U.S. patent application number 16/013540 was filed with the patent office on 2018-12-20 for integrated photovoltaic module mounting system for installation on a sloped surface.
This patent application is currently assigned to Watershed Solar LLC. The applicant listed for this patent is Watershed Solar LLC. Invention is credited to Michael R. Ayers, S. Kyle Ehman, Neta Reef, Sharone Zehavi.
Application Number | 20180367090 16/013540 |
Document ID | / |
Family ID | 64657740 |
Filed Date | 2018-12-20 |
United States Patent
Application |
20180367090 |
Kind Code |
A1 |
Ayers; Michael R. ; et
al. |
December 20, 2018 |
INTEGRATED PHOTOVOLTAIC MODULE MOUNTING SYSTEM FOR INSTALLATION ON
A SLOPED SURFACE
Abstract
A mounting system 180 for a solar panel 11 includes a rail 114
having an elongated mounting slot 116 secured to a flexible
attaching connector 188 with fasteners and the flexible attaching
connector for welding to a geomembrane overlying a slope surface,
and a photovoltaic module 11 connected with fasteners to the rail,
and optionally a ballast system 145 that includes a ballast tray
146 and ballast 152 coupled with fasteners to the rail.
Inventors: |
Ayers; Michael R.; (Johns
Creek, GA) ; Ehman; S. Kyle; (Milton, GA) ;
Reef; Neta; (Beit Elazari, IL) ; Zehavi; Sharone;
(Cupertino, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Watershed Solar LLC |
Alpharetta |
GA |
US |
|
|
Assignee: |
Watershed Solar LLC
Alpharetta
GA
|
Family ID: |
64657740 |
Appl. No.: |
16/013540 |
Filed: |
June 20, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62522402 |
Jun 20, 2017 |
|
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|
62616705 |
Jan 12, 2018 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24S 2025/6005 20180501;
H02S 20/20 20141201; H02S 20/25 20141201; F24S 25/634 20180501;
F24S 25/636 20180501; H02S 40/22 20141201; F24S 25/61 20180501;
H02S 40/425 20141201; F24S 25/20 20180501; H02S 20/10 20141201;
F24S 25/33 20180501; F24S 25/13 20180501; F24S 2025/6003 20180501;
H02S 30/10 20141201; H01L 31/0475 20141201; F24S 25/632
20180501 |
International
Class: |
H02S 20/25 20060101
H02S020/25; H02S 30/10 20060101 H02S030/10; H02S 40/22 20060101
H02S040/22; H02S 40/42 20060101 H02S040/42 |
Claims
1. A solar photovoltaic module mounting system for installation on
a sloped surface, comprising: a geomembrane sheet for overlaying on
a sloped surface; a pair of elongate flexible strips for disposing
in spaced-apart parallel relation to the geomembrane; a pair of
elongate rails, each for securing to a respective one of the
flexible strips; and at least one solar photovoltaic module for
attaching to the rails, whereby the flexible strips being secured
to the rails and attached to the geomembrane in spaced-apart
parallel relation, support the solar photovoltaic module attached
with fasteners to the rails while resisting sliding movement
relative to the geomembrane and resisting wind uplift.
2. The solar photovoltaic module mounting system as recited in
claim 1, wherein the rail comprises a U-channel having a base and
opposing side walls extending in a first direction therefrom, each
side wall with a free distal end and a lip projecting towards the
lip of the opposing distal end.
3. The solar photovoltaic module mounting system as recited in
claim 2, further comprising a plurality of fasteners for securing
the photovoltaic module to the rails, each fastener comprising a
plate having a threaded shaft extending therefrom for receiving the
plate between the opposing side walls and the shaft for rotating to
drive opposing ends of the plate into contact with the lips of the
side walls, the threaded shaft for extending through an opening in
a bracket of the solar photovoltaic module and being secured with a
nut thereon.
4. The solar photovoltaic module mounting system as recited in
claim 3, wherein said plate has a selected width smaller than the
width of a channel defined by the opposing side walls and a length
larger than the width of said channel.
5. The solar photovoltaic module mounting system as recited in
claim 1, further comprising at least one ballast tray having
opposing ends for attaching to the opposing rails and a tray
surface for supporting a ballast thereon, the ballast tray attached
to the opposing rails prior to attaching the solar photovoltaic
module to the rails in overlying relation.
6. The solar photovoltaic module mounting system as recited in
claim 1, wherein the geomembrane and the flexible strips are made
of a synthetic material for heat welding together for secure
attaching of the flexible strips to the geomembrane.
7. The solar photovoltaic module mounting system as recited in
claim 5, wherein the geomembrane includes a light-reflective
component.
8. The solar photovoltaic module mounting system as recited in
claim 1, wherein the sloped surface comprises a protected membrane
roof; and further comprising an adhesive for securely attaching the
geomembrane to the sloped surface.
9. The solar photovoltaic module mounting system as recited in
claim 1, further comprising a spacer for attaching between the rail
and the solar photovoltaic module to define an air flow space
between a bottom surface of the solar photovoltaic module and the
geomembrane, whereby air flow therethrough reduces heat build-up in
the solar photovoltaic module.
10. The solar photovoltaic module mounting system as recited in
claim 9, wherein the spacer comprises a U-shaped channel having a
base with at least one opening for receiving a fastener for
securing the spacer to the rail, and opposing side walls extending
in a first direction therefrom, each side wall with a free distal
end and a lip projecting towards the lip of the opposing distal
end.
11. A method of installing a solar photovoltaic module on a sloped
surface, comprising the step of: (a) providing a geomembrane sheet
that overlays a sloped surface; (b) attaching a pair of elongate
flexible strips in spaced-apart parallel relation to the
geomembrane, the flexible strip each including an elongate rail
secured thereto; and (c) attaching at least one solar photovoltaic
module to the rails, whereby the flexible strips being secured to
the rails and attached to the geomembrane in spaced-apart parallel
relation, support the solar photovoltaic module attached with
fasteners to the rails while resisting sliding movement relative to
the geomembrane and resisting wind uplift.
12. The method as recited in claim 11, wherein the rail comprises a
U-channel having a base and opposing side walls extending in a
first direction therefrom, each side wall with a free distal end
and a lip projecting towards the lip of the opposing distal
end.
13. The method as recited in claim 11, further comprising the step
of securing the photovoltaic module to the rails with a plurality
of fasteners.
14. The method as recited in claim 13, wherein securing comprises
receiving a plate between the opposing side walls and being rotated
the opposing ends of the plate contact the lips of the side walls,
and a threaded shaft extending from the plate receiving a nut.
15. The method as recited in claim 11, forming the geomembrane and
the flexible strips of a synthetic material for heat welding
together for secure attaching of the flexible strips to the
geomembrane.
