbed posts 2500 is held in place at the corresponding post
retaining end 2480 by the corresponding neck 2470. In yet another
example, each of ribbed posts 2500 is clicked into position at the
corresponding post retaining end 2480. In yet another example, one
or more adhesive materials are applied to each of the ribbed posts
2500 and/or each of the post retaining ends 2480 prior to inserting
each of the one or more ribbed posts 2500 into a corresponding one
of the one or more notched mounts 2400.
[0168] As discussed above and further emphasized here, FIGS. 24A,
249, 25, 26, and 27 are merely examples, which should not unduly
limit the scope of the claims. One of ordinary skill in the art
would recognize many variations, alternatives, and modifications.
In some embodiments, variations to the one or more notched mounts
2400 are possible. For example, the insertable end 2430 of each of
the one or more notched mounts 2400 is replaced with a post similar
to the post shown for the foldable mount 1300 as shown in FIGS. 13A
and 139, the post shown for the angled mount 2030 as shown in FIG.
20, and/or the post shown for the angled mount as shown in FIG. 22.
In yet another example, the post of each of the one or more notched
mounts is attached to the modular rail 2620 using a hole 1430
and/or 2060 and one or more adhesive materials 1440 and/or 2070 as
shown for the foldable mount 1300 in FIG. 14 and/or as shown for
the angled mount 2030 in FIG. 20. In yet another example, the post
of each of the one or more notched mounts is attached to the
modular rail 2620 using one or more adhesive materials 1630 and/or
2260 as shown for the foldable mount 1300 in FIG. 14 and/or as
shown for the angled mount 2030 in FIG. 20. In yet another example,
the process 2730 for inserting one or more notched mounts into the
modular rail in method 2700 is replaced by variations in the
processes 1550-1570 as shown for the foldable mount 1300 in FIG. 15
an or variations in the processes 2130-2150 as shown for the angled
mount 2030 in FIG. 21. In yet another example, the process 2730 for
inserting one or more notched mounts into the modular rail in
method 2700 is replaced by variations in the processes 1750-1760 as
shown for the foldable mount 1300 in FIG. 17 and/or variations in
the process 2330 as shown for the angled mount 2130 in FIG. 23. In
some embodiments, the one or more ribbed posts 2500 are replaced
with one or more clip-on ribbed posts. For example, the one or more
clip-on ribbed posts are clipped along one or more edges of the PV
module 2610. In another example, one or more gasket materials are
placed between the one or more clip-on ribbed posts and the PV
module 2610. In yet another example, the one or more clip-on ribbed
posts are further attached to the PV module 2610 using one or more
adhesive materials.
[0169] FIGS. 28A and 28B are simplified diagrams showing two views
of a PV module mounting system using one or more flanged beams and
one or more spacers according to some embodiments of the present
invention. These diagrams are merely an example, which should not
unduly limit the scope of the claims. One of ordinary skill in the
art would recognize many variations, alternatives, and
modifications. As shown in FIGS. 28A and 28B, a PV module 2810 is
mounted to a modular rail 2820 using one or more flanged beams 2830
and one or more spacers 2860. For example, each of the one or more
flanged beams 2830 is attached to the PV module 2810 using a
respective flange 2840. In another example, each of the one or more
flanged beams 2830 varies in length from a few centimeters to most
of the span of the PV module 2810. In yet another example, the
flange 2840 of each of the one or more flanged beams 2830 is
attached to the PV module 2810 using one or more adhesive materials
2880. In yet another example, the one or more adhesive materials
2880 are fast curing. In yet another example, the one or more
adhesive materials 2880 form a flexible bond between the flange
2840 of each of the one or more flanged beams 2830 and the PV
module 2810. In yet another example, the one or more adhesive
materials 2280 are each selected from a group consisting of
silicone, organo-silane modified ethylene-vinyl acetate (EVA),
organo-silane modified thermoplastic polyolefin (TPO), epoxy,
organo-silane modified epoxy, polyurethane, polyacrylic,
organo-silane modified polyurethane, organo-silane modified
acrylic, polydimethylsiloxane (PDMS), poly(methyl-phenylsiloxane)
(PMPS), ether-type polyurethane, ester-type polyurethane,
poly(methyl methacrylate) (PMMA), and the like. In yet another
example, the PV module 2810 is primed with an
organo-silane-containing primer and the one or more adhesive
materials 2280 further include one or more general-purpose adhesive
materials.