16. The method as recited in claim 11, further comprising the step
of providing the geomembrane with a light-reflective component.
17. The method as recited in claim 11, further comprising the step
of adhering the geomembrane with an adhesive to a roof surface.
18. The method as recited in claim 11, further comprising the step
of positioning a spacer between the rail and the solar photovoltaic
module to define an air flow space between a bottom surface of the
solar photovoltaic module and the geomembrane, whereby air flow
therethrough reduces heat build-up in the solar photovoltaic
module.
Description
CROSS REFERENCE TO RELATED APPLICATIONS:
[0001] This application claims the benefit of U.S. Provisional
Patent Application Serial No. 62/616,705 filed Jan. 12, 2018 and
entitled Integrated Photovoltaic Module Mounting System For Use
With Tufted Geosynthetics, the benefit of U.S. Provisional Patent
Application Ser. No. 62/522,402 filed Jun. 20, 2017 and entitled
Integrated Photovoltaic Module Mounting System For Use With Tufted
Geosynthetics, which provisional patent applications are
incorporated herein by reference in their entireties.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT:
[0002] Not applicable.
TECHNICAL FIELD
[0003] This invention relates to an integrated mounting system for
photovoltaic modules for use in solar energy collection. In a more
specific aspect, this invention relates to a non-ballasted and
non-ground penetrating integrated photovoltaic mounting system for
use with, and supported by, tufted geosynthetics.
[0004] More particularly described, the present invention in a more
specific aspect relates to a ballasted and non-penetrating
integrated photovoltaic mounting system for use with, and supported
by, a sloped surface, such as but not limited to a protected
membrane roof.
[0005] In this application, the following terms will be understood
to have the indicated definitions:
[0006] "photovoltaic module"--a module which utilizes the
generation of voltage when radiant energy (such as solar energy)
falls on the module; sometimes referred to as a solar cell.
[0007] "tufted geosynthetics"--a system which is adapted to cover
waste sites and other environmental closures and which is generally
comprised of synthetic grass having synthetic fibers tufted to a
backing and a geomembrane. Examples of a tufted geosynthetic cover
system are shown in Ayers and Urrutia U.S. Pat. No. 7,682,105 and
U.S. Pat. No. 9,163,375. The term "tufted geosynthetics" is also
used to refer to a synthetic turf cover system.
[0008] "synthetic grass"--refers to a composite which comprises at
least one geotextile (woven or nonwoven) tufted with one or more
synthetic yarns or strands and which has the appearance of
grass.
[0009] "geomembrane"--refers to a polymeric material, such as high
density polyethylene, very low density polyethylene, linear low
density polyethylene, polyvinyl chloride, etc.
[0010] "surface"--refers to a surface which has an angle of slope
of zero or more.
[0011] "creep"--refers to a behavior of materials (such as soils
and geosynthetics) to move or deform slowly under a constant load
or stress.
BACKGROUND OF THE INVENTION
[0012] Photovoltaic solar modules have historically been mounted by
use of a rigid racking system over a variety of surfaces such as
rooftops, greenfields and brownfields. These rigid racking systems
have not been integrated onto the photovoltaic module. Typical
systems include racking structures that the photovoltaic module
must be placed upon and then mechanically fastened to the racking
structure.
[0013] Racking structures are placed in spaced-relation and the
racking structures enable orienting the photovoltaic module at an
energy-generating efficient angle. However, the spacing limits the
number of photovoltaic modules that can be installed in an area
because the angling causes shadows. An adjacent rack must be spaced
sufficiently that the photovoltaic modules are not within a shadow
area.
[0014] There is a need in the solar industry for an integrated
photovoltaic module in which the mounting mechanism is attached to
the photovoltaic module which eliminates the need for a rigid
racking system. The integration allows for an economical
alternative to a traditional rigid racking system and enables the
increasing of the density of the photovoltaic modules placed at a
solar energy generation site, thereby increasing the potential
generation of electrical power while allowing flexibility of
installation by using non-traditional racking installers.
[0015] While use of solar as a renewable alternative energy source
has "clean energy" favorabilities, there are drawback to such
installations. Solar energy generation sites typically require
large tracts of land. In some location circumstances, wooded lands
are cleared or farm lands are re-purposed for use as solar energy
generation sites. Other sites are significantly remote from tie-in
connections to the power transmission and distribution grid of
power generating and supply companies. These remote sites require
capital expenditures to install and maintain transmission lines to
the electrical grid and such transmission lines occupy additional
land. Also, recent changes in power generation capacity has
decreased reliance on coal and increased reliance on cleaner
combustion fuels such as natural gas and, alternatively, power
plants that generate electricity with turbines operated with steam
heated by nuclear fuel sources. The coal-fired power plants
nevertheless have large areas of ash holding ponds or storage
areas. These areas are subject to closing with covers such as
geomembranes that restrict environmental waters, such as rain or
other precipitation or surface water flow, from passing through the
covered site and leaching into the ground or pond.
[0016] Further, buildings such as homes, apartment buildings,
offices, and other building structures have large roof areas that
provide surface space for installation of solar panels. Roof
surfaces may be flat, or may have a sloped pitch. Often roofs have
a roofing structure to seal the surface such as from rain. For
example, shingles are elongated sheets that are placed in
overlapping courses to cover a roof surface. Another roof structure
provides a having an insulation layer attached to a roof deck and
overlaid by a membrane. Ballast such as stones or cement pavers may
be placed on the membrane. Articles and structures placed on a roof
surface however need to be secured or held in place. On sloped
surfaces, securing the article prevents creep type movement.
However, it is undesirable for sealing from leakage to have opening
formed in the membrane to secure the article to the roof deck.
[0017] Accordingly, there is a need in the art for an improved
mounting system for securing photovoltaic modules to a sloped roof
surface for generating solar power. It is to such that the present
invention is directed.
SUMMARY OF THE INVENTION
[0018] The integrated mounting system of this invention allows for
easy installation supported by a tufted geosynthetic on a surface.
This combination of the integrated mounting system and tufted
geosynthetic results in a lower cost, lower maintenance of the
surrounding surface, adaptable for variety of grades from flat to
sloping ground and generates more solar power per unit area.
[0019] Briefly described, the present invention integrates a
photovoltaic module mounting system over tufted geosynthetics on
various surfaces (such as a ground cover system, roof, reservoir,
pond, etc.). There are two preferred components of this invention
that may be combined or used separately within the integrated
photovoltaic module mounting system and within any combination
thereof.
[0020] The first component is one or more anti-creep strip(s) that
enhances interface friction between the photovoltaic module and the
tufted geosynthetic, while also reducing shearing forces between
the photovoltaic module and its mounting surface, thus preventing
or substantially preventing sliding forces from mobilizing the
module. If desired, a monitoring device can be used to measure the
amount of creep.