[0170] In yet another example, each of the one or more flanged
beams 2830 includes one or more materials. In yet another example,
each of the one or more flanged beams 2830 is flexible. In yet
another example, each of the one or more flanged beams 2830 adds
stiffness to the PV module 2810. In yet another example, the one or
more materials are selected from a group consisting of polyvinyl
chloride (PVC), chlorinated polyvinyl chloride (CPVC), high-density
polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene
(PP), polyethylene terephthalate) (PET), polycarbonate (PC),
polyamide (PA), poly(methyl methacrylate) (PMMA), polyoxymethylene
(POM), polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), poly(ethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, each of the one or more flanged beams 2830 is coated with
a non-conductive coating.
[0171] According to some embodiments; each of the one or more
flanged beams 2830 is slid into one or more spacers 2860. For
example, each of the one or more flanged beams 2830 includes a
flange 2830, which is slid into a slot 2870 of each of the one or
more spacers 2860. In another example, the flange 2830 is sized to
provide a slip fit with the slot 2870 of each of the one or more
spacers 2840. In yet another example, one or more adhesive
materials is placed in the slot 2870 of each of the one or more
spacers 2860 to further anchor the flange 2830. In yet another
example, one or more mechanical fasteners attach the flange 2830 to
the one or more spacers 2860.
[0172] In yet another example, each of the spacers 2840 includes
one or more materials each selected from a group consisting of
polyvinyl chloride (PVC), chlorinated polyvinyl chloride (CPVC),
high-density polyethylene (HDPE), low-density polyethylene (LDPE),
polypropylene (PP), poly(ethylene terephthalate) (PET),
polycarbonate (PC), polyamide (PA), poly(methyl methacrylate)
(PMMA), polyoxymethylene (POM), polyphenylene oxide (PPO),
polyphenylene sulfide (PPS), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), poly(ethylene terephthalate) (Rynite),
polyphenylene ether (PPE) modified by polystyrene (PS) or polyamide
(PA) (Xyron), acrylonitrile butadiene styrene (ABS), polyphenylene
oxide (PPO) blended with polystyrene (PS) (Noryl), engineering
polymers, non-engineering plastics, polyolefins, elastomeric
polymers, hot-dipped zinc-coated steel, anodized aluminum,
powder-coated metal, painted metal, polymeric over molded metal,
polymer over extruded metal, and the like. In yet another example,
each of the one or more spacers 2860 is coated with a
non-conductive coating. In yet another example, each of the one or
more spacers 2860 is partially hollow to reduce the amount of the
one or more materials.
[0173] In yet another example, the modular rail 2820 is the modular
rail 100 and/or the modular rail 300. In yet another example, each
of the one or more spacers 2860 is attached to the modular rail
2820 using one or more adhesive materials 2890. In yet another
example, the one or more adhesive materials 2890 are fast curing.
In yet another example, the one or more adhesive materials 2890
form a rigid bond between each of the one or more spacers 2860 and
the modular rail 2820. In yet another example, the one or more
adhesive materials 2890 are each selected from a group consisting
of silicone, ethylene-vinyl acetate (EVA), thermoplastic polyolefin
(TPO), epoxy, polyurethane, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the modular rail 2820 is first
primed. In yet another example, the one or more adhesive materials
2890 are different from the one or more adhesive materials
2880.
[0174] In yet another example, a size of each of the one or more
spacers 2860 is selected to provide sufficient pull strength of the
mounting system based on the wind loads to which the PV module 2810
is subjected. In yet another example, the size of each of the one
or more spacers 2860 is selected to provide sufficient surface area
between each of the one or more spacers 2860 and the modular rail
2810 to provide sufficient attachment strength to withstand the
wind loads to which the PV module 2810 is subjected. In yet another
example, each of the one or more spacers 2860 varies in height from
2.5 cm to 15 cm. In yet another example, each of the one or more
spacers 2860 varies in length from 1 cm to 25 cm. In yet another
example, each of the one or more spacers 2860 varies in
cross-sectional area from 0.25 mm.sup.2 to 30,000 mm.sup.2.
[0175] In yet another example, the one or more flanged beams 2830
reduces the flexibility of the PV module 2810. In yet another
example, the one or more flanged beams 2930 stiffens the PV module
2810. In yet another example, a size of flange 2840 is selected to
provide sufficient surface area between the each of the one or more
flanged beams 2830 and the PV module 2810 to provide sufficient
attachment strength to withstand the wind loads to which the PV
module 2810 is subjected. In yet another example, the flange 2840
of each of the one or more flanged beams 2830 varies in width from
10 mm to 100 mm. In yet another example, a distance between the
flange 2840 and the flange 2850 of each of the one or more flanged
beams 2830 varies from 2 min to 50 mm.