[0021] The second component is a flexible attachment connection
which may be used, in addition to the anti-creep strip(s), as an
additional factor to increase interface friction and to counter
potential shearing and uplift forces which could be caused by high
wind gusts. The attachment connection can be welded directly to the
tufted geosynthetic or the geomembrane and attached to the bottom,
top or side of the photovoltaic module. Other means of attaching
the connection to the geosynthetic include mechanical means (e.g.,
screws, bolts, etc.) and adhesive means such as glue, tape,
etc.
[0022] These two components eliminate the need for ballast compared
to a traditional photovoltaic racking system which does not have
foundation anchoring. The integrated photovoltaic module mounting
system supported by a tufted geosynthetic requires no ballast on a
surface. These two components enable multiple configurations (as
shown in the drawings).
[0023] The result of a non-ballasted integrated photovoltaic module
mounting system allows for a lower cost and increased power
generation through higher density of module placement at an energy
generation site An additional advantage of an integrated
photovoltaic module mounting system is that the system does not
require grounding.
[0024] The integrated photovoltaic module mounting system of this
invention allows for a higher density (i.e., one or more) of
photovoltaic modules in a defined area as compared to traditional
systems, and a higher density of modules enables the integrated
photovoltaic module mounting system to provide more electrical
power per unit area.
[0025] However, a two component ballasted integrated mounting
system readily and gainfully installs on sloped roof surfaces of
protected membrane roofs for securing photovoltaic modules for
generation of electrical power. The first component is one or more
flexible attachment anti-creep connections that attaches directly
to a geomembrane adhered to a roof deck to counter potential
shearing and uplift forces which could be caused by high wind gusts
between the photovoltaic module and its mounting surface, thus
preventing or substantially preventing sliding forces from
mobilizing the module. If desired, a monitoring device can be used
to measure the amount of creep.
[0026] The second component is a mechanical rail connected to the
flexible attachment connection and to the photovoltaic module. The
attachment connection can be welded directly to the geomembrane and
attached through the mechanical rail to the photovoltaic module.
Other means of attaching the flexible attachment connection to the
geomembrane include mechanical means (e.g., screws, bolts, etc.)
and adhesive means such as glue, tape, etc.
[0027] More particularly described, the present invention meets the
need in the art by providing a solar photovoltaic module mounting
system for installation on a sloped surface, comprising a
geomembrane sheet for overlaying on a sloped surface. A pair of
elongate flexible strips for attaching in spaced-apart parallel
relation to the geomembrane and a pair of elongate rails, each for
securing to a respective one of the flexible strips. At least one
solar photovoltaic module is for attaching to the rails, whereby
the flexible strips being secured to the rails and attached to the
geomembrane in spaced-apart parallel relation, support the solar
photovoltaic module attached with fasteners to the rails while
resisting sliding movement relative to the geomembrane and
resisting wind uplift.
[0028] In another aspect, the present invention provides a method
of installing a solar photovoltaic module on a sloped surface,
comprising the steps of:
[0029] (a) providing a geomembrane sheet that overlays a sloped
surface;
[0030] (b) attaching a pair of elongate flexible strips in
spaced-apart parallel relation to the geomembrane, the flexible
strip each including an elongate rail secured thereto; and
[0031] (c) attaching at least one solar photovoltaic module to the
rails,
[0032] whereby the flexible strips being secured to the rails and
attached to the geomembrane in spaced-apart parallel relation,
support the solar photovoltaic module attached with fasteners to
the rails while resisting sliding movement relative to the
geomembrane and resisting wind uplift.
[0033] Objects, advantages and features of the present invention
will become apparent upon a reading of the following detailed
description in conjunction with the drawings and the appended
claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 shows multiple flexible attachment connections (i.e.,
single weld harnesses) mounted on a photovoltaic module.
[0035] FIG. 1A shows a detailed bottom view of a single flexible
attachment connection exploded away from a mounting baseplate
attached to photovoltaic solar module.
[0036] FIG. 2 is a view of multiple weld harness strips mounted on
a photovoltaic module.
[0037] FIG. 3 is a view of two anti-creep strips mounted on a
photovoltaic module.
[0038] FIG. 4 is a view of multiple single weld harnesses used with
multiple anti-creep strips.
[0039] FIG. 5A is a view of two weld harness strips used with
multiple anti-creep strips.
[0040] FIG. 5B shows two weld harness strips used with a single
anti-creep strip.
[0041] FIG. 5C shows two weld harness strips used with multiple
anti-creep strips and multiple single weld harnesses.
[0042] FIG. 6 shows a cross section of a single weld harness strip
used with a photovoltaic module.
[0043] FIG. 6A illustrates in side elevational view an embodiment
of the photovoltaic module mounting system using a tilting device
for selective orienting at an angle to the geosynthetic for optimal
positioning relative to the sun for energy generation.
[0044] FIG. 7 shows a top view of a single weld harness.
[0045] FIG. 8 is a perspective view of the mounting system in
another preferred form.
[0046] FIG. 9 is a perspective view of the mounting system in
another preferred form.
[0047] FIG. 10 is a side view of a portion of the mounting system
of FIG. 9.
[0048] FIG. 11 is a side view of the mounting system in another
preferred form.
[0049] FIG. 12 is a top view of the mounting system of FIG. 11,
shown with multiple solar panels mounted together.
[0050] FIG. 13 is a perspective view of the mounting system in yet
another preferred form.
[0051] FIG. 14 is an end view of a wiring tray system for solar
panels in a preferred form.
[0052] FIG. 15 is a side view of the wiring tray system of FIG.
14.
[0053] FIG. 16 is an exploded end view of the wiring tray system of
FIG. 14.
[0054] FIG. 17 is a perspective view of a mounting system in yet
another preferred form.
[0055] FIG. 18 is an exploded, end view of the mounting system of
FIG. 17.
[0056] FIG. 19 is an end view of the mounting system of FIG. 17
shown with the spacer removed.
[0057] FIG. 20 is a top view of a portion of the mounting system of
FIG. 17.
[0058] FIG. 21 is a perspective view of an alternate embodiment of
a rail for use with photovoltaic module mounting system shown in
FIG. 17 in yet another preferred form.
[0059] FIG. 22 is a perspective view of a mounting system in yet
another preferred form particularly adapted for sloped
surfaces.
[0060] FIG. 23 is a perspective view of the mounting system
illustrated in FIG. 21 deployed on a sloped protected membrane
roof.
[0061] FIG. 24 is a perspective view of an alternate embodiment of
a rail for use with photovoltaic module mounting system shown in
FIG. 22 in yet another preferred form.
DETAILED DESCRIPTION
[0062] The present invention provides in reference to FIGS. 22-24 a
photovoltaic module mounting system for installation on a sloped
surface for generation of electricity. The present invention
developed from applicant's earlier integrated photovoltaic module
mounting systems disclosed herein for use with a tufted
geosynthetic system on a surface without a racking structure and in
some embodiments without ballast for support and in other
embodiments with support.
[0063] The essential components are a tufted geosynthetic system
and one or more integrated photovoltaic module mounting systems.
The particular present invention gainfully uses the geomembrane
component of the tufted geosynthetic system and mounting structures
for attaching thereto for supporting the photovoltaic. Before
describing in reference to FIGS. 22-24 the structure and use of the
present invention of a sloped surface mounting system for
photovoltaic modules, the following discloses integrated
photovoltaic module mounting systems.
[0064] Cover System
[0065] Examples of tufted geosynthetic systems useful in the
integrated photovoltaic module mounting system of this invention
are the covers marketed by Watershed Geosynthetics LLC under the
registered trademarks ClosureTurf and VersaCap. These covers 11
comprise a composite of at least one geotextile 213 which is tufted
with a plurality of spaced-apart tufts 215 with one or more
synthetic yarns (i.e., a tufted geosynthetic) to simulate grass
blades in a synthetic grass, and an impermeable geomembrane 217
comprised of a polymeric material.
[0066] The synthetic grass blades of the system may contain an
infill material and/or a material for protection of the synthetic
grass blades against ultraviolet rays.
[0067] Solar Module
[0068] One or more mono- or multi-crystalline solar modules can be
used in the integrated photovoltaic module mounting system of this
invention, such as commercially available polycrystalline silicon
solar modules. Examples of effective solar modules are available
from BYD (China) under the designation BYD 260P6C-30-DG and from
Trina (China) under the designation Solar Duomax TSM-PEG14, Tallmax
PE14A, and BYD P6C-36. An alternate embodiment discussed below
gainfully uses a bifacial solar module.
[0069] Referring now to the drawings, in which like numerals
represent like elements, FIG. 1 shows in top view multiple single
weld harnesses 1 secured by a mounting baseplate 2 attached to a
solar module 3. The weld harnesses 1 or tabs that extend flexibly
laterally from a side edge of the solar module 3 and attach to at
least some of the plurality of tufts 215. The attaching may be
accomplished by mechanically attached such as with a fastener,
chemically attached, welding (heat or sonic), or thermoset
bonding.
[0070] FIG. 1A shows a detailed bottom view in which a single
flexible weld harness 1 is exploded away from the mounting
baseplate 2 that attaches, such as with adhesive 9, to a bottom
surface of the photovoltaic solar module 3. The flexible weld
harness 1 has a first portion 19 that defines an opening 12 for
receiving a fastener such as a screw or bolt that engages a
threaded passage 23 in the baseplate 2. The threaded passage 23
extends in a raised spacer portion 21 of the baseplate 2, such as a
nut mounted therein. A second portion 22 of the flexible attachment
connection 1 extends laterally as a flap to overlie and connect (by
mechanically linking with a fastener, chemically connecting, heat
or sonic welded, thermoset bond or attached, or adhesive) to a
portion of a tufted geosynthetic ground cover 11.
[0071] Instead of a tab 1 for the weld harness, FIG. 2 shows
multiple elongated weld harness strips 4 secured by the respective
mounting baseplates 2 attached to the solar module 3.
[0072] FIG. 3 shows two anti-creep strips 5 secured by the
respective mounting baseplates 2 attached to solar module 3.
[0073] FIG. 4 shows multiple single weld harnesses 1 in combination
with anti-creep strips 5, both secured by mounting baseplate 2
attached to solar module 3.
[0074] FIG. 5A shows two weld harness strips 4 in combination with
anti-creep strips 5 secured by mounting baseplate 2 attached to
solar module 3.
[0075] FIG. 5B shows two weld harness strips 4 used with single
anti-creep strip 5 secured by mounting baseplate 2 attached to
solar module 3.
[0076] FIG. 5C shows two weld harness strips 4 used with multiple
anti-creep strips 5 and secured by mounting baseplate 2 attached to
solar module 3.
[0077] FIG. 6 shows a side elevational view of a single weld
harness 1 secured to solar module 3.
[0078] FIG. 6A illustrates in side elevational view an embodiment
of the photovoltaic module mounting apparatus using a tilting
device generally 223 for selective orienting of the photovoltaic
module 3 at an angle a to the geosynthetic cover 11 for optimal
positioning relative to the sun for energy generation.
[0079] FIG. 7 shows a top view of a single weld harness 1 having a
single weld attachment in combination with wind disturbing openings
6 and openings 7 for attaching optional mechanical connections.
[0080] Friction
[0081] This invention also provides a method for a non-ballasted
module mounting system utilizing one or more anti-creep strips 5
integrated on the photovoltaic module when mounted over tufted
geosynthetics, by increasing the coefficient of friction between
the anti-creep strips and the tufted geosynthetic. The anti-creep
strips 5 include a plurality of spaced-apart feet 46 depending from
a bottom surface. The feet 46 inter-engage with the tufts 215 to
provide frictional connection of the photovoltaic solar module 3 to
the tufted geosynthetic cover 11. In the illustrated embodiment,
the anti-creep strips 5 connect to the mounting plate 2 using a
threaded fastener to engage the threaded passageway 23 in the
baseplate 2. In embodiments that uses both the anti-creep strips 5
and the weld harness 1 (or elongated attaching strip 4), the
fastener extends through the anti-creep strip and the weld harness
and threadably engages the passage 23. Alternatively, separate, or
additional baseplates 2 may be used.
[0082] The anti-creep strips footing is generally a structured
geomembrane or tufted geosynthetic cover 11.
[0083] The anti-creep strips, when used in this invention, comprise
a polymeric material such as polyethylene, polypropylene, ethylene
propylene diene monomer, rubber, metal, textured metal, polyvinyl
chloride, polyurethane, etc.
[0084] Further, an alternate embodiment may charge the geosynthetic
cover 11 with ballast infill 221, to provide a mass that increases
the frictional resistance to movement with the plurality of
particles of the infill that fill interstices and spaces above the
geotextile 213 and among the tufts 215. When used in this
invention, suitable materials for infill are sand, concrete and
materials available from Watershed Geosynthetics LLC (Alpharetta,
Ga.) under the trademarks HydroBinder and ArmorFill. Infill can be
of various colors, sizes and textures.
[0085] When used in this invention, examples of suitable materials
for anti-creep strips are calendared, textured and structural
membranes made by Agru America, Inc. under the trademark
SureGripnet.