[0176] As discussed above and further emphasized here, FIGS. 78A
and 28B are merely examples, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. In some
embodiments, the number of flanged beams 2830 is varied. For
example, the PV module 2810 is mounted to the modular rail 2820
using only one flanged beam 2830. In another example, two or more
flanged beams 2830 are used. According to some embodiments, the
number of spacers 2860 used per flanged beam 2830 is varied. For
example, only one spacer 2860 is used per flanged beam 2830. In yet
another example, two or more spacers 2860 are used. In some
embodiments, a different style of modular rail 2820 is used. For
example, each of the one or more spacers 2860 for one of the one or
more flanged beams 2830 is mounted into a different one of the one
or more mounting surfaces 110 of the modular rail 100 as shown in
FIG. 1. In some embodiments, the flange 2840 of each of the one or
more flanged beams 2830 is attached to the PV module 2810 using
bolts, screws, and/or other mechanical fasteners. In yet another
example, one or more gasket materials are used between the flange
2840 of each of the one or more flanged beam 2830 and the PV module
2810. In yet another example, each of the one or more gasket
materials is selected from a list consisting of ethylene propylene
diene monomer (EPDM), UV-resistant rubber, and the like.
[0177] FIG. 29 is a simplified diagram showing a method of mounting
a PV module 2810 to a modular rail 2820 using one or more flanged
beams 2830 and one or more spacers 2860 according to one embodiment
of the present invention. This diagram is merely an example, which
should not unduly limit the scope of the claims. One of ordinary
skill in the art would recognize many variations, alternatives, and
modifications. As shown in FIG. 29, the method 2900 includes a
process 2910 for attaching one or more flanged beams to a PV
module, a process 2920 for forming a modular rail, a process 2930
for attaching one or more spacers to the modular rail, and a
process 2940 for inserting the one or more flanged beams into the
one or more spacers. According to certain embodiments, the method
2900 of mounting a PV module to a modular rail using one or more
notched mounts and one or more ribbed posts is performed using
variations among the processes 2910-2940 as would be recognized by
one of ordinary skill in the art.
[0178] At the process 2910, one or more flanged beams 2830 are
attached to a PV module 2810. For example, the PV module 2810 is
the PV module 200. In another example, the flange 2840 of each of
the one or more flanged beams 2830 are attached to the PV module
2810 using one or more adhesive materials 2880. In yet another
example, the one or more adhesive materials 2880 form a flexible
bond between each of the one or more flanged beams 2830 and the PV
module 2810. In yet another example, the flange 2840 of each of the
one or more flanged beams 2830 is attached to the PV module 2810
using bolts, screws, and/or other mechanical fasteners. In yet
another example, one or more gasket materials is placed on the PV
module 2810 before the flange 2840 of each of the one or more
flanged beams 2830 is attached. In yet another example, the one or
more flanged beams 2830 are arranged in a predetermined pattern and
spacing. In yet another example, the PV module 2810 is primed
before each of the one or more flanged beams 2830 is attached. In
yet another example, the surface of the PV module 2810 is roughened
before the one or more flanged beams 2830 is attached. In yet
another example, the surface of the PV module 2810 is chemically
modified using an atmospheric corona discharge and/or an
atmospheric plasma discharge. In yet another example, the process
2910 is performed in the factory. In yet another example, the
process 2910 is performed in the field.
[0179] At the process 2920, the modular rail 1820 is formed. For
example, the modular rail 2820 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 2820 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-form extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 2820 is preformed in the factory and
transported to the installation site.
[0180] At the process 2930, the one or more spacers 2860 are
attached to the modular rail 2820. For example, each of the one or
more spacers 2860 is attached to the modular rail 2220 using one or
more adhesive materials 2890. In another example, the one or more
adhesive materials 2290 form a rigid bond between each of the one
or more spacers 2860 and the modular rail 2820. In yet another
example, the mounting surface of the modular rail 2820 is roughened
before the one or more spacers 2860 is attached. In yet another
example, the one or more spacers 2860 are arranged to coincide with
the predetermined pattern and spacing for the one or more flanged
beams 2830 attached to the PV module 2010.
[0181] At the process 2940, each of the one or more flanged beams
2830 are inserted into one or more of the one or more spacers 2860.