[0086] Wind Uplift Resistance
[0087] The present invention comprises a wind-resistant
non-ballasted integrated photovoltaic module mounting system for
use on a tufted geosynthetic, which preferably includes both
anti-creep strips and an attachment layer. The system does not rely
on weight to resist wind forces, but instead relies on
wind-breaking turf blades (i.e., the synthetic grass) and an
attachment to the turf blades (synthetic grass). The cover of the
present invention can be deployed over a large area with very minor
ballasting. Wind-breaking elements 219 may also be utilized to
break up the airflow over the integrated photovoltaic module to
provide wind uplift resistance. As illustrated in FIG. 6, one or
more wind breaking elements generally 219 may attach to an edge of
the photovoltaic module 3. The wind breaking elements 219 comprise
a plurality of thin spaced-apart pins that extend upwardly, for
example, about 1-12 inches, preferably about 2-6 inches, and more
preferably, about 2-3 inches. In an alternate embodiment, the weld
harness 4 may include wind breaking or disturbing openings 6.
[0088] With this invention, the wind velocity on the impermeable
surface (geo-membrane) becomes turbulent near the surface of the
cover, thus greatly reducing the actual wind velocity at the liner
surface and decreasing associated uplift. The reaction of the
synthetic grass of the tufted geosynthetic to the wind forces can
also create a downward force on the geomembrane. This reaction is
caused by the filaments of the synthetic grass applying an opposing
force against the wind which is transferred as a downward force on
the geomembrane.
[0089] The integrated photovoltaic module of this invention can be
used with an optional tilting device to raise or lower the module
for better results depending on the location. FIG. 6A illustrates
in side elevational view an embodiment of the photovoltaic module
mounting apparatus using the tilting device generally 223 for
selective orienting of the photovoltaic module 3 at an oblique
angle a relative to the geosynthetic cover 11 for optimal
positioning relative to the sun for energy generation. The tilting
device 223 comprises at least a pair of the mounting base plates
2a, 2b having riser portions 21a, 21b of different lengths, whereby
the photovoltaic module 3 is disposed at the angle a to the
geosynthetic cover 11, for optimal energy generation.
[0090] Further, the mounting baseplate 2 spaces the photovoltaic
solar module 3 from the tufted geosynthetic ground cover 11. The
spacing thereby creates a gap between the tufted geosynthetic
ground cover and the photovoltaic solar module 3, which gap
facilitates air flow therealong for heat dissipation in that
heating of the photovoltaic solar module 3 which occurs reduces the
solar generation efficiency of the solar module. In an alternate
embodiment, the mounting base plate 2 is sized to provide at least
an 18 inch to 24 inch gap under the photovoltaic solar module 3. To
further enhance solar generation energy capacity, the photovoltaic
solar module 3 is bifacial and the tufted geosynthetic ground cover
11 includes light reflective features, such reflectants added into
the polymeric used the extrusion of the yarn from which the tufts
215 are formed during tufting. As shown in FIG. 1, tuft 215a
illustrates a reflectant 216, for example, a small light-reflecting
body or chip. Further, a light reflective color pigment material
may be included in the polymeric to enhance reflectivity of ambient
light from the tufted geosynthetic ground cover 11 proximate the
photovoltaic solar module 3. For example, tufts 215b are tufted
with yarns that include a coloring pigment 218.
[0091] With reference next to FIG. 8, there is a shown a mounting
system 10 in another preferred form of the invention. The system 10
is shown mounted to a double glass photovoltaic module or solar
panel 11. The system 10 includes an elongated base plate 14 having
an elongated mounting channel 16 defined by a generally planar,
elongated base member 17, two oppositely disposed elongated,
vertically oriented channel walls 18 having inwardly extending
clamping tangs 19, and an elongated, vertically oriented central
support wall 20. The system also includes an elongated I-beam or
rail 24 having a horizontal lower member 25, a horizontal upper
member 26 and a vertical spanning member 27 extending between the
lower member 25 and upper member 26. The I-beam 24 is selectively,
releasably coupled to and slideable relative to the underlying base
member 17 for slideable movement therebetween through a force
placed upon the I-beam 24. The clamping tangs 19 of the channel
walls 18 abut the top surface of the lower member 25 while the
lower member rests upon the central support wall 20, thereby
holding the I-beam 24 in place relative to the base plate 14.
[0092] A C-shaped bracket 30 is slidably coupled to the upper
member 26 for selective longitudinal movement along the upper
member 26. The C-shaped bracket 30 includes a threaded mounting
post or bolt 32 extending upwardly and through a mounting hole 34
within a staggered clamp 36. The staggered clamp 36 includes a
contact ledge 37. A nut 38 is threadably coupled to the mounting
post 32 to force the contact ledge 37 of the staggered clamp 36
downwardly against the peripheral margin of the solar panel 11,
thus locking the position of the solar panel 11. The tightening of
the nut 38 upon the post 32 also causes the staggered clamp 36 to
be forced downward into abutment with the upper member 26 of the
I-beam, thereby locking the position of the C-shaped bracket 30 and
staggered clamp 36 relative to the I-beam 24. The base plate 14,
I-beam 24, bracket 30, and clamp 36 may all be made of a polymer or
metal material, such as aluminum.
[0093] Lastly, the mounting system 10 includes a weld harness or
weld harness strip 39 and anti-creep strips 44 which are coupled to
the base member 17 through bolts 40. As with all embodiments
herein, the anti-creep strips 44 include a generally planar support
45 and an array or arrangement of downwardly extending feet or
projections 46. The anti-creep strip 44 may be made of a polymer
material or the like. The weld harness strip 39 has a first portion
39' which is coupled to the base plate 14, and a second portion
39'' which is meltable to the underlying tufted geosynthetic
41.
[0094] In use, the weld harness strip 39 overlays a portion of the
tufted geosynthetics 41 wherein heat, or other form of welding, is
applied to the weld harness strip 39 so that the weld harness strip
39 partially melts or becomes molten and thereby bonds or coupled
with the strands or yarns 42 of the geosynthetic material when
cooled. The bonding of the weld harness strip 39 to the yarns is
depicted by welding reference W.
[0095] It should be understood that the geosynthetic material may
be used in combination with one or more layers of additional
geosynthetic materials.
[0096] With reference next to FIGS. 9 and 10, there is shown a
portion of a double glass solar panel 11 with a side edge mounting
bracket 50. Here, the side edge mounting bracket 50 has a U-shaped
member 52 and a mounting flange 54 extending laterally and
horizontally from the U-shaped member 52. The mounting flange 54
includes one or more mounting holes 56. The member 52 grips a side
portion of the solar panel 11, and may be secured thereto with
fasteners or adhesive.
[0097] The side edge mounting bracket 50 may be coupled to
mechanical means shown in FIG. 8. Specifically, the side edge
mounting bracket 50 may be coupled to the C-shaped bracket 30 with
the mounting post 32 extending through one of the mounting holes 56
of the mounting flange 54 and secured thereto with a mounting nut
38. As with the embodiment of FIG. 8, the C-shaped bracket 30 is
coupled to the I-beam 24 which in turn is coupled to the base plate
14. The welding harness strip 39 and anti-creep strip 44 are also
utilized to prevent relative movement with respect to the
geosynthetic material to which the welding harness strip is
mounted. Again, the welding harness strip may be mounted through
heat welding, ultrasonic welding, adhesive, or mechanical means
such as a nut and bolt. However, heat or ultrasonic welding is
preferred as it provides a superior bond between the yarn of the
preferred tufted geosynthetic material.
[0098] With reference next to FIGS. 11 and 12, there is a shown a
solar panel 11 and mounting system 60 in another preferred form of
the invention. Here, the mounting system 60 includes a side edge
mounting bracket 50 similar to that shown in FIGS. 9 and 10.
However, the mounting system 60 includes a mounting rail or
attachment 62 which essentially replaces the C-shaped bracket 30,
I-beam 24 and base plate 14 of the previous embodiments. The
mounting bracket 50 is captured within a channel 63 within the
mounting attachment 62 so as to be selectively releasably coupled
to and slideable relative to the mounting attachment 62. The
mounting attachment 62 may be made of any suitable material, such
as a metal or polymer.
[0099] Here, the mounting attachment 62 includes a top portion 64
which captures the mounting flange 54 of the side edge mounting
bracket 50 extendingly attached to the solar panel 11 and is
affixed thereto and secured in position through a threaded mounting
bolt 38. Optionally, the mounting attachment 62 may be made of a
polymer material which allows it to flex, thereby allowing for the
solar panel to be snap fitted into the top portion 64 without the
need for the use of the mounting post and nut to secure the
position of the solar panel 11 to the mounting attachment 62. The
top portion 64 extends to and merges with a lower portion or cradle
66 which extends about the side and bottom of the mounting bracket
50. The lower portion 66 may be considered to be an elongated base
plate or base portion and is integrally coupled with or extending
from the mounting attachment 62. The lower portion 66 includes feet
68 to which the anti-creep strip 44 is coupled through conventional
means, such as bolts, screws, or adhesive. The lower portion 66
also includes weld harness strips 39 which are welded W or
otherwise coupled to the tufted geosynthetic material, and
specifically the yarns of the tufted geosynthetic material, as
previously discussed.
[0100] The lowest part of lower portion 66 may be considered to be
a base plate as it forms the base of the lower portion 66.
Therefore, the highest part of lower portion 66, which forms the
C-shaped channel about bracket 50, may be considered to be an
elongated rail which is integrally formed with or extends from the
portion considered to be the base plate.
[0101] With this configuration, ballast B, such as elongated weight
members, may be easily coupled to the mounting attachment 62 if
desired, as shown in FIG. 12.
[0102] Multiple mounting attachments may be mounted end to end, as
shown in FIG. 12, to form a compart series of solar panels 11 and
mounting systems 10.
[0103] With reference next to FIG. 13, there is shown a solar panel
11 and mounting system 70 in another preferred form of the
invention. Here, a weld harness strip 72 is mounted directly to a
side edge mounting bracket 74. The weld harness strip 72 includes
mounting holes 76 which are aligned with mounting holes 78 in the
side edge mounting bracket 74. A fastener 79, such as a mounting
bolt, is passed through the mounting holes 76 and 78. Anti-creep
strips 80 may be attached to the bottom of solar panel 11.
[0104] In use, the weld harness strip 72 is once again welded to
the strands or yarns of the underlying tufted geosynthetic
material, as previously discussed.
[0105] With reference next to FIGS. 14-16, there is shown a wire
tray system 90 for a solar panel mounting system for tufted
geosynthetic material in a preferred form of the invention. The
wire tray system 90 includes a hollow conduit 91 having a top
portion 92 and a bottom portion 93 snap fitted to top portion 92,
the conduit 91 forming a channel C through which the wiring of the
solar panels may be positioned. The wire tray system 90 also
includes a base, foot or stand 94 which is snap fitted to the
conduit 91.
[0106] The top portion 92 is generally a half cylinder having ends
95 in the form of tangs that are releasably received within
longitudinal grooves 96 along the upper ends of the bottom portion
93. The bottom portion 93 also being in the form of a half cylinder
and includes longitudinal stand grooves 99.
[0107] The stand 94 has a bottom portion 94' is generally
triangular in shape and includes an anti-creep strip 96 coupled to
the bottom surface of the stand 94. The stand bottom portion 94'
also includes oppositely disposed weld harness strips 97. Lastly,
the stand bottom portion 94' includes a pair of oppositely disposed
longitudinal catches 100 which are configured to be releasably
received within the longitudinal grooves 99 of the conduit bottom
portion 93.
[0108] In use, the weld harness strips are welded or otherwise
coupled to the yarn of the tufted geosynthetic material, as
previously discussed. Again, the anti-creep strip 96 prevents
relative movement of the wire tray system 90 relative to the tufted
geosynthetic material.
[0109] The conduit top portion 92 may be easily released from the
conduit bottom portion 93 to provide easy access to the wiring
within the conduit 91. Also, the entire conduit 91 may be easily
removed from the stand 94 for replacement purposes.
[0110] With reference next to FIGS. 17 and 18, there is a shown a
solar panel 11 and mounting system 110 in another preferred form of
the invention. Here, the mounting system 110 includes a side edge
mounting bracket 112 which may be formed as part of the solar panel
11, but which alternatively may be formed similar to bracket 50
shown in FIGS. 9 and 10. The mounting bracket 112 includes a
mounting hole 113 therethrough. In this embodiment, the mounting
system 110 includes ballast; therefore, the need for a welding
strip is optional.
[0111] The system 110 includes a generally U-shaped, elongated base
plate 114 having an elongated mounting slot or channel 116 defined
by a generally planar, elongated base member 117 and two oppositely
disposed elongated, vertically oriented channel walls 118 having
inwardly extending lips or flanges 119. The base member 117
includes a series of elongated mounting holes 120. It should be
understood that the system includes pairs of like components to
complete the system, i.e., pairs of base members 117, spacers beams
124, corresponding fasteners, and the like.
[0112] The system also includes an elongated U-shaped spacer beam
or rail 124 having a horizontal lower member 125, two oppositely
disposed side walls 126 each having an inwardly extending lip or
flange 127 defining a slot or channel 128 therebetween. The lower
member 125 has mounting holes 129 therethrough. A first T-shaped
fastener 131 having an elongated mounting plate 132 and an
externally threaded mounting post 133 which extends through the
spacer beam mounting hole 129 and is threadably coupled to an
internally threaded first mounting nut 134. The spacer beam 124 is
selectively, releasably coupled to and slideable relative to the
underlying and longitudinally aligned base member 117 for slideable
movement therebetween through a force placed upon the spacer beam
124 through the loosening of first mounting nut 134 and locked in
place by the tightening of first mounting nut 134. The width of the
mounting plate 132 is slightly smaller than the size (width) of the
mounting slot 116 while the length of the mounting plate 132 is
larger than the size (width) of the mounting slot 116, so that the
mounting plate 132 may be passed through the slot 116 and then
rotated so that it then cannot pass back through the slot 116. The
corners of the mounting plate 132 are rounded so that they may bear
against the interior surface of the channel walls 118.