For example, the flange 2850 of each of the one or more flanged
beams 2830 is slid into a corresponding slot 2870 of a
corresponding one or more of the one or more spacers 2860. In
another example, one or more adhesive materials are placed into the
slot 2870 of each of the one or more spacers 2860 before the flange
2850 of each of the one or more flanged beams 2830 is slid into the
corresponding slot 2870. In yet another example, the one or more
flanged beams 2830 are further anchored to the one or more spacers
2860 by utilizing one or more mechanical fasteners.
[0182] FIG. 30 is a simplified diagram showing a side view of a PV
module mounting system using one or more spacers according to
another embodiment of the present invention. This diagram is merely
an example, which should not unduly limit the scope of the claims.
One of ordinary skill in the art would recognize many variations,
alternatives, and modifications. As shown in FIG. 30, a PV module
3010 is mounted to a modular rail 3020 using one or more spacers
3030. For example, each of the one or more spacers 3030 includes a
first surface for mounting to the PV module 3010 and a second
surface opposite the first surface for mounting to the modular rail
3020. In another example, each of the one or more spacers 3030
varies in thickness from 0.2 cm to 25 cm. In yet another example,
each of the one or more spacers 3030 is flexible. In yet another
example, each of the one or more spacers 3030 is attached to the PV
module 3010 using one or more adhesive materials 3040. In yet
another example, the one or more adhesive materials 3040 are fast
curing. In yet another example, the one or more adhesive materials
3040 form a flexible bond between each of the one or more spacers
3030 and the PV module 3010. In yet another example, the one or
more adhesive materials 3040 are each selected from a group
consisting of silicone, organo-silane modified ethylene-vinyl
acetate (EVA), organo-silane modified thermoplastic polyolefin
(TPO), epoxy, organo-silane modified epoxy, polyurethane,
polyacrylic, organo-silane modified polyurethane, organo-silane
modified acrylic, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the PV module 3010 is first primed
with an organo-silane-containing primer and the one or more
adhesive materials 3040 further include one or more general-purpose
adhesive materials.
[0183] In yet another example, each of the one or more spacers 3030
includes one or more materials. In yet another example, each of the
one or more spacers 3030 is flexible. In yet another example, each
of the one or more spacers 3030 is sufficiently stiff to support
part of the weight of a PV module. In yet another example, the one
or more materials are selected from a group consisting of polyvinyl
chloride (PVC), chlorinated polyvinyl chloride (CPVC), high-density
polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene
(PP), poly(ethylene terephthalate) (PET), polycarbonate (PC),
polyamide (PA), poly(methyl methacrylate) (PMM), polyoxymethylene
(POM), polyphenylene oxide (PPO), polyphenylene sulfide (PPS),
polysulphone (PSU), polystyrene-butadiene-styrene (SBS), ethylene
propylene diene monomer (EPDM), poly(ethylene terephthalate)
(Rynite), polyphenylene ether (PPE) modified by polystyrene (PS) or
polyamide (PA) (Xyron), acrylonitrile butadiene styrene (ABS),
polyphenylene oxide (PPO) blended with polystyrene (PS) (Noryl),
engineering polymers, non-engineering plastics, polyolefins,
elastomeric polymers, hot-dipped zinc-coated steel, anodized
aluminum, powder-coated metal, painted metal, polymeric over molded
metal, polymer over extruded metal, and the like. In yet another
example, each of the one or more spacers 3030 is coated with a
non-conductive coating.
[0184] In yet another example, the modular rail 3020 is the modular
rail 100 and/or the modular rail 300. In yet another example, each
of the one or more spacers 3030 is attached to the modular rail
3020 using one or more adhesive materials 3050. In yet another
example, the one or more adhesive materials 3050 are fast curing.
In yet another example, the one or more adhesive materials 3050
form a rigid bond between each of the one or more spacers 3030 and
the modular rail 3020. In yet another example, the one or more
adhesive materials 3050 are each selected from a group consisting
of silicone, ethylene-vinyl acetate (EVA), thermoplastic polyolefin
(TPO), epoxy, polyurethane, polydimethylsiloxane (PDMS),
poly(methyl-phenylsiloxane) (PMPS), ether-type polyurethane,
ester-type polyurethane, poly(methyl methacrylate) (PMMA), and the
like. In yet another example, the modular rail 3020 is first
printed. In yet another example, the one or more adhesive materials
3050 are different from the one or more adhesive materials
3040.
[0185] In yet another example, a cross-sectional area of each of
the one or more spacers 3030 is selected to provide sufficient pull
strength of the mounting system based on the wind loads to which
the PV module 3010 is subjected. In yet another example, the
cross-sectional area of each of the one or more spacers 3030 is
selected to provide sufficient surface area between the each of the
one or more spacers 3030 and the PV module 3010 and/or the modular
rail 3020 to provide sufficient attachment strength to withstand
the wind loads to which the PV module 3010 is subjected. In yet
another example, each of the one or more spacers 3030 varies in
cross-sectional area from 25 mm.sup.2 to 30,000 mm.sup.2. In yet
another example, a size of the one or more spacers 3030 is selected
to provide sufficient pull strength for the mounting system based
on the wind loads to which the PV module 3010 is subjected.
[0186] As discussed above and further emphasized here, FIG. 30 is
merely an example, which should not unduly limit the scope of the
claims. One of ordinary skill in the art would recognize many
variations, alternatives, and modifications. In some embodiments,
the number of spacers 3030 is varied. For example, the PV module
3010 is mounted to the modular rail 3020 using only one spacer
3030. In another example, four spacers 3030 are used. In yet
another example, six or more spacers 3030 are used. In some
embodiments, a different style of modular rail 3020 is used. For
example, each of the one or more spacers 3030 is attached to the
mounting surface 310 of the modular rail 300 as shown in FIG.
3.
[0187] FIG. 31 is a simplified diagram showing a method of mounting
a PV module 3010 to a modular rail 3020 using one or more spacers
3030 according to another embodiment of the present invention. This
diagram is merely an example, which should not unduly limit the
scope of the claims. One of ordinary skill in the art would
recognize many variations, alternatives, and modifications. As
shown in FIG. 31, the method 3100 includes a process 3110 for
forming a modular rail, a process 3230 for attaching one or more
spacers to the modular rail, and a process 3230 for attaching a PV
module to the one or more spacers. According to certain
embodiments, the method 3100 of method of mounting a PV module to a
modular rail using one or more spacers is performed using
variations among the processes 3110-3130 as would be recognized by
one of ordinary skill in the art.
[0188] At the process 3110, the modular rail 3020 is formed. For
example, the modular rail 3020 is the modular rail 100, and/or the
modular rail 300. In another example, the modular rail 3020 is
formed in-situ in the field using a slip-form extrusion machine. In
yet another example, the extrusion speed of the slip-form extrusion
machine is varied. In yet another example, the extrusion speed
should be slow enough to produce one or more mounting surfaces
which are substantially planar. In yet another example, the
extrusion speed should be slow enough to produce the one or more
mounting surfaces with a high planarity and little sagging to allow
for uniformity in the PV module mounting system. In yet another
example, if a large planarity variability in the one or more
mounting surfaces could be allowed, a much higher extrusion speed
of slip-form extrusion machine could be achieved, causing reduction
of the construction cost of the finished rail. In yet another
example, the modular rail 3020 is preformed in the factory and
transported to the installation site.
[0189] At the process 3120, the one or more spacers 3030 are
attached to the modular rail 3020. For example, each of the one or
more spacers 3030 is attached to the modular rail 3020 using one or
more adhesive materials 3050. In another example, the one or more
adhesive materials 3050 form a rigid bond between each of the one
or more spacers 3030 and the modular rail 3020. In yet another
example, the mounting surface of the modular rail 3020 is roughened
before the one or more spacers 3030 is attached. In yet another
example, the one or more spacers 3030 are attached to the modular
rail 3020 using a predetermined pattern and spacing.
[0190] At the process 3130, the PV module 3010 is attached to the
one or more spacers 3030. For example, the PV module 3010 is the PV
module 200. In another example, the one or more spacers 3030 are
attached to the PV module 3010 using one or more adhesive materials
3040. In yet another example, the one or more adhesive materials
3040 form a flexible bond between each of the one or more spacers
3030 and the PV module 3010. In yet another example, the PV module
3010 is primed before each of the one or more spacers 3030 is
attached. In yet another example, the surface of the PV module 3010
is roughened before the one or more spacers 3030 is attached. In
yet another example, the surface of the PV module 3010 is
chemically modified using an atmospheric corona discharge and/or an
atmospheric plasma discharge. In yet another example, the process
3130 is performed in the factory. In yet another example, the
process 3130 is performed in the field.