[0113] A second T-shaped fastener 137 having an elongated mounting
plate 138 and an externally threaded mounting post 139 is coupled
to the spacer beam 124. The threaded mounting post 139 extends
through the slot 128, through the mounting hole 113 in mounting
bracket 112 and is threadably coupled to an internally threaded
second mounting nut 140. The solar panel 11 is selectively,
releasably coupled to and slideable relative to the underlying
spacer beam 124 for slideable movement therebetween for mounting
and adjustment purposes through the loosening of second mounting
nut 140 and locked in place by the tightening of second mounting
nut 140. The width of the mounting plate 138 is slightly smaller
than the size (width) of the mounting slot 128 while the length of
the mounting plate 138 is larger than the size (width) of the
mounting slot 128, so that the mounting plate 138 may be passed
through the slot 128 and then rotated so that it then cannot pass
back through the slot 128. The corners of the mounting plate 138
are rounded so that they may bear against the interior surface of
the spacer beam side walls 126.
[0114] The mounting system 110 also includes a ballast system 145
which is releasably and slideably coupled to the base member 117.
The ballast system 145 includes a ballast tray 146 having a floor
147, two oppositely disposed side walls 148 and a mounting flange
149 extending outwardly from each side wall 148. Each mounting
flange 149 has two mounting holes 150 therethrough. One of more
ballast modules 152, preferably in the form of concrete slabs, may
be positioned upon the floor 147 of the ballast tray 146, to
provide adequate weight to prevent the solar panels 11 and the
mounting system 110 from being displaced. The ballast tray 146 may
be made of a metal or other suitable material.
[0115] A third T-shaped fastener 155 having an elongated mounting
plate 156 and an externally threaded mounting post 157 which
extends through the ballast tray mounting hole 150 and is
threadably coupled to an internally threaded third mounting nut
158. The ballast tray 146 is selectively, releasably coupled to and
slideable relative to the underlying base member 117 for slideable
movement therebetween through a force placed upon the ballast tray
146 through the loosening of third mounting nut 158 and locked in
place by the tightening of third mounting nut 158. The width of the
mounting plate 156 is slightly smaller than the size (width) of the
mounting slot 116 while the length of the mounting plate 156 is
larger than the size (width) of the mounting slot 116, so that the
mounting plate 156 may be passed through the slot 116 and then
rotated so that it then cannot pass back through the slot 116. The
corners of the mounting plate 156 are rounded so that they may bear
against the interior surface of the channel walls 118.
[0116] Lastly, the mounting system 110 includes anti-creep strips
161 which are coupled to each base member 117 through fourth
T-shaped fasteners 162. The anti-creep strips 161 include a
generally planar support 163 and an array or arrangement of
downwardly extending feet or projections 164. The anti-creep strip
161 may be made of a polymer material or the like. The fourth
T-shaped fastener 162 have an elongated mounting plate 166 and an
externally threaded mounting post 167 which extends through the
base member elongated mounting holes 120 and is threadably coupled
to an internally threaded fourth mounting nut 168. The width of the
mounting plate 166 is slightly smaller than the size (width) of the
mounting slot 116 while the length of the mounting plate 166 is
larger than the size (width) of the mounting slot 116, so that the
mounting plate 166 may be passed through the slot 116 with the
mounting post 167 extending through the elongated mounting hole 120
and secured with fourth nut 168 to secure the anti-creep strip 161
to the base plate 114. The corners of the mounting plate 132 are
rounded so that they may bear against the interior surface of the
channel walls 118.
[0117] It should be understood that the first, second, third and
fourth T-shaped fasteners 131, 137, 155, and 162 are preferably all
the same to provide less inventory and easy exchange of pieces.
These fasteners pass through the slots or holes (113, 116, and 128)
and bind upon rotation so that they do not need to be held in place
with a tool during installation, as shown in FIG. 20.
[0118] In use, the anti-creep strip 161 prevents relative movement
of the mounting system 110 relative to the tufted geosynthetic
material. The array of downwardly extending feet or projections 164
inter-engage with the tufts for frictionally resisting movement
relative to the tufted geosynthetic.
[0119] With reference next to FIG. 19, there is a shown a solar
panel 11 and mounting system 210 in another preferred form of the
invention. Here, the mounting system 210 is essentially the same as
that shown in reference to FIGS. 17 and 18 except that the spacer
beam 124 and its correlating parts are not included.
[0120] With the absence of the spacer beam 124, the first T-shaped
fastener 131 is coupled directly to the solar panel 11 with the
mounting post 133 extending through the mounting hole 113 within
the solar panel mounting bracket 112. The first mounting nut 134 is
threaded upon the mounting post 133 to secure the solar panel 11 in
place. This configuration may be preferred when a large amount of
ventilation below the solar panel is not required.
[0121] FIG. 21 illustrates an end view of an alternate embodiment
of the mounting system shown in FIG. 17, using a one-piece extruded
rail 251 (as the base plate referenced above). The rail 251
comprises an elongated member having at least one web 253 attached
to opposing side walls 255. The illustrated embodiment includes a
pair of webs 253. The sides walls 255 define a channel 256 and
opposing profiles for a base 257 for contacting the attaching
connection 188 and an opposing seat 259 for connecting to the
bracket 112 of the photovoltaic module 11. The bracket 112 may be
integral with the photovoltaic module 11 as supplied by the module
manufacturer, or may be part of a Y-shaped bracket similar to
bracket 50 shown in FIGS. 9 and 10 for engaging a side edge of the
module.
[0122] The side walls 255 have inwardly extending lips or flanges
261, respectively, and each pair defines a respective slot 263
therebetween for the base 257 and for the seat 259. A plurality of
fasteners 162 secure the rail 251 to the anti-creep strip 161. The
post of the fastener extends though the slot 263 and through the
anti-creep strip 161. Upon rotating, the plate 166 on the flanges
261 bears on the side walls 255, and the nut 168 threads on the
post to secure the attaching connection 188 to the rail 251. The
feet 164 extending from the anti-creep strip than engages the tufts
215 of the geosynthetic cover 11. The photovoltaic module 3 then
rests with the bracket 112 on the seat 259. A post 133 of a
fastener 131 extends upwardly through the slot 263 in the seating
end 259, and through the opening in the bracket 112. The plate 132
rotates into engagement with the side walls 255. The nut 134
threadably engages the post 133 to secure the photovoltaic module
11 to the rail. Although not illustrated, a spring attached to the
plate may assist by holding the plate between the web 253 and the
flanges 261 in contact with the flanges 261 until the nut secures
the fastener to the rail.