[0191] According to one embodiment, a system for mounting one or
more photovoltaic modules includes one or more flexible rods, each
of the one or more flexible rods including a first end and a second
end opposite the first end, each of the one or more flexible rods
further including an inner core and a first jacket surrounding the
inner core between the first end and the second end. The first end
is configured to be attached to at least one photovoltaic module
using one or more first adhesive materials. The second end is
configured to be inserted into at least one hole of a modular rail
and attached to at least the modular rail using one or more second
adhesive materials. The one or more flexible rods are configured to
allow at least a lateral movement in a first direction between the
photovoltaic module and the modular rail and support at least the
photovoltaic module in a second direction. For example, the system
is implemented according to at least FIG. 7 and/or FIG. 8.
[0192] In another example, the first direction is substantially
parallel to a face of the photovoltaic module and the second
direction is substantially vertical. In yet another example, the
photovoltaic module includes a first glass panel and the first end
is further configured to be attached to at least the first glass
panel using the one or more first adhesive materials. In yet
another example, the modular rail includes one or more concrete
materials and the second end is further configured to be attached
to at least the one or more concrete materials using the one or
more second adhesive materials. In yet another example, the inner
core includes one or more fibers. In yet another example, the one
or more fibers are substantially parallel. In yet another example,
the one or more fibers are braided. In yet another example, the
first jacket is braided. In yet another example, each of the one or
more flexible rods further includes a second jacket surrounding the
first jacket between the first end and the second end. In yet
another example, the second jacket is cross-braided. In yet another
example, the one or more first adhesive materials are flexible. In
yet another example, the one or more second adhesive materials are
rigid. In yet another example, an excess of the one or more second
adhesive materials are displaced from the hole.
[0193] According to another embodiment, a method for mounting one
or more photovoltaic modules includes preparing one or more
flexible rods, each of the one or more flexible rods including a
first end and a second end opposite the first end, each of the one
or more flexible rods further including art inner core and a first
jacket surrounding the inner core between the first end and the
second end, forming at least one hole in a modular rail, attaching
the first end to at least one photovoltaic module using one or more
first adhesive materials, placing one or more second adhesive
materials in the at least one hole, inserting the second end into
the at least one hole, allowing at least a lateral movement in a
first direction between the photovoltaic module and the modular
rail, and supporting at least the photovoltaic module in a second
direction. For example, the method is implemented according to at
least FIG. 9.
[0194] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more foldable
mounts, each of the one or more foldable mounts including a
mounting flange, a rotatable joint, and a mounting post. The
rotatable joint is attached to the mounting flange and the mounting
post. The mounting flange is configured to be rotated relative to
the mounting post using the rotatable joint. The mounting flange is
configured to be attached to at least one photovoltaic module and
the mounting post is configured to be attached to at least one
modular rail. The one or more foldable mounts are configured to
allow at least a lateral movement in a first direction between the
photovoltaic module and the modular rail and support at least the
photovoltaic module in a second direction. For example, the system
is implemented according to at least FIG. 10A, FIG. 10B, FIG. 11,
FIG. 13A, FIG. 13B, FIG. 14, and/or FIG. 16.
[0195] In another example, the first direction is substantially
parallel to a face of the photovoltaic module and the second
direction is substantially vertical. In yet another example, the
photovoltaic module includes a first glass panel and the mounting
flange is further configured to be attached to at least the first
glass panel. In yet another example, the modular rail includes one
or more concrete materials and the mounting post is further
configured to be attached to at least the one or more concrete
materials. In yet another example, the rotatable joint includes at
least one selected from a group consisting of a hinge and a ball
and socket joint. In yet another example, the mounting post
includes an insertable end distal to the rotatable joint, the
insertable end being tapered and the insertable end is configured
to be inserted into at least the modular rail. In yet another
example, the insertable end includes at least one selected from a
group consisting of barbs and ribs. In yet another example, the
mounting post is configured to be attached to at least the modular
rail using one or more adhesive materials. In yet another example,
the mounting post is further configured to be inserted into at
least one hole of the modular rail. In yet another example, an
excess of the one or more adhesive materials are displaced from the
hole. In yet another example, the mounting flange is configured to
be attached to at least the photovoltaic module using one or more
adhesive materials. In yet another example, the mounting flange is
configured to be attached to at least the photovoltaic module using
one or more mechanical fasteners.
[0196] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes attaching one or more
foldable mounts, each of the one or more foldable mounts including
a mounting flange, a rotatable joint, and a mounting post, to at
least a photovoltaic module using the mounting flange; rotating the
mounting flange relative to the mounting post using the rotatable
joint; attaching the mounting post to a modular rail; allowing at
least a lateral movement in a first direction between the
photovoltaic module and the modular rail; and supporting at least
the photovoltaic module in a second direction. For example, the
method is implemented according to at least FIG. 12, FIG. 15,
and/or FIG. 17.
[0197] In yet another embodiment, a system for mounting one or more
photovoltaic modules includes one or more angled mounts, each of
the one or more angled mounts including a mounting post with a
mounting face, the mounting post extending in a first direction.
The mounting face is not perpendicular to the first direction. The
mounting face is configured to be attached to at least one
photovoltaic module using one or more first adhesive materials. The
mounting post is configured to be attached to a modular rail. The
one or more angled mounts are configured to allow at least a
lateral movement in a second direction between the photovoltaic
module and the modular rail and support at least the photovoltaic
module in the first direction. For example, the system is
implemented according to at least FIG. 18, FIG. 20, and/or FIG.
22.
[0198] In another example, the second direction is substantially
parallel to a face of the photovoltaic module and the first
direction is substantially vertical. In yet another example, the
photovoltaic module includes a first glass panel and the mounting
face is further configured to be attached to at least the first
glass panel using the one or more first adhesive materials. In yet
another example, the modular rail includes one or more concrete
materials and the mounting post is further configured to be
attached to at least the one or more concrete materials. In yet
another example, the mounting post includes an insertable end
distal to the rotatable joint, the insertable end being tapered and
the insertable end is configured to be inserted into at least the
modular rail. In yet another example, the insertable end includes
at least one selected from a group consisting of barbs and ribs. In
yet another example, the mounting post is configured to be attached
to at least the modular rail using one or more second adhesive
materials. In yet another example, the mounting post is further
configured to be inserted into at least one hole of at least the
modular rail. In yet another example, an excess of the one or more
second adhesive materials are displaced from the hole.
[0199] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes providing one or more
angled mounts, each of the one or more angled mounts including a
mounting post with a mounting face, the mounting post extending in
a first direction; attaching the mounting face to at least a
photovoltaic module using one or more adhesive materials; and
attaching the mounting post to a modular rail, allowing at least a
lateral movement in a second direction between the photovoltaic
module and the modular rail, and supporting at least the
photovoltaic module in the first direction. For example, the method
is implemented according to at least FIG. 19, FIG. 21, and/or FIG.
23.
[0200] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more notched
mounts and one or more ribbed posts. Each of the one or more
notched mounts including a mounting flange, a rotatable joint, and
a mounting post. Each of the one or more ribbed posts including one
or more ribs alternating with one or more grooves. The rotatable
joint is attached to the mounting flange and the mounting post. The
mounting flange is configured to be rotated relative to the
mounting post using the rotatable joint. The mounting flange
includes a receiving notch, the receiving notch including an
opening at a first end configured to receive at least one of the
one or more grooves. Each of the one or more ribbed posts is
configured to be attached to at least one photovoltaic module using
one or more first adhesive materials. The mounting post is
configured to be attached to at least one modular rail. The one or
more notched mounts and the one or more ribbed posts are configured
to allow at least a lateral movement in a first direction between
the photovoltaic module and the modular rail and support at least
the photovoltaic module in a second direction. For example, the
system is implemented according to at least FIG. 24A, FIG. 24B,
FIG. 25, and/or FIG. 26.
[0201] In another example, the first direction is substantially
parallel to a face of the photovoltaic module and the second
direction is substantially vertical. In yet another example, the
photovoltaic module includes a first glass panel and the one or
more ribbed posts are further configured to be attached to at least
the first glass panel using the one or more first adhesive
materials. In yet another example, the modular rail includes one or
more concrete materials and the mounting post is further configured
to be attached to at least the one or more concrete materials. In
yet another example, the mounting post includes an insertable end
distal to the rotatable joint, the insertable end being tapered and
the insertable end is configured to be inserted into at least the
modular rail. In yet another example, the insertable end includes
at least one selected from a group consisting of barbs and ribs. In
yet another example, the mounting post is configured to be attached
to at least the modular rail using one or more second adhesive
materials. In yet another example, the mounting post is further
configured to be inserted into at least one hole of at least the
modular rail. In yet another example, an excess of the one or more
second adhesive materials are displaced from the hole. In yet
another example, the receiving notch is flared. In yet another
example, the receiving notch includes a neck, the neck being
narrower than the opening. In yet another example, the receiving
notch further includes a post retaining end and the post retaining
end is configured to receive at least one of the one or more
grooves.