[0123] With reference next to FIG. 22 illustrating in perspective
view a mounting system 180 in yet another preferred form
particularly adapted for securing one or more photovoltaic modules
11 to sloped surfaces. The sloped surfaces include but not by
limitation, a sloped protected membrane roof 182 as illustrated, or
alternatively, a geosynthetic cover for landfill or waste site
covering. In the illustrated embodiment, a geomembrane 184 overlies
the surface of a roof deck 185 of a protected membrane roof 182.
The geomembrane 184 secures with an adhesive 186 to the roof deck
185 and provides a sealing impermeable sheet for preventing water
flow into the protected membrane roof 182. Rather the water such as
from rain, flows to discharge gutters or channels (not
illustrated). The rail 114 connects with a plurality of the
fasteners 162 to a flexible attachment connector 188. The rail 114
includes the elongated rail slot 116 and defines the openings 120,
for the fasteners such as fasteners 162, 131, 137 or 155. These
fasteners include the mounting plate having the selected width
smaller than the width of the rail slot and the length larger than
the width of the rail slot 116, with a threaded post for receiving
a threaded nut. The flexible attachment connector 188 comprises an
elongated strip preferably of a material that readily welds W in
securing engagement with the geomembrane 184. The rail 114 connects
to the mounting bracket 112 of the photovoltaic module 11, or
alternatively as illustrated, to a spacer member or beam 124. As
illustrated, a second rail 126 may define a spacer that sits on the
upper end of the rail 114, for elevating the photovoltaic module
11, such as for an air flow channel or for accommodating one or
more of the ballast systems 145, if necessary, as an optional
securing feature in some installations. As discussed below in an
alternate embodiment, the rails 114, 126 may be a one piece tubular
extrusion with a first open slot facing towards the attaching
connection 188 and an opposing open slot facing towards the bracket
112 when the photovoltaic module is installed.
[0124] FIG. 23 is a perspective view of the mounting system 180
illustrated in FIG. 22 deployed on the sloped protected membrane
roof 182. In the illustrated embodiment, a the mounting systems 180
includes a pair of the elongate flexible attaching connections 188,
or strips. The rail 114 attaches with a plurality of the fasteners
162 received in the channel 116 with the threaded post 167
extending through the respective opening 120 for securing with the
nut 168. The attaching connections 188 are then disposed in
spaced-apart parallel relation on the sloped surface and secured
preferably by welding W to the geomembrane 184. The photovoltaic
module 11 then attaches to the rail 114 with a plurality of the
fasteners 137 and nuts 140, or optionally alternatively to the beam
124 if additional height is needed in addition to the height of the
rail 114. Additional mounting systems 180a may be positioned in
spaced-apart relation for a portion of the sloped surface.
[0125] The flexible attaching connections or strips 188, being
secured to the rails 114 and welded W to the geomembrane 184 in
spaced-apart parallel relation support the solar photovoltaic
modules 11 that attach with the fasteners to the rails, while
resisting sliding movement relative to the geomembrane and
resisting wind uplift.
[0126] Further, optionally, one or more ballast systems 145
similarly connect with fasteners 155 to the rail 114 in spaced
relation. However, it is contemplated that while ballast may be
required for some installation such as on some roofs, not all
installations will need such, based on expected wind loads.
[0127] FIG. 24 illustrates an end view of an alternate embodiment
of the mounting system shown in FIG. 22, using a one-piece extruded
rail 251. The rail 251 comprises an elongated member having a pair
of spaced-apart webs 253 attached to opposing side walls 255. The
sides walls 255 define a channel 256 and opposing profiles for a
base 257 for contacting the attaching connection 188 and an
opposing seat 259 for connecting to the bracket 112 of the
photovoltaic module 11. The bracket 112 may be integral with the
photovoltaic module 11 as supplied by the module manufacturer, or
may be part of a Y-shaped bracket similar to bracket 50 shown in
FIGS. 9 and 10 for engaging a side edge of the module.
[0128] The side walls 255 have inwardly extending lips or flanges
261, respectively, and each pair defines a respective slot 263
therebetween for the base 257 and for the seat 259. A plurality of
fasteners 162 secure the rail 251 to the attaching connection 188.
The post of the fastener extends though the slot 263 and through
the attaching connection 188. Upon rotating, the plate 166 on the
flanges 261 bears on the side walls 255, and the nut 168 threads on
the post to secure the attaching connection 188 to the rail 251.
The attaching connection 188 than attaches, preferably by welding
W, to the geomembrane 184. The geomembrane 184 being resilient,
forms a slight depression to accommodate the nut 168. The
photovoltaic module 11 then rests with the bracket 112 on the seat
259. A post 133 of a fastener 131 extends upwardly through the slot
263 in the seating end 259, and through the opening in the bracket
112. The plate 132 rotates into engagement with the side walls 255.
The nut 134 threadably engages the post 133 to secure the
photovoltaic module 11 to the rail. Although not illustrated, a
spring attached to or supporting the plate may assist by holding
the plate in contact between the web 253 and the flanges 261 with
the flanges 261 until the nut secures the fastener to the rail.
[0129] It should be understood that in these embodiments the weld
harness strip is preferably made of a polyethylene material.
Similarly, the yarns of the tufted geosynthetic material are also
made of a polyethylene material. With this construction, the
melting point of the weld harness strip is generally that of the
yarns of the tufted geosynthetic material, thereby creating a
superior bold or weld there between. However, it should be
understood that other types of polymer materials may also be used
for these components without departing from the scope of the
invention.
[0130] The distinct advantage to the invention described in the
multiple embodiments herein is that the solar panels may be
positioned or arranged in a manner that provides for a higher
density of solar panels per area of land. This higher density
allows for the generation of more electricity per land area.
Another advantage is the easy of mounting solar panels without the
need for a racking system or without the occurrence of panel
movement over time.
[0131] In all embodiments wherein two base plates, spacers, or
rails are shown, it should be understood that the invention may
include at least one such component, however, such an arrangement
is not preferred.
[0132] The wind breaking element, such as members 219, readily
attach to the photovoltaic module 3, or alternatively, to the
bracket 50 or 112, for wind uplift resistance, by creating
turbulent flow near the surface of the cover, thus greatly reducing
the actual wind velocity at the cover surface and decreasing
associated uplift.
[0133] This invention has been described with particular reference
to certain embodiments, but variations and modifications can be
made without departing from the spirit and scope of the
invention.
* * * * *