[0202] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes attaching one or more
ribbed posts, each of the one or more ribbed posts including one or
more ribs alternating with one or more grooves, to at least a
photovoltaic module using one or more first adhesive materials;
providing one or more notched mounts, each of the one or more
notched mounts including a mounting flange, a rotatable joint, and
a mounting post; attaching the mounting post to at least a modular
rail; rotating the mounting flange relative to the mounting post
using the rotatable joint; inserting at least one of the one or
more grooves into the receiving notch; allowing at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail; and supporting at least the photovoltaic module
in a second direction. For example, the method is implemented
according to at least FIG. 27.
[0203] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more flanged beams
and one or more spacers. Each of the one or more flanged beams
including a first flange and a second flange opposite the first
flange. The one or more spacers include one or more slots
respectively. The first flange is configured to be attached to at
least one photovoltaic module. The second flange is configured to
be inserted into the one or more slots. The one or more spacers are
configured to be attached to at least one modular rail using one or
more first adhesive materials. The one or more flanged beams and
the one or more spacers are configured to allow at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail and support at least the photovoltaic module in a
second direction. For example, the system is implemented according
to at least FIG. 28A and/or FIG. 28B.
[0204] In another example, the first direction is substantially
parallel to a face of the photovoltaic module and the second
direction is substantially vertical. In yet another example, the
photovoltaic module includes a first glass panel and the flanged
beams are further configured to be attached to at least the first
glass panel. In yet another example, the modular rail includes one
or more concrete materials and the one or more spacers are further
configured to be attached to at least the one or more concrete
materials using the one or more first adhesive materials. In yet
another example, the one or more flanged beams are configured to
stiffen the photovoltaic module. In yet another example, the second
flange is configured to be attached to the one or more slots using
one selected from a group consisting of one or more second adhesive
materials and one or more mechanical fasteners. In yet another
example, the first flange is configured to be attached to at least
the photovoltaic module using one or more second adhesive
materials.
[0205] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes providing one or more
flanged beams, each of the one or more flanged beams including a
first flange and a second flange opposite the first flange;
attaching the first flange to at least a photovoltaic module;
attaching one or more spacers, each including one or more slots
respectively, to a modular rail using one or more adhesive
materials; inserting the second flange into the one or more slots;
allowing at least a lateral movement in a first direction between
the photovoltaic module and the modular rail; and supporting at
least the photovoltaic module in a second direction. For example,
the method is implemented according to at least FIG. 29.
[0206] According to yet another embodiment, a system for mounting
one or more photovoltaic modules includes one or more flexible
spacers. Each of the one or more flexible spacers including a first
surface and a second surface opposite the first surface. The first
surface is configured to be attached to at least one glass panel of
a photovoltaic module using one or more first adhesive materials.
The second surface is configured to be attached to at least one or
more concrete materials of one modular rail using one or more
second adhesive materials. The one or more flexible spacers are
configured to allow at least a lateral movement in a first
direction between the photovoltaic module and the modular rail and
support at least the photovoltaic module in a second direction.
Each of the one or more flexible spacers includes one selected from
a group consisting of polyvinyl chloride (PVC), chlorinated
polyvinyl chloride (CPVC), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), polyolefins, and elastomeric polymers. For example,
the system is implemented at least according to FIG. 30.
[0207] According to yet another embodiment, a method for mounting
one or more photovoltaic modules includes forming a modular rail
including one or more concrete materials; providing one or more
flexible spacers, each of the one or more flexible spacers
including a first surface and a second surface opposite the first
surface, each of the one or more flexible spacers including one
selected from a group consisting of polyvinyl chloride (PVC),
chlorinated polyvinyl chloride (CPVC), polysulphone (PSU),
polystyrene-butadiene-styrene (SBS), ethylene propylene diene
monomer (EPDM), polyolefins, and elastomeric polymers; attaching
the first surface to at least a glass panel using one or more first
adhesive materials; attaching the second surface to at least the
one or more concrete materials of the modular rail using one or
more second adhesive materials; allowing at least a lateral
movement in a first direction between the photovoltaic module and
the modular rail; and supporting at least the photovoltaic module
in a second direction. For example, the method is implemented at
least according to FIG. 31.
[0208] Although specific embodiments of the present invention have
been described, it will be understood by those of skill in the art
that there are other embodiments that are equivalent to the
described embodiments. For example, various embodiments and/or
examples of the present invention can be combined. Accordingly, it
is to be understood that the invention is not to be limited by the
specific illustrated embodiments, but only by the scope of the
appended claims.
